Show off your tubular projects here.

[NASTYZEN]

Show off your projects made with tubing here.If it has something to do with tubing,then this is the place to show it off. That kind of makes it wide open......
I'll start it off.
Here goes....

Custom headers for a prototype car.Cut up a bunch of U bends and welded them up with tig using .035 filler rod.




Let's make this thread as good as the show off your sheet metal thread guys! I figure there's more tube guys out there than sheet guys.

 

[lilredex]

Here is a re-purposed old chair into a sturdy rear carrier and a trailer in the works:



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[blue dog]

I'll play, here is the bed cage in the back of my truck, with this, i now have 14" of limited wheel travel in the back of a 2500 dodge ram with a dana 80 rear axle. Mounted my fuel pump off to protect it from rocks.

 

[blue dog]

Rear hydraulic bump stops under the same truck. And my 10,000 lb hitch/ light bar.

 

[AlchemyMetalworks]

Show off your projects made with tubing here.If it has something to do with tubing,then this is the place to show it off. That kind of makes it wide open......
I'll start it off.
Here goes....

Custom headers for a prototype car.Cut up a bunch of U bends and welded them up with tig using .035 filler rod.

Thought that looked familiar, so here's another shot...

The HTT Locus Plethore...have they actually sold any yet?

 

[Travis E.]

I'll play, here is the bed cage in the back of my truck, with this, i now have 14" of limited wheel travel in the back of a 2500 dodge ram with a dana 80 rear axle. Mounted my fuel pump off to protect it from rocks.

Its good to see a 4wd truck built to be used and abused. What are you doing for front suspension?

 

[Boiler]

This is why I don't do more fab projects. For my aluminum roof rack I measured the roof, modeled a rack, performed stress analysis on the model..., modeled a welding fixture (so that I can reproduce them, I sold them for a while) built the rack from drawings and the fixture, and it fit perfectly the first time (well, the second time once I figured out the weld order to manage warpage), powdercoat, route wires, build a fuse panel (or two) for the lights and other accessories, drill a 5/8" hole through a 3/8" thick portion of my roof, and presto, rack is done.

 

[blue dog]

Its good to see a 4wd truck built to be used and abused. What are you doing for front suspension?

The front is a work in progress, it has 2.5 fox race shox's and variable rate coil, race sway bar, has chase control arms with rubicon express joints that can not survive one trip to the desert { soon to be hybrid arms with race joints } I have a 09 tie rod assembly that needs to be installed as well as new 2" fox bumps, psc ram assist steering and new custom built track bar and limit strap's. Front gets just under 11" of wheel travel, not bad for a solid axle under a dino powered cummins engine. Making the front work and survive is a challenge in a 8,000 lb truck, but it can hold it's own and no f250 can keep up with it when hauling the mail across the desert.

 

[blue dog]

Here is some more tube work, had to sell this truck when the economy went to poop, it now lives in Cabo San Lucas and runs in local races down there.

 

[ZTFab]

Here are some tube projects I've done;

 

[blue dog]

zt, it's good to see an other stock full in the mix, that class has really died in score in the last few years.

 

[ZTFab]

A few more;


Score keepers for my buddies bean-bag toss game...

 

[ZTFab]

zt, it's good to see an other stock full in the mix, that class has really died in score in the last few years.

Thanks blue dog...unfortunately that truck hasn't been campaigned in a few years.

This is Dave Turner Motorsports Factory FORD sponsored stock full. In '05 we ran it for the full BITD and SCORE seasons...it was rough. I helped with prep and co-driving. After that we ran it in select races between the sanctions.

BITD has/had a much larger stock full class. We used to race against Merrit, Foutz, Barnett, etc...All are great competitors.

Vegas to Reno is this next week and my buddy still races in Stock full with the La Paz drink mix team and there are only two entries in SF for the race. Kinda sad.

 

[Aspen RT]

My God those are nice welds!!!

 

[blue dog]

ZT, if you raced the score season 05, i raced against you. I built and ran the sheriffs dodge the entire season that year. And i kinda know the La paz guys, they are friends with Mark Handly and Mark Stein, old stock full guys for a long time. Are you familiar with Mike Mc comes in San Jacinto and his fab guy Lorin ? Anyway, you got skills, very nice fab, and it seems you are a well rounded metal worker Maybe i will give you a shout for some stuff that needs to be done, you are about an hour north with no traffic from me.

 

[hunter1151]

Excellent welds with excellent fit up............nothin better

 

[ZTFab]

Wow...right on! Yes, we did race against each other.

Yes, I know Mike McComas and Marc Stein. They were the Ace motorsports crew and ran the Explorer and Expedition...Dave Turner was part of their team also. His shop was a couple miles down Esplanade from McComas's...across from Stadium Pizza.

Thanks for the compliments...I appreciate it.

 

[ZTFab]

My God those are nice welds!!!

Excellent welds with excellent fit up............nothin better

Thanks.

 

[NASTYZEN]

Right on! A lot of nice and varied work already has been posted.Seems tubing can take us in many directions....
I like the wooden assembly jig for that roof rack, good idea.


A bit more header stuff from over the years...

Formula Ford 1600

I make those reverberation chambers (balls) with dies on the press.

FF-2000

FF-1600

Repairs

2011-08-14


Go dig up some of your past projects and show them off.
Thank's to all those who already have.

 

[NASTYZEN]

Thought that looked familiar, so here's another shot...

The HTT Locus Plethore...have they actually sold any yet?

As far as I know , seven have already been sold...I am to deliver the first chassis end of this month or so depending on the engineering side of things.
Things are beginning to rock n roll.

 

[ZTFab]

Nice work NASTYZEN!!

Proper headers like that take a lot of knowledge, time, patience, and skill!

Any pics of the dies you have for the reverb chambers?

Any pics of the that HTT Locus? Mid-engine car?

 

[ZTFab]

Here are some more shots of the SS mid-pipe that I posted earlier.

I formed the ball socket on my 20 ton press by using a trailer ball set in the platens and just pressed the tube down over it. Worked much better than I thought it would and matched the factory piece perfectly.

The last pic shows the custom SS hanger I made for the pipe.

 

[blue dog]

Nastyzen, building headers is a real artform, and you seem to have it down pat.
There was a duralast ford truck that had an 8 into 1 exhaust some time ago, it had the best sound when it would go flying by, loved it.

ZT, pm me your phone number or email, got a few things on the bucket list that need taking care of if interested. Just do not have the time to do these things myself.

 

[theoldwizard1]

Excellent welds with excellent fit up............nothin better

What rookies need to know is it is the fit up that allows you to make those excellent welds.

ZTFab, any tips on making "fish mouths", especially more or less than 90 degrees ?

What tool(s) do you use, besides a die grinder ?

ZTFab, those welds are a thing of beauty ! I can appreciate the craftsmanship/artistry there !!

 

[ZTFab]

What rookies need to know is it is the fit up that allows you to make those excellent welds.

ZTFab, any tips on making "fish mouths", especially more or less than 90 degrees ?

What tool(s) do you use, besides a die grinder ?

ZTFab, those welds are a thing of beauty ! I can appreciate the craftsmanship/artistry there !!

Thank you very much.

You are 100% correct....prep work and fit-up is crucial to a proper/good weld.

I have a saying;

90% of a good weld is all in the prep.

You wouldn't try to paint your car without doing all of the proper prep work and expect a professional finish, would you?

I am constantly amazed at the amount of people that will try to weld to a rusty, greasy, dirty, or mill-scale covered piece of metal and wonder why their welds don't hold or don't look good.

As for the notching I use a JMR TN-1000 hole saw notcher with either Starret or Lenox hole saws. Once notched I will clean up the burrs and remove the coating on the tube with my burr-king belt sander or my Makita 4" hand grinder.

I measure the angles with an adjustable protractor and take my time with the notch...often check-fitting multiple times if I have to to ensure full contact of the saddle. When de-burring I ensure that I remove the thin portions of tubing that are tangent to the holesaw to get back to a consistent land area to allow for a consistent weld.

 

[NASTYZEN]

Nice work NASTYZEN!!

Proper headers like that take a lot of knowledge, time, patience, and skill!

Any pics of the dies you have for the reverb chambers?

Any pics of the that HTT Locus? Mid-engine car?

Thanks ZT, all I'm missing is your robotic welding skills!

Actually, all you need to know about headers is that the pulse or expanding gases from each cylinder needs to reach the collector for the primaries in sequence.Thats's how headers work. Say you have a 4 cylinder engine. You will have 4 tubes(Primaries) joining at the collector. You need to sequence the firing order such that it goes in a circular pattern,thus creating a vortex that helps **** out the gasses faster.Voila!
That's the reason that tube lengths are so critical for the primaries. So that the pulses reach the collector at the same time.
To make a set of headers, you need to have lengths and diameter of primaries as well as the length and diameter of secondary or tail pipe from the engine builder. He gets those from the volume of displacement of the motor.

I'm no rocket scientist, just a fabricator......

Those chambers are supposed to catch the shock wave that is ahead of the pulse.Being faster, the shock wave bounces back from the collector towards the cylinder and screws up the cycle a little. So these chambers catch it before it reaches the cylinder.The primary tube extends 3/4 of the way into the ball.Thats where the shock wave goes,in between the ball and the tube. While the next cycle goes by, unobstructed.Again where you put this chamber on is critical in order for it to work.

I need to dig out that die for those chambers out. But all it is ,is a piece of tube that I turned a cone at one end and a rad at the other. A bit like your use of a hitch ball for your bike project. Wich looks awesome btw.

I will post up on the Pléthore at a later time. I may get crucified if I put pics of a priceless prototype on the web before getting the OK from HTT.

These are 304s/s 4 into 2 into 1 for FF-1600 The advantage with these is that you get both low end and high end torque.

 

[NASTYZEN]

Nastyzen, building headers is a real artform, and you seem to have it down pat.
.

Thank's Bluedog, I enjoy making headers, somehow I find it relaxing.

You do some fine work yourself, I would like to see some more.

 

[zmotorsports]

Some of my latest tubing work.

Sandrail chassis construction.

More tubing bent, fishmouthed and welded. In the background is my son's new tube project. A sand quad which will have a large two stroke engine.

Tubes powder coated.

Rolling chassis.

Completed.

Black quad is my son's which we back-halfed with 4130 tubing. Rear frame sup-frame and rear swingarm. Green bike is completely fabbed by my son and I in our shop from 4130 tubing and has a GS1100 bullet bike engine. Both bikes were featured in Jan/Feb 2010 Sand Sports Magazine. Mike.

 

[motorbreath53]

I'm almost ashamed to post after the REAL fabricators... but, here's my modest offering. Its my first tube chassis. And its as straight as my crooked garage floor, tape measure and HF digital angle finders allow it to be.

 

[blue dog]

Thank's Bluedog, I enjoy making headers, somehow I find it relaxing.

You do some fine work yourself, I would like to see some more.

I would never even attempt to make headers, would have no idea where to start, i will leave that to the guys that are masters in metal like yourself. My work is far more crude and i do not get to do it enough, but i do love it. Here is a truck that has been basterdized by as many people that have owned it over the years, since we got our hands on it from a guy that was in serious financial trouble, we have re done 1/4 of the truck, it is now just a pre runner as it has a cage that is not score legal and would be far to much work to rebuild in 2" 4130 and it has a 513 that seems to always have some kind of issue, other then that it is fast enough to scare you and it has a clean 21" of travel in the front and 26" out back. I love this thread, it brings out all the folks that have a serious common interest.

 

[blue dog]

This is not mine, but i got to take a good look at it when i was at King of the hammers last year, It is a crazy machine, all stainless, all fabricated by hand, has a nissan engine that runs hydraulic motors at each wheel, This was the most insane machine i have ever seen. There is a thread about it on PIRATE4X4.COM somewhere.

 

[ZTFab]

This is why I don't do more fab projects. For my aluminum roof rack I measured the roof, modeled a rack, performed stress analysis on the model..., modeled a welding fixture (so that I can reproduce them, I sold them for a while) built the rack from drawings and the fixture, and it fit perfectly the first time (well, the second time once I figured out the weld order to manage warpage), powdercoat, route wires, build a fuse panel (or two) for the lights and other accessories, drill a 5/8" hole through a 3/8" thick portion of my roof, and presto, rack is done.

That's a good looking rack Boiler. Nice job on the whole project.

....wait, did I just tell another guy that he had a nice rack?

 

[ZTFab]

I'm almost ashamed to post after the REAL fabricators... but, here's my modest offering. Its my first tube chassis. And its as straight as my crooked garage floor, tape measure and HF digital angle finders allow it to be.

Don't see anything wrong with what you've got there. In fact, I see a lot of nice looking work.

 

[ZTFab]

Here's another Polaris RZR that I built;

 

[motorbreath53]

ah, that RZR is too bitchin. We're hoping to buy one next season. I'd buy one today if my bug was finished...

 

[ZTFab]

Thanks.

I have a 2011 RZR 4 and LOVE it!

 

[Camshaftcarb]

I feel silly to add this following the gorgeous projects already posted, but it is a form of tubing.

Here is a little something I whipped up for the girlfriend to get myself out of the doghouse after a horrible birthday present earlier this year.

It's 3/16" copper brake line I soldered together, its about 20" x 20". Total time was about 20 hours, but it was all free time at the office. She was happy.

Second pic is my attempt at going for the "Oil rubbed bronze" finish to match the door handles and hardware around the house, but looking at it up close I think I really need to redo it.

 

[illmatyk]

Some of my latest tubing work.

Sandrail chassis construction.

More tubing bent, fishmouthed and welded. In the background is my son's new tube project. A sand quad which will have a large two stroke engine.

Tubes powder coated.

Rolling chassis.

Completed.

Black quad is my son's which we back-halfed with 4130 tubing. Rear frame sup-frame and rear swingarm. Green bike is completely fabbed by my son and I in our shop from 4130 tubing and has a GS1100 bullet bike engine. Both bikes were featured in Jan/Feb 2010 Sand Sports Magazine. Mike.

Thats an awesome buggy!

 

[PCO6]

It's been a long time since I've done a "tube" project but that's basically what this is. I designed it my head and chalked it out on the floor ... which fortunately was flat.

Does "square" tubing count?

 

[Heavy Metal Doctor]

Great work everyone! I wish I had the chance to work with some of these projects...All I get to do is chop up straight chunks of square and rect. tubing for assorted machinery stuff.....simple stuff like this: