Show off your sheet metal fab projects

[ZRX61]

Vintage aircraft are so cool.Please post more shots!Need to see airplane guts.

I hardly have any. I need to get the album from the other guy who worked on it & get the pics scanned.

 

[ZRX61]

Yup, It's a '48 Flxible Starliner.

Leno's shop manager also has one, used for race transport.

 

[NASTYZEN]

Porsche front hubs.I forget for witch model.The originals are Magnesium and even more expensive that fabricated ones?

 

[NASTYZEN]

One of the boys from the Jim Russell racing school went on to become a pilot.He has a run to do between here and somewhere way up north but can't quite make it to destination with the Navajo airplane he pilots because the fuel tanks are too small.So he has to make a very expensive gas stop.He managed to find an axillary tank that fits in behind the engine compartment but not the other.With that as an example,I made him the other.

 

[MP&C]

Nice job on the fuel tank.... what is the capacity? I guess every bit helps with the run he's making.


Some more progress on a tailgate....a bit of connect the dots...

The rear side of the weld....

Getting closer...

 

[hyvolt]

New floor in the plow truck.

 

[NASTYZEN]

Nice job on the fuel tank.... what is the capacity? I guess every bit helps with the run he's making.


Some more progress on a tailgate....a bit of connect the dots...

The rear side of the weld....

Getting closer...

Nice work.How do you keep it from distorting all to heck so well?Is there access from the backside for dollying?

Re.fuel capacity.I can only assume that auxiliary fuel tank held just enough for him to make it.I've not herd from him since.

 

[NASTYZEN]

Replacement oil tank for a Titan Formula B car.

 

[MP&C]

Nice work.How do you keep it from distorting all to heck so well?Is there access from the backside for dollying?

Re.fuel capacity.I can only assume that auxiliary fuel tank held just enough for him to make it.I've not herd from him since.

The outer skin is removed at this point, so the welds are getting planished as I go.

 

[ZTFab]

DANG! those sure are some pretty welds

Man those are sick welds!To keep the weld that even over a long distance like that is really hard.I've been trying for 29 years now....
You have awesome skills.Keep showing us some of that work.

Thanks guys!

Here's some TIG welding from the other day.

Sorry, it's not sheet metal fab but at least it's welding and fab.

 

[ZTFab]

The outer skin is removed at this point, so the welds are getting planished as I go.

Awesome work Robert!

I used to work for Williams Classic Chassis Works building Tri-5's.

 

[Skyline]

This is an aluminum off-road bumper I made with a guy I work with. I did the design, we both made parts, he welded it, and we both finished it. Finally it was powdercoated. Not the greatest paint surfaces...we're used to round tube that hides a lot more. Turned out pretty good I think. I've got about 5 people that are waiting for me to make them one after I finish tweaking the design.

Boiler;

That is one of the nicest looking Jeep bumpers I've seen. Great job!

I'm about to build some bumpers for my off-road Grand Cherokee, and was toying with the idea of using aluminum. My concern is the recovery points and for the front, the winch mount, and the rear, the receiver. Is aluminum really strong enough to attach that stuff? Have you computer modeled the strength of those points?

There's a company (Iceland Offroad) that makes some great looking fiberglass bumbers for Jeeps. While I'm sure your aluminum bumper is a lot less likely to be smashed to bits on a rock, they deal with the recovery points (and winch mount) by tying them in iternally with steel right to the frame. So you're never pulling on fiberglass. I would never consider fiberglass bumpers; more for posers I think. But steel bumpers are likely to add a LOT of weight; aluminum seem like a great option if I can get around my strength concerns.

http://www.icelandoffroad.com/

 

[MP&C]

Williams Classic is very well respected in the Tri Five Group. Looks like you're continuing in some nice fab work still....

 

[Jim Stabe]

Thanks guys!

Here's some TIG welding from the other day.

Sorry, it's not sheet metal fab but at least it's welding and fab.

Do you use a turntable to get those welds that consistent?

 

[ZTFab]

Williams Classic is very well respected in the Tri Five Group. Looks like you're continuing in some nice fab work still....

Thanks Robert. Williams Classic is based in my home town and I had a lot of fun and learned a lot while building some very nice cars in the years that I worked there.

Do you use a turntable to get those welds that consistent?

Yes, Jim. I use an Aircrafter brand rotary positioner.

 

[bobadame]

Do you use a fixture to hold the torch or do you hold it by hand?

 

[littletoes]

WOW went through all 7 pages, and am just amazed at the craftsmanship, the PATIENCE, and the sheer forward-thinking of the project, of what it will take to get it done.

It seems, a sharpie is a cold-formers best friend! Kinda funny....was in a parts house yesterday, and a lady from comes from behind the counter and asks if anyone has a sharpie, all of us grab for the one in our pockets....funny....

Thanks Guys, for taking the time to take all the photos, I know how it must be to have to stop to take a pic, but it does give a bit more time to just think.

 

[ZTFab]

Do you use a fixture to hold the torch or do you hold it by hand?

All freehand.

 

[bjaspud]

Looking at the quality of workmanship from you guys makes me wonder if I should sell my mig welder and take up golf !

 

[littletoes]

How 'bout layout???

I only saw one pic of a protractor, what else are you guys using to make your job easier?

Lots of sharpies, but no scribes, or inside/outside calipers......

 

[NASTYZEN]

Thanks Robert. Williams Classic is based in my home town and I had a lot of fun and learned a lot while building some very nice cars in the years that I worked there.



Yes, Jim. I use an Aircrafter brand rotary positioner.

O to be able to weld as pretty as you.
Years ago I used a positioner like yours.Great when you have oodles of parts to put together.The hardest thing to do was to use two different pedals at the same time,took some getting used to.

 

[NASTYZEN]

How 'bout layout???

I only saw one pic of a protractor, what else are you guys using to make your job easier?

Lots of sharpies, but no scribes, or inside/outside calipers......

This is the bulk of what I use.

 

[afazz]

I'm certainly no master, but here are some of my layout tools

The 1/8" fineline tape is great for laying out curves and lines that need to "look" right, you can remove and re-position it once or twice, it's easier to view from multiple angles or a distance, and shows up better in photos. Protractors and angle gauges are on my list, I need to upgrade from the plastic toy set I have now

 

[NASTYZEN]

Not really sheet metal but it is .028 walled Aluminum tubing.Total weight without wheels 4.5lbs.

 

[MP&C]

Any more details on the trike? A racing version perhaps?


Well after a couple weekends of spring cleaning distraction (took three loads to the dump) I can walk around in the shop with less trip hazard, and the welding is finished on the tailgate. Now need to dress the welds, sandblast the inside, and mix up some epoxy primer. Inching closer.

 

[NASTYZEN]

Any more details on the trike? A racing version perhaps?


Well after a couple weekends of spring cleaning distraction (took three loads to the dump) I can walk around in the shop with less trip hazard, and the welding is finished on the tailgate. Now need to dress the welds, sandblast the inside, and mix up some epoxy primer. Inching closer.

Spring cleaning won't start here for a couple more weeks till the white **** melts away.That tailgate is looking good.

That trike is a prototype Olympic racing wheel chair built for a customer.

 

[MP&C]

That trike is a prototype Olympic racing wheel chair built for a customer.

With the operator using both hands for propulsion (usually), how does the steering function?

 

[jsaw]

Not really sheet metal but it is .028 walled Aluminum tubing.Total weight without wheels 4.5lbs.

Wow, is there a story behind that?

 

[NASTYZEN]

With the operator using both hands for propulsion (usually), how does the steering function?

If you look closely at the front fork you will see a small leaver attached to it.There is one on the other side as well.A bit like handlebars.Also you can see what looks like a pneumatic cylinder,in fact it is a friction type damper.When the driver nudges the handlebars a little,it remains in that position until more corrections are needed.(make any sense?)

Wow, is there a story behind that?

It was used mainly as a training chair.Although it was entered in a couple of competitions.It was also custom built for a girl.The customer had me build a couple of other different designs.
Carbon fiber constructed chairs are more rigid and even lighter.But more expensive and fragile.Those are the ones that get to do all the real racing.While they beat the heck out of the trainers daily.

 

[NASTYZEN]

Here's a different model.

 

[MP&C]

These yellow vehicles can't seem to stay away....



....with another one (accident repairs....someone ran into the side of it) after this is finished.

This jumped out in the way....

First to cut profile template. This will help in reproducing the "cover" and also to see where the buckled metal needs to be moved out of the way. I can't fit the whole bus in the booth, so a cover that we can assemble after painting will have to do.

Tools we'll be using....

Because the corner leans in at the top, from both the rear and the side, the top cut will not be a straight one, as you can see when a strip of metal is wrapped around the radius....

test fit, and marking the top cut

Flanged and fitted

We'll let this set until Sunday afternoon and then put it back together..

 

[littletoes]

Nice work on the bus!

NASTYZEN-That tailgate is exceptional, how the heck you guys do it, I just don't know.

 

[Krokodil]

Nice bus repair!

 

[MP&C]

Nice work on the bus!

NASTYZEN-That tailgate is exceptional, how the heck you guys do it, I just don't know.

Thanks for the comments guys. Littletoes, the wagon gate was my work, I think Nastyzen had just quoted my post. He does the killer work on aluminum bodied cars made from scratch..... Oh to be an apprentice.....wax on, wax off..


Got it put back together this morning. They even had matching yellow caulking at the bus dealership to seal everything up...

 

[Sterff]

Great job on the bus

 

[tig]

All freehand.

 

[falconflyer04]

Oh well... I might not have the talent that some of you have here! :O
But here's my parts done with sheet metal...

A pair of 10 gallons aluminium fuel tank...

-First I cutted the sides and bottom...

-Then I pressed the sides and worked them straight with crimpers...

-Folded the bottom to match the sides...

-All ready for soldering...

-Soldering done...built the baffle and inserted it in...

-All done with top and filler neck! Also pressure tested and no leaks!

 

[DrunkSmurf]

I crushed a few beer cans today if that counts...

Great work all and thanks for sharing. I've always been fascinated by this type of work and watching/learning how many different techniques can be used to accomplish basically the same task. Old school, new school it's all just amazing honestly.

I do have to say though, ZTFab you're throwing down some of the best beads I've ever seen, and I've seen a lot.

 

[Beaumont67]

I had a problem with my MicroWave Exhaust Venting over my Gas Range, that I needed to correct & reroute some.
- used my $20 sheet metal break and some left over tin, from my 24x30 garage build
- essentially, lengthening the 3x10"w/90^ elbow by several inches to clear newly added wall studs (fix load bearing)
Here is how it went together using sheet metal screws, as fasteners...works great now, using "custom-made" elbow.



Drywall cutouts sealed with foam & tape (temp. fix) to avoid heat loose, in main part of house.

2 ft. sheet metal BREAK, was made by a retired Tool & Die Maker:







Rail Road Tie ANVIL, is my dollar garage-sale-find.





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Beaumont { :>)) www.petperfectexpress.com
1965 Malibu S/S, 1966 Beaumont Custom original paint, 1967 Beaumont Custom, 1967 Beaumont Custom original paint, 1967 Beaumont 396-350HP Sport Deluxe M21-411's - SOLD 1970 Judge

 

[NASTYZEN]

NASTYZEN-That tailgate is exceptional, how the heck you guys do it, I just don't know.

Sorry not my tailgate.Robert the MP&C man, is the exceptional body man in this case.