 BUILD-OFF CHALLENGE: Tygaboy's '75 LS3, It seemed a good idea at the time... |
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| tygaboy |
 Apr 30 2019, 04:07 PM
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#1581
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914 Guru  Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California 
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I decided to go all in on the carbon fiber insert look. So today, I drew up and cut the stamping dies for the fire wall's main panels. Here's the driver's side done. It looks so much more refined than the one on the passenger side. Plus, it's a bunch more rigid with the shape it now has.
One thing you can just barely see (but that I didn't think through) is that the door bar trim piece will need to be a tic smaller in diameter as it nearly touches the edge of the recess. Not a big deal but one of those fun "Hmmm, didn't see that coming" moments that cause a small step back. Ah well, just another of the joys of handmade... (IMG:style_emoticons/default/smash.gif) On to the passenger side! Attached thumbnail(s) 
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| tygaboy |
Apr 30 2019, 04:14 PM
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#1582
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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And if you're interested in a bit more detail on the stamping dies, here's a quick vid on how it all works. One of the folks on the ArcLight plasma table user forum asked for some details so I figured I share here, too.
https://www.youtube.com/watch?v=iqzP--Jd4c0 |
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| restore2seater |
Apr 30 2019, 04:44 PM
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#1583
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Future 914 copilot. Group: Members Posts: 311 Joined: 30-October 04 From: Dunlap,IL Member No.: 3,037 Region Association: None |
How are you going to attach the carbon fiber to the steel?
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| tygaboy |
Apr 30 2019, 06:25 PM
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#1584
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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QUOTE(restore2seater @ Apr 30 2019, 03:44 PM)  How are you going to attach the carbon fiber to the steel? I'm going to test out using a 3m structural panel bonding adhesive around the recess, then I'll lay up (standard wet layup) additional carbon fiber across the entire back of the panel so the recess lip is sandwiched between the carbon insert and carbon backing. |
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| Andyrew |
Apr 30 2019, 07:52 PM
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#1585
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Spooling.... Please wait Group: Members Posts: 13,377 Joined: 20-January 03 From: Riverbank, Ca Member No.: 172 Region Association: Northern California
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Man that looks great!!!
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| tygaboy |
Apr 30 2019, 09:14 PM
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#1586
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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QUOTE(Andyrew @ Apr 30 2019, 06:52 PM) Man that looks great!!! Thanks Andrew! I spent some time tuning up a few spots on this panel and gave it a once over with the DA. After all the time and various iterations, IMO, this firewall is finally coming together - and I really like it. Now to come up with a console design that keeps this same thing going... I hope to get started on it this week. Attached thumbnail(s) 
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| tygaboy |
May 3 2019, 01:29 PM
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#1587
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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I reversed the stamping die pieces and completed the passenger side main panel.
This is a major milestone as that, for the first time, I have all the needed fire wall panels (in a design I like!) and I can begin final / permanent installation of the main pieces. Attached thumbnail(s) 
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| Andyrew |
May 3 2019, 01:36 PM
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#1588
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Spooling.... Please wait Group: Members Posts: 13,377 Joined: 20-January 03 From: Riverbank, Ca Member No.: 172 Region Association: Northern California
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QUOTE(tygaboy @ May 3 2019, 12:29 PM) I reversed the stamping die pieces and completed the passenger side main panel. This is a major milestone as that, for the first time, I have all the needed fire wall panels (in a design I like!) and I can begin final / permanent installation of the main pieces. (IMG:style_emoticons/default/aktion035.gif) |
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| Krieger |
May 3 2019, 06:55 PM
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#1589
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Advanced Member Group: Members Posts: 4,765 Joined: 24-May 04 From: Santa Rosa CA Member No.: 2,104 Region Association: None
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| markhoward |
May 3 2019, 07:39 PM
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#1590
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Member Group: Members Posts: 385 Joined: 5-March 17 From: Lafayette, CA Member No.: 20,897 Region Association: Northern California
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| 914forme |
May 4 2019, 09:48 AM
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#1591
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Times a wastin', get wrenchin'! Group: Members Posts: 3,896 Joined: 24-July 04 From: Dayton, Ohio Member No.: 2,388 Region Association: None
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Looks great Chris, and thanks for the video (IMG:style_emoticons/default/beer.gif) it explained everything. (IMG:style_emoticons/default/idea.gif) Off to CAD land - actually off to my son, as he is faster than I am and cheaper labor rates (IMG:style_emoticons/default/laugh.gif)
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| defianty |
May 4 2019, 10:50 AM
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#1592
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Senior Member Group: Members Posts: 659 Joined: 9-August 06 From: Essex, UK Member No.: 6,621 Region Association: None  |
That looks beautiful!
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| billium01 |
May 4 2019, 12:12 PM
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#1593
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Member Group: Members Posts: 136 Joined: 12-April 13 Member No.: 15,764 Region Association: None |
Looks great!
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| tygaboy |
May 5 2019, 05:20 PM
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#1594
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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Thanks much for the compliments. It helps to hear from others that I'm not completely off track!
Today was prepping the fire wall panels for installation so nothing picture worthy. The problem happened when I noticed the carbon fiber covers I'd made for the longs. I figured I'd give a go to fitting one. None of this sort of thing does anything to helping get the car on the road. But messing with the visuals does help with motivation. It turned out pretty well and I think it'll look really good with the carbon inserts on the fire wall. I'll need to come up with some sort of trim / covers for around the door bar verticals and out to the door seal. Attached thumbnail(s) 
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| tygaboy |
May 6 2019, 04:21 PM
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#1595
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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The raw panels were starting to rust where I regularly handle them so after removing the rust, I gave them a squirt of weld-through primer. I ran out of the silver so some of the parts got the copper-rich stuff.
In any case, adding the recesses to the cover panels really helped control the distortion. There was WAY less this time. Or could it be because I was more judicious with the welding heat? (IMG:style_emoticons/default/idea.gif) Or was it that I planished the tacks and test fit the cover after every 5-10 tacks? Probably everything helped. In the metal shaping world, a sorta rule of thumb is that the panel is ready if it requires only a finger's force (ish) to hold it in place against the shape of the buck. This pic shows the cover in place with no fingers! No fasteners, either. It fits perfectly into the recesses. Yes, there will be some filler to address some of the surface imperfections but overall, it's one of the best results I've been able to achieve so far. And famous last words but I think I'm finally getting the hang of TIG welding. It certainly doesn't hurt that I get practice with the metal art I do. Attached thumbnail(s) 
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| tygaboy |
May 9 2019, 06:35 PM
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#1596
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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Here's the first go at the seal for the removable cover. Just a simple rubber U-channel from McMaster-Carr. Nice and tidy and from what I can see from the engine's perspective, it looks like it'll work just fine.
Next on the list is to work out the cover fasteners. I ordered a couple different sized rivnuts and bolt head styles so I should know what's what early next week. Once that's determined, I really need to get this fire wall fully installed. Attached thumbnail(s)  
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| Andyrew |
May 9 2019, 07:42 PM
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#1597
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Spooling.... Please wait Group: Members Posts: 13,377 Joined: 20-January 03 From: Riverbank, Ca Member No.: 172 Region Association: Northern California
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Boy that looks great!
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| tygaboy |
May 13 2019, 07:51 PM
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#1598
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914 Guru Group: Members Posts: 5,452 Joined: 6-October 15 From: Petaluma, CA Member No.: 19,241 Region Association: Northern California
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Simplicity vs plainness. Simplicity can be elegant but IMHO, plainness is, in most cases, boring. So rather than doing something constructive, today I added some style points to the drive train spacers. You may recall that I used these to move the engine/trans forward in the chassis. They are totally visible, what with the trunk floor removed.
Anyway, they we just big chunky looking things so I cut some relief pockets in them. Then I soda blasted the surfaces before draw filing them, leaving a contrasting finish in the pocket. I may come back and cut them deeper. But they sure look LOTS better. And hey, they're lighter, too! (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/laugh.gif) Attached thumbnail(s)   
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| bbrock |
May 13 2019, 08:08 PM
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#1599
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains
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That is most definitely "Ore-Ida." Nice work! (IMG:style_emoticons/default/thumb3d.gif)
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| preach |
May 13 2019, 08:13 PM
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#1600
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Ridge Runner Group: Members Posts: 1,039 Joined: 27-March 10 From: Live Free or Die Member No.: 11,513 Region Association: North East States
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Haven't been in this thread in a few days. Firewall is looking fantastic!
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