Nasties corner, a collection of shop projects past and present

[NASTYZEN]

I have had several members suggesting that I start a projects thread where all my shop projects can be found in one place.
Also inspired by other craftsman's threads like MP&C as well as others.
I also am starting this thread in the hopes of inspiring other members to go out in there garages and make something.
Please step in and interact, it makes it more fun!

So, welcome to my work shop!

I am a welder,fabricator by trade and have been in the business for 31 years and have been in business for 23........man, time flies!
Along the way I gathered most of my experience on the job. (breaking things all along)
I'm also a bit of a photo buff, so I've got pictures going back pretty far.
Might as well share them with you guys rather than let them go to waste.

I call my little fabshop Fabri-Plus and I make all kinds of stuff out of metal.

Here is the link to the back shop build:

http://www.garagejournal.com/forum/showthread.php?t=70953

Below I shall start to add links to threads I have posted in the past so you can find them easily.

Enjoy!

Restoring Jim Hall's Chaparral 1
http://www.garagejournal.com/forum/showthread.php?t=90819

Restoring the good Doctor's 52 Aston Martin DB-2
http://www.garagejournal.com/forum/showthread.php?t=92578

Turning a Porsche 944 Turbo into a Spyder.
http://www.garagejournal.com/forum/showthread.php?t=88103

Topkick fifth wheel hauler project
http://www.garagejournal.com/forum/showthread.php?t=189747

Restoring the triplets of Belleville
http://www.garagejournal.com/forum/showthread.php?t=166716

 

[NASTYZEN]

My first exposure to Vintage racing cars. I was instantly hooked!
All these cars are hand built and are, to me, beautiful.
This project took place at my mentors shop in 88. I was only partially involved in this one, I had to pay my dues and earn the mentors respect before being let loose.

A Lotus 23-B needing total restoration.

Corrosion as well as crashes took it's toll. Time for a new chassis.

All of these chassis are brazed together using a fluxer Oxy-Ace with low fuming bronze alloy rod. I like to use .065 dia.

Making panels and fitting up suspension components.

Getting closer.

Engine and gearbox in.

Rear end.

Front end.

Sand bent headers. My mentor was awesome at sand bending. It's a lot more difficult than one might think.

 

[NASTYZEN]

We had to mod the fiberglass parts from England here and there in order to get a perfect fit up.



Getting mold creative.



Fitting up the body work.



Wiring plumbing and such.



I took all these shots with a Yashika 35mm camera at the time and scanned the old picks with my scanner.



Putting it back together after painting.

I like this one.

 

[RivennHewn]

Looking forward to this one!

 

[yaidunno]

Great looking stuff as always. Subscribed to this one.

 

[MP&C]

I've been waiting for this thread.. Always enjoy seeing your fabrication work Claude!

 

[NASTYZEN]

Thanks for the words guys!

Some long nights went into this Lotus to be able to have it ready on time.

Just about done.














The boss took it for a test drive around the industrial complex and we loaded it just in time!

 

[jkfinity]

Man, you are the one of the Garage Gods I want to be when I grow up!

 

[NASTYZEN]

Man, you are the one of the Garage Gods I want to be when I grow up!

Thanks!

The last project I did before closing for the holidays.
Ski hill people got a new 6X6 and needed a custom rack.

The drawing I got plus some loose dimensions.




First thing was mounting it to the box with double sheer brackets.
This is what I thought was an easy way to do it.



Using 2 x 3 x 1/4 left over angle. Trimming on the band saw.



Test fitting.



I pre assembled the 4 brkts with the stand off's, so I could lay the top tube on top to get a feel for where the front grill will go.





Next, after laying out the front grill on the bench, I fit the outer frame tubes.




Off to the dungeon to shear some flattened expanded Alu. grill on my old Pexto shear.



After some trimming, I welded it to the front frame.



Next came attaching it to the side rails. I mitered the other ends and welded them up first.



The final rack, triangulated and with removable strobe light tube.
Safety first on the ski hills.







2 days later, they came back with a broken strobe light tube. The guy went into a heavily wooded trail and forgot to take the strobe off....DOH!!

 

[DoghouseForge]

And the G.J. gains another valuable Shop thread!


THANKYOU!

JP

 

[NASTYZEN]

Happy new year to everyone! I wish you all health for 14. With that, you should be able to move mountains.

And the G.J. gains another valuable Shop thread!


THANKYOU!

JP

Thank you, Doghouse. I am enjoying your wrought iron thread as well.
Don't you love this place. A great melting pot of ideas.

Up next,

An Aluminum collapsible electronic wight scale platform.
I built this for the Subaru road race team up here, last winter.



Some of the hardware I had to machine bits for.



Bushings for the leveling feet. They have an Allen hole so you can turn them from the top.



Level bubbles for rough leveling during assembly.



Pre cut and debured.



Assembly of the main platforms.



The under side. I have lots of angle off cuts from other jobs, so I used it where ever I could. I built this scale a bit heavy to handle the weight of these cars.



This is how I decided to join the two main platforms with bridges.
I drilled holes thru for bolting with 3/8'' bolts



Assembly of the bridges.



Lastly, some ramps.
Making some loong cuts.



Making some loong welds. Back stepping all the way.



Adding some sheet.



First test assembly for drilling those 3/8'' holes.



Some details.

 

[stock z/28]

Hello,

I dont post here very often and honestly I only looked at some of your posts for a few seconds, but I must say I am very impressed with your work. About as good as it gets only any level.

An artist in my opinion.

Wish I knew you personally.

Thanks for the posts and when I have time I will look them over.

Jeff

 

[Thumper68]

I will have my eye on this one, all your work impresses the hell out of me.

 

[deere2210]

Nasty, great stuff!! Keep 'em coming!

 

[nine4gmc]

Good stuff!

 

[JTH]

This from bringatrailer.com, the other big time drain in my life after GJ. Thought of you when I saw this picture http://www.rmauctions.com/lots/lot.cfm?lot_id=1063982. Pure pleasure to see your work. Thanks again JT

 

[NASTYZEN]

Gee, thank you guys.
Glad everyone is enjoying.
Thanks for the spectacular link JTH

 

[Deadhead]

True craftsmanship. Outstanding work on the scales.


Did you ever get to drive the Lotus? just had to ask.

 

[ddawg16]

Guys....as an FYI....I've been in his shop....actually, both of them. The pictures don't do the quality of work justice.....

You should see his tree house.....

One of these guys is Nasty.....take your pick

 

[johno]

Love the frame of the Lotus, ART.
You could just hang that from the ceiling and look at it.

 

[NASTYZEN]

Aw man.... I must learn to smile properly in front of a camera.
Anyhow, off to the beach! As white as I am, I hope I won't spontaniously combust as I step off the plane...

 

[e-tek]

I guess when you work on Lotus' (Lotuses?), you can afford to go on vacation!!!

Great to see you start a shop thread Claude - now I won't have to miss so much of your great work - definitely Subscribed!!

So John - you travel to Winnipeg AND St. Colomban, QUEBEC, but haven't made it to the center of Canada yet??!! I'm guessing I'll see you in Cali before I see you here...

 

[NASTYZEN]

I guess when you work on Lotus' (Lotuses?), you can afford to go on vacation!!!

Great to see you start a shop thread Claude - now I won't have to miss so much of your great work - definitely Subscribed!!

Ouch! what a brutal return to reality...Even had to do the inventory.
Thanks for the kind words Ed.
It may come as a surprise to you but, cnc machining is more lucrative than fabrication and easier. Fabrication is more a passion and sort of a hobby.
I must create!
Thats why it took my 20 years to take my gal on a honeymoon..

On a side note, I was thinking of you guys on my recent vacation.





I was so impressed with the cars of Cuba that I started a thread about the cars I saw there.
Here is the link. I'll be adding some more pics as time permits.

http://www.garagejournal.com/forum/showthread.php?t=232002

 

[NASTYZEN]

So it started as an easy coolant change for the mill and quickly degenerated.
First I noticed an oil line tube had broken feeding the X axis ball screw...So I had to pull the table to get to it.



Here it is..



Then I see this!





My balloon has been deflated...

 

[longlivepunk]

Wow. Awesome work as I'm sure you know! When reading other posts of yours I always thought it was a one man shop, do you still have employees? I hope you're able to pass your knowledge on at some point to someone worthy and able to soak up as much as they can!

Edit: and I just saw your post about your mill. Ouch. My condolences. :S

 

[larry_g]

Is that a factory layer of Turcite in there? If so it may be not to hard of a fix if the ways have not gotten to worn. Tough find but I don't think it is deadly.

lg
no neat sig line

 

[NASTYZEN]

Wow. Awesome work as I'm sure you know! When reading other posts of yours I always thought it was a one man shop, do you still have employees? I hope you're able to pass your knowledge on at some point to someone worthy and able to soak up as much as they can!

Edit: and I just saw your post about your mill. Ouch. My condolences. :S

Thanks, I am a one man shop.That Lotus 23 was before being self employed. But I do have my eldest Son working for me part time. I am trying to pass on my knowledge the best I can..

Is that a factory layer of Turcite in there? If so it may be not to hard of a fix if the ways have not gotten to worn. Tough find but I don't think it is deadly.

lg
no neat sig line

I am lucky in that I caught it be fore there was metal to metal contact.On the phone this morning to see if I can find the parts and the glue to fix it before putting it all back together.Turcite huh? Some sort of plastic?
I am wondering if this wear can be happening on the Y and z axis also?? I really don't want to have to take those apart as well.

 

[sselander]

Here is a look at a Turcite application by the Machine Tool Groups:

http://mtsandtg.com/turcite-application

http://mtsandtg.com/

 

[NASTYZEN]

Thanks for the links sselander!
Turcite..Learn stuff all the time! I always thought mill ways were metal on metal.
I'm trying to find it through my usual machine supplier guy. Someone in Montreal must have it on a shelf somewhere.

 

[michel]

Man youre not far from me, I might show up one of these days.

 

[MP&C]

I am wondering if this wear can be happening on the Y and z axis also?? I really don't want to have to take those apart as well.

Claude, if the damage was just caused by bad oil line, do you have someone you know with a borescope, maybe you could verify the y/z axis oil lines and that should suffice that they would be OK without taking everything apart?

 

[NASTYZEN]

Man youre not far from me, I might show up one of these days.

You would be welcome.

Claude, if the damage was just caused by bad oil line, do you have someone you know with a borescope, maybe you could verify the y/z axis oil lines and that should suffice that they would be OK without taking everything apart?

The way oil lines are fine Robert. It was only the ball screw plastic oil hose that dried up and broke. A good thing or I wouldn't of caught the Tercite wear.
I have a piece of 12 x 16 as well as glue on the way fro Toronto. I should have it Monday.
I may just pull the Y axis to make sure while I'm at it. I can always do the Z at a later time.
They make a boroscope that fits in a 1/8'' oil line?

Did a quick job for an ice racer today. He asked me to fudge something for his rear wheel with some bits he already had.




I can see why the rules call for some sort of chain saw guard!
Those can ruin your day.



First up was to bend up a 3/16th plate to mount to the axle.



They use u bolts to hold the rods together so that vibration doesn't break the welds.



You get more traction on ice with this setup than you do with a slick on pavement.



Ah! Kids!!

 

[pepi]

Thank you, thank you, a thousand times. I will be looking at all of these cars many times very rare indeed.

 

[MP&C]

They make a boroscope that fits in a 1/8'' oil line?

I was thinking alongside the screw drive to check the oil lines as they are clamped to the machine. If that was possible.....

 

[racingtadpole]

They make a boroscope that fits in a 1/8'' oil line?

Not specifically a bore scope, but I have an optic fibre inspection tool at work that's only the thickness of the fibre and a couple of layers of plastic protection jacket, maybe 1.5mm total diameter.

At least you can't complain you don't have variety coming through the door

 

[petawawarace]

We race sleds along side with those bikes. Traction on ice is amazing. We hit 60mph in less than 2 seconds with 130hp

I have a borescope at work that's 2mm diameter but its an 80k system

 

[NASTYZEN]

Thanks for the input guys.

Got the Tercite the next day! But I had to buy a big piece.



So I started to pull it apart some more...



At this point I could pull the cross slide out and sure enough, Tercite.



My 17 year old had this look of Dad, what have you done!On his face as he helped me take the cross slide off the machine.
Guess I'm committed now huh?



Can I shear .047'' Tercite on my foot shear? How do I carve out the oiling grooves. Knife or die grinder?

 

[NASTYZEN]

Well, turns out Turcite can be easily sheared, cut with tin snips and be sanded.



I have to send out the protective way plates to be Nickel plated because of corrosion, so I'll have time to clean up the machine all over and repair a few tid bits.



Polished the main ways to my liking.



First bonding of the Turcite.

 

[NASTYZEN]

Crazy week, at least my other cnc is 100%!



But I got some time to work on that saddle some more.
Bottom done, now for the top.
Preping the surface.



Setting weight on the strips with wax paper in between. Let it sit 24hrs.



Ready for facing on the conventional mill.



Aw man! I have to take all the oiling lines out.
I really need to sit this directly on the table. Table a Table.



I engraved everything first so I can put it all back together again!



Finally facing. Milling machine milling milling machine.



Voila! Oil ways all done, all I need now is a teenager to help me get it of this mill and on the other.

 

[JTH]

very cool! Love to see all you do. JT