The fabrication thread.

[D.Adams]

Originally Posted by duffman1278

Any of you guys have any suggestions for mocking up an exhaust before cutting and welding? I was thinking about using PVC to see where all the bends and layout would be but it seems really restrictive?

Originally Posted by drftmark

I would like to hear some advice on this topic as well... I am in the process of making one also.

I was planning on cutting a bunch of 15 degree pie slices and just going from there. Or possibly spending some extra money and getting pre-bent pieces.

Any input from the pros?

I use Tig welding ROD. I do all my bends leaving 2 1/2'' to 3'' around the rod for the actual exhaust pipe size. Then i transfer it to the pipe as i bend it. I also do that for roll cages and pre runner bumpers.

[atutt]

Originally Posted by Otto347

Yeah, atutt has no fucking clue what hes talking about.

I concur. I'm just a crazy bitch! lol

Originally Posted by duffman1278

Any of you guys have any suggestions for mocking up an exhaust before cutting and welding? I was thinking about using PVC to see where all the bends and layout would be but it seems really restrictive?

Originally Posted by drftmark

I would like to hear some advice on this topic as well... I am in the process of making one also.

I was planning on cutting a bunch of 15 degree pie slices and just going from there. Or possibly spending some extra money and getting pre-bent pieces.

Any input from the pros?

It's really hard to comment because each exhaust will most likely be different.
The is no "set way" of doing it.
using PVC can work. It may be more costly up front and more time consuming.
But, doing an exhaust in one shot with out any fuck ups tends to be more cost efficient in the end.

You could also try that dryer ducting crap. It's thin and comes in large diameters. So it'll be nice and light to work with. I don't know what it costs though. And you can get that flexy shit for it.
Toilet paper rolls could be used.

I just use a shit ton of clamps. Modify them if need be.

[duffman1278]

I think I'm going to try that dryer ducting material, seeing as this will be the first exhaust system I've ever done I'm trying not to make too many mistakes along the way.

[Jonnie Fraz]

Well fabbed up some mounts for my buddies car...


Bonus points if you can name the chassis and the motor...lol

[mestizo]

Originally Posted by Jonnie Fraz

Bonus points if you can name the chassis and the motor...lol

I can! lol but I guess it would be cheating if I said something. hahaha

[Houseof1817]

Hell, I was wondering if anyone would be able to point me into the right direction..
I'm looking for some replacement rocker panels, and have no idea who is custom fabbing them or what else I could do instead
just in case I am already screwed.

[E Double]

damn Jonnie, those mounts are nice.

[repda916]

where did you get that rubber isolator?

[Wolf45]

Ae86 Beams motor. Hahaha The motor mounts is a dead giveaway. Give me something harder.LOL

[Jonnie Fraz]

Originally Posted by Wolf45

Ae86 Beams motor. Hahaha The motor mounts is a dead giveaway. Give me something harder.LOL

Good job! The motor is a giveaway, but not too common here in the states, and really not common on Zilvia.

Here is another pic...


Down pipe is gonna be fun.

[Jonnie Fraz]

Originally Posted by repda916

where did you get that rubber isolator?

Brewed them up in my secret lab...lol.

Stock AE86 mounts...I was thinking they would be awesome for S chassis, to lower the motor a bit. Maybe I will give it a try...lol.

[Peter89#2]

read the entire thread. epic.

[shiftdrift]

at work today they had me make a prototype for something, this isn't the finished product, afterwards i put on a lid with hinge's/handle.

[xdumbxguyx]

spec miata cage ive been working on just need to finish the nascar door bars

[Broadfield]

Well this has nothing to do with welding, like most other fabrication on here, but it is fabrication nonetheless. I do a ton of custom fiberglass fabrication for audio systems, but I won't bore you with that. I will only post relative to the 240 performance world. I also won't post anything on my own car since it's been seen before.

Some how I got into building custom clusters for people. It obviously started with the creation of my own, but I have received a lot interest in building one-off units for customers. So I have been doing some molded HUD steering shrouds like my own, various clusters, molded in turbo timers etc. I never supply any of the actual gauges, electronics etc... just the fab work.

***You can click on each title for a link to the actual build pictures***

Please feel free to ask me any questions. I am always forthcoming with my tips, tricks, materials used etc. I posted the picture link to each build because I feel that pictures tend to describe the process on this type of work better than words. Also, if you want any pics/info about custom fiberglass audio work, just let me know and I can post up a couple pics and a build link to those.


S13 Map Light Molded Turbo Timer









S13 Defi Gauge Cluster









S13 Defi HUD Molded In Steering Shroud









S13 52mm Center Vent Gauges











S13 Glove Box Control Center












S13 Digital Fuel Level In Cluster Shroud










S13 Race Tech. Dash2 Cluster

[Nezahualcoyotl]

Such quality work Broadfield.

[thaivietg714]

wow excellent work Broadfield. What kind of paint did you use?

EDIT: nvm i see it in the photos.

[Broadfield]

Originally Posted by Nezahualcoyotl

Such quality work Broadfield.

Originally Posted by thaivietg714

wow excellent work Broadfield. What kind of paint did you use?

Thanks guys!

First of all, I like to use all SEM products for my small project finishing coats. So for the texture, I use SEM Texture Coating 39853. For almost all of my finishing colors, as the texture coat is not a final finish, I like to use SEM Landau Black 15013.

[shiftdrift]

interested in the fuel level light. how much?

[atutt]

Truly impressive Broadfield... Post up more awesomesauce if you got any!!

[ka-titties]

wow thats some really, really cool work.

[Broadfield]

Originally Posted by shiftdrift

interested in the fuel level light. how much?

The fuel level is actually really easy if you want to attempt it yourself. But if you just had to have me do it, it would be $75 labor. You would have to send me your shroud and whatever 52mm fuel level gauge you want in there.

[shiftdrift]

ah, i was just interested in the actual gauge. i can do the work.

[Broadfield]

Originally Posted by shiftdrift

ah, i was just interested in the actual gauge. i can do the work.

Yeah, you didn't read my post... "I never supply any of the actual gauges, electronics etc... just the fab work."

[shiftdrift]

Originally Posted by Broadfield

Yeah, you didn't read my post... "I never supply any of the actual gauges, electronics etc... just the fab work."

haha, i read it. it was more just of a question of where to get it. sorry.

[Broadfield]

Originally Posted by shiftdrift

haha, i read it. it was more just of a question of where to get it. sorry.

Lol, I just hit ya back with a PM.

[atutt]

Broadfield. If you wouldn't mind, could you PM me where you got that as well?
I'm really diggin it.

[Broadfield]

Originally Posted by atutt

Broadfield. If you wouldn't mind, could you PM me where you got that as well?
I'm really diggin it.

No need for a PM, otherwise everyone else is just gonna keep PM'n me about the same thing.

It's just a round 52mm digital fuel level gauge. You can get them from Summit, Jegs etc. etc. Or a million places online. I use a Nordskog piece, but the exact one I use is no longer available. I think they may still make it in other colors though. You can also try Cyberdyne, Dakota Digital etc.

That's why I used the smoked plexi on the front, that way you can't tell it's a round gauge behind a square hole. It's blacked out when off, then just the digits shine through when on.

[GSXRJJordan]

Broadfield, you're a class act. Great projects, great finish-work, and excellent documentation/posts.

[Om1kron]

I fapped....