BUILD-OFF CHALLENGE: Tygaboy's '75 LS3, It seemed a good idea at the time... Options

[tygaboy]

Okay I got it, the picture left out one detail, the upper upper die, or that flat piece that sets onto of the 10ga plate that presses down.

I like the setup here, and the bulk head for the fuel lines. Same general setup going inlace at the back of the cabin?

And if you think a plasma table is cheating then keep right on doing it, as the end product is worth the "cheat".

Thanks Stephen. Yep, I'm laying out the rear bulkhead now. It's more complicated as it has to support the fuel lines, brake and clutch lines and throttle cable. Should be fun to make, though. Pics as I get to it...
Thanks again!

[Curbandgutter]

Chris love how your project is coming out. Saw your Tilton pedal assembly....excellent. Loved your magnetic brake and how you did that 1" radius. All that incredible work on that firewall.....my goodness. (IMG:style_emoticons/default/pray.gif) (IMG:style_emoticons/default/pray.gif) Loved your rear trunk/hood and how it opens backward. I may steal that idea. (IMG:style_emoticons/default/shades.gif)

[bbrock]

Using the plasma table really does feel like cheating.

The only thing wrong with using a plasma table is that it fuels my tool envy. (IMG:style_emoticons/default/icon8.gif)
I seriously love seeing this quality of fabrication and attention to detail. (IMG:style_emoticons/default/pray.gif)

[914dave]

it’s a pleasure to watch you exercise your fabrication skills!!!

[tygaboy]

I really appreciate all the kind words. I'll keep posting the details...

Today it was the rear bulkhead. I decided to try a multi-area raise:
one for the fuel lines and throttle cable and one each for the hydraulics (brake line and clutch). Note the only holes that are cut to approximate size are the fuel lines. I'll come back to the others later in the process.

So, first I designed the panel and cut it. I'm using 18 ga. for these sorts of parts.
Then determined the shapes and locations for the raised areas and cut the dies. For this, it's 10 ga. It seems that gives a nice dimension for the raise.
I cut the male parts first, came back and cut the female sections then cut the outline.

[tygaboy]

Then, set the female part on top of the panel and trace the locations of each opening.

[tygaboy]

Assemble the set up for the press:

Female die, then the panel, then the male dies (placed as symmetrically as I can get them!)

I also ran into what I hoped wouldn't be an issue:
I don't have press plates that are large enough to cover this whole piece.
So I figured "what the heck, it's only metal..." and I tried a two-step operation.

First I stamped the dog bone shape, then came back and stamped the two circles.

It worked great!

[tygaboy]

Set in place, just to see how it'll work. Looks good to me.

And I have to say, this all happened with no "practice pieces". Famous last words, but I think I'm starting to figure this out.

[tygaboy]

A quick mock up of the fittings.

[worn]

A quick mock up of the fittings.

Yep. But you oughta make a bunch of them maybe. While you are at it. Nice.

[tygaboy]

Not much progress lately as my wife and I just returned from a week at Cycle Oregon. ~400 miles on our road tandem. Great weather, challenging routes and a wonderful group of people. All you bicyclists should check it out...

Back to the build: There are so many things to do... I decided to go after prepping the fuel tank. Here's the in-tank pump plate nearly ready for welding.

[tygaboy]

The pump I'm running (Aeromotive Phantom 340) has a large piece of foam that sits in its own perforated, rubber-ish "sump". Anyway, this contraption interfered with the stock tank's internal baffling so I sliced out the bottom of the tank to remove it and create the needed clearance.
You can see the "small hole" I now need to close up!

[Krieger]

Looking good! Dang, perfectly cut replacement panel...

[914forme]

Nice work Chris. I'm starting to think we ( as in you ) need to start doing videos of this.

I would gladly be the videographer for this project. Have a access to a couple of 4K cameras and a sling studio so we could stream this work live.


(IMG:style_emoticons/default/drooley.gif)


Sorry all if I get distracted and you miss so of the action or all of the action, you would understand. (IMG:style_emoticons/default/confused24.gif)

I would get the test stream setup, before I got distracted and started to watch Chris work, and all you all get shots of is the floor or ceiling. I know everyone would understand. (IMG:style_emoticons/default/confused24.gif)

[Dion]

Nice to see ya back, but yeah you deserved a break! That tank panel is slick.
Tuned in for more.

[tygaboy]

Nice work Chris. I'm starting to think we ( as in you ) need to start doing videos of this.

I would gladly be the videographer for this project. Have a access to a couple of 4K cameras and a sling studio so we could stream this work live.


(IMG:style_emoticons/default/drooley.gif)


Sorry all if I get distracted and you miss so of the action or all of the action, you would understand. (IMG:style_emoticons/default/confused24.gif)

I would get the test stream setup, before I got distracted and started to watch Chris work, and all you all get shots of is the floor or ceiling. I know everyone would understand. (IMG:style_emoticons/default/confused24.gif)

Thanks Stephen. I can do video so I'll try and remember to do that going forward. In the meantime, it sounds like some folks want more detail on the "how" parts. So I'll provide a bit more on info on how I finalized the fuel filler plate...

[tygaboy]

What you couldn't see in the earlier pics is that one of the corners of the plate needs to curve to match the profile of the tank. I hadn't started on that yet.

So first, I did a rough bend to get that corner closer to the correct shape. This allows for a more accurate scribe/cut line. If I tried to scribe the cut line before I bent the corner, I'd end up removing too much material - the corner will "fall inward" as it's bent down, meaning I need more material there.

[tygaboy]

Then I applied some Dykem. Mostly to make the scribe line show up better in the pics, but it does make things easier to see.

Then I use the handy dandy Harbor Freight body saw to make a rough cut.

I just want to get close with this cut.

[tygaboy]

Next, it's the drum sander to take the opening to the line.

[tygaboy]

Finally, it's "fit, drum sand, fit, tweak the corner bend, fit, drum sand..." until things slip into place and I'm happy with the fit.

Done and done!

There is usually a bit of minor tweaking, maybe some hammer and dolly, as the welding is happening, just to get the edges aligned as cleanly as possible.