The fabrication thread.

[GSXRJJordan]

Originally Posted by atutt

I don't know if you know this.

Welding galvanized is really dangerous. The fumes given off while welding are highly toxic. This is caused by the galvanization process.

Make sure you are in a well ventilated area and wear a respirator....

When I say this shit is toxiz. It's really bloody toxic. Can can a whole heap of problems...

I knew that it was dangerous, but I always wear a mask. I'll make sure to set up the fan for that, too good lookin out!

Originally Posted by Om1kron

you would have to make an angry earl bash bar to utilize those....

That's not enough, because the whole weight of the front of the car will be on that bar - you need a vertical support that ties into the upper radiator support, or at least up the sides.. then there's the trouble fitting said supports around the intercooler...

... and if you run any "real"/aggressive aero, you'll need the wheels on the outer corners, which looks lame. Corvettes have that long nose, then about a foot behind that is the actual air dam, which has the wheels on it. Recessed air dam's are laaaaaaaaaaaame.

[ThatGuy]

No intercooler for me, and not very aggressive on the Aero. Thus I'm trying to design this.

[GSXRJJordan]

Originally Posted by ThatGuy

No intercooler for me, and not very aggressive on the Aero. Thus I'm trying to design this.

Here's what I'm thinking:


You want the force to push the car up not back. Also, like I said above, you'd need some more vertical reinforcement - and those need to tie into something significant, hence the up/down mounting bars (like the OG bash bar has on the bottom).

Not *bashin* the original bash bar design (pun! ), just saying it needs some mods to work for this purpose

I've got 3/4" square tubing, and picking up the welder tomorrow, might attempt this just for *shits and giggles* myself.

[alexander500]

Originally Posted by GSXRJJordan

How's it connected to the frame? The 2" angle stock is welded to... what?

Need moar pics!

Your favorite, Jb weld son.

It is just tacked together in that pic, the angle bolts to t e stock location and the DOM is welded to the angle.

Super precision engineered relief cuts were made in the foward facing DOM so it will buckle oh so softly and cushion the impact.

[GSXRJJordan]

Originally Posted by alexander500

Your favorite, Jb weld son.

I dig it. I don't know about any relief cuts protecting the stock bolt location, that shit looks like it'd crumple if I look at it funny, much less hit something with the car.

[Jonnie Fraz]

here is one I did for Mestiso for his December comp. at Thunderhill.

In this pic you can see it is not just a straight piece of tube.

Basicly it was a bumper support for his new kit. The OEM one would have had to be cut to pieces for it to fit.

Fits pretty nice I think

[rappadan]

^ alexander500 did the same thing for his crash bar but better. Actually gave it room to give. bar goes all the way to the front of the bumper. basically you can kick the bumper and its just the bar right there. will get more pics up asap.

[bloodangels13]

did it for you Dan... lol slacker

[roco]

im new here but just thaught id add a few of my builds, not quiet up to the standard of the others but hey.

tunnel and turrets i did in a ae86 corolla.
Tacked in place



and finished


Big hole



the finished product, my sexy new turrets,



coilovers bolted in, lookin sweet.

[Saskacer]

A nice first post for roco. Nice work.

[GSXRJJordan]

Going IRS on a AE86 or Foxbody is always cool with me

Welds look good, my question is how'd you measure where you wanted them? Mock it up with your best guess-timate, and then make sure the other side matched?

Very cool regardless!

Just got back from picking up my Hobart 135 welder (cheaaaaaaaaaaap) and a mandatory trip to Harbor Freight for misc other stuff - ended up spending like $200, but I got a chop saw, grinder, pneumatic seat (to roll around with, finally), cordless drill (my $200 Craftsman got jacked I think :/ ), bearing race drivers (for pressing out bushings/bearings, fuck using sockets), metal files, etc, etc.

Super excited to start on all the fab stuff I never did before due to not having a welder of my own.

[babowc]

chop saws are such a bitch to work with... i have one...
band saws are nice... I wants one...
I need to clean up my work table so I can do some of this shit too.. I'll post up my exhaust "pie" cut fab.. looks like shit though.

[GSXRJJordan]

Originally Posted by w00tang

chop saws are such a bitch to work with... i have one...
band saws are nice... I wants one...
I need to clean up my work table so I can do some of this shit too.. I'll post up my exhaust "pie" cut fab.. looks like shit though.

I like chop saws because they cut straight every time - as long as you angle the piece how you want it, the saw will cut straight (not always the case with bandsaws/me moving the metal).

Althought I almost bought this cute lil bandsaw they had lol. I swear I'm never an impulse buyer except at Harbor Freight, or a car/bike dealership where I have a huge hookup.

[roco]

Originally Posted by GSXRJJordan

Going IRS on a AE86 or Foxbody is always cool with me

Welds look good, my question is how'd you measure where you wanted them? Mock it up with your best guess-timate, and then make sure the other side matched?

Very cool regardless!

Just got back from picking up my Hobart 135 welder (cheaaaaaaaaaaap) and a mandatory trip to Harbor Freight for misc other stuff - ended up spending like $200, but I got a chop saw, grinder, pneumatic seat (to roll around with, finally), cordless drill (my $200 Craftsman got jacked I think :/ ), bearing race drivers (for pressing out bushings/bearings, fuck using sockets), metal files, etc, etc.

Super excited to start on all the fab stuff I never did before due to not having a welder of my own.

thanks guys. thats my current project. its a ae86 with a 1uzfe v8, s13 rear axle, s13 front lca's,hubs and breaks, and loads more stuff, ill put up a full build thread, where do i post full builds?

@gsxrjjordan, yeah thats prety much it. i mounted the rear axle. then cut out the original turrets, sat the shock in. i measured the compresion on the coil with the weight of the car which was 30mm and then tacked the top plate in place when it was sitting prety. i meant to take pics as i do stuff. but i always forget.

[babowc]

Originally Posted by GSXRJJordan

I like chop saws because they cut straight every time - as long as you angle the piece how you want it, the saw will cut straight (not always the case with bandsaws/me moving the metal).

Althought I almost bought this cute lil bandsaw they had lol. I swear I'm never an impulse buyer except at Harbor Freight, or a car/bike dealership where I have a huge hookup.

really?..
apparently.. my shitty home depot chop saw clamp sucks ass.. :/

[GSXRJJordan]

Originally Posted by roco

i meant to take pics as i do stuff. but i always forget.

Haha me too! That's why I love having my g/f around, she loves to take pics while I'm doin shit.

Originally Posted by w00tang

really?..
apparently.. my shitty home depot chop saw clamp sucks ass.. :/

Lol guess so. I use rubberized "quik" clamps to the base of my chop saw (with the rear adjustment set at the angle I want) and it's easy peasy.

I used to try and cut bar stock/etc with a sawzall or a circular saw lol - nooooottt fun.

[roco]

this is a converion i did to a customers car. ae86 with f20c. i just did the fab, the customer wanted to do the rest of the wireing and plumbing himself.

started at the start.



what we were given



f20c

fabricated up the cross member,



we used mk2 escort engine mounts as the s2k ones were shot.
after we had the engine sitting where we wanted, we made a frame for the new tunnel. this gave a bit of rigidity to the bulkhead and tunnel.






we then primed and painted the new tunnel.









after that we just bolted it all back together, and we had another f20ae86

[bardabe]

FUCK tig welding sunroofs shut! lol

[Otto347]

UPS man just dropped this off for me!

Going to make bending a lot better!

[Om1kron]

it's a tube? does it have those mandrel rings in it or something?

[Otto347]

Originally Posted by Om1kron

it's a tube? does it have those mandrel rings in it or something?

lol nah its the cylinder add on for my bender

[Om1kron]

oh cooooooooooooooooooool!

[Otto347]

Originally Posted by Om1kron

oh cooooooooooooooooooool!

Yeah, its going from a bolted in the ground stationary manual bender to a roll around hydraulic. So no more "shit the benders in the way" crap lol

[GSXRJJordan]

^^^ Awesome Otto! If I was a baller, I'd have a roll-around hydraulic bender...

... as it is, I have a roll around pneumatic...chair?

[Otto347]

Originally Posted by GSXRJJordan

^^^ Awesome Otto! If I was a baller, I'd have a roll-around hydraulic bender...

... as it is, I have a roll around pneumatic...chair?

lol well its not as baller as it seems.

I got the bender for $295 from tricktools.com built my own stand and cheater bar and was up and running. I wanted a hydraulic from the get go but the $900 price tag on top of the bender was a little much at the time. So I have been checking around and found a guy that was selling that cylinder for $250 (trick tools and JD2 wanted around $380) and the adapter kit to put the ram on the bender is on tricktools for $95 dollars. Found an air/hydraulic pump on ebay for around $200 to $250 and having the hose made should be around $40 max.

So all in all I saved myself $400 just because people want to overcharge for that cylinder for some odd reason. But the next closest thing to what I have with the cart I built for it is the JRM unit (which is a electric/hydraulic unit) and retails for around $2500

My cart looks very close to that one.

So all in all im kind of a cheap ass

[silviaguy240]

how much filler do you guys use when tig'ing stuff? i seemed to have better results not using any on my one project i did in school. i actually layed down a nice weld too, gotta get some pics of it.

[sidewayz240]

Picked up some broken battle version t/c rods on the cheap. One of the aluminum pieces was snapped.


Lathed a piece of 6061 aluminum down, drilled it and CNC'd it flat



All done


Also machined a bunch of spacers for some adjustable arms I'm working on.

[Jakob]

wow that looks incredible!! i love cnc'd things.

[roco]

thats some good machine work. i have alot of respect for machine work as id love to be able to do it. nothin like makin yor own parts.

[fakeshemp44]

while these same pics are in my build thread, this was my first attempt at pie cuts, with the Full Race manifold I have the twin waste gate design just begs for some nice dump tubes, but no one makes them, so I did. Be nice fokes.





while I still need to get the turbo bolted on to check clearance of the downpipe and the wg tubes, this is just scrap pipe I had laying around, the final product will be much nicer and hi-temp painted or ceramic coated.