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  #11  
Old 12-14-2014, 08:52 AM
Mike Motage Mike Motage is online now
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The box was planned to be only as long as the underside would be flat, which was to the front and rear edges of the respective wheel openings. Slightly narrower than modified body lines, I used easy dimensions. The box is 36"wide x20"tall. 0124131233.jpg

0419131736a.jpg At each end of the box I have full width rib laid out in the same manner as shorter ribs. These full ribs make these areas obviously inline and serve as datum for the all other ribs. Smaller boxes serve to take up space on the ends of main box. Everything is checked and verified square.
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Last edited by Mike Motage; 01-01-2015 at 07:57 PM.
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  #12  
Old 12-14-2014, 09:25 AM
Mike Motage Mike Motage is online now
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Small spacer/ locater blocks were cut from cutoff scrap and screwed into the box at an angle, which draws tight against the individual ribs enough to hold them secure but temporarily. When all ribs were cut I tried to determine logical locations for outer spacer blocks to aid in clamping and the viewing/ lightening openings.0205131838.jpg

1115131229.jpg
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Last edited by Mike Motage; 12-20-2014 at 12:47 PM.
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  #13  
Old 12-14-2014, 10:49 AM
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Kerry Pinkerton Kerry Pinkerton is offline
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Mike, how did you handle the slope? Is the contact point on each rib the "HIGH" side, which would mean your spacing has to change as the slope changes from positive to negative? Or did you use the same side of each rib and sand away to match the profile?
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Old 12-14-2014, 11:13 AM
Mike Motage Mike Motage is online now
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Kerry, the ribs were cut slighty large about (2mm) in areas where slope is a concern. In those areas I marked the center of the ribs so when I profile sanded them down I could sneak up on the shape.0606131159a.jpg
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Old 12-14-2014, 12:20 PM
Mike Motage Mike Motage is online now
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I found a better picture to show the slope on individual ribs. At least half of the width gets blended.1115131230.jpg
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Old 12-15-2014, 10:52 AM
Mike Motage Mike Motage is online now
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In the last picture, if look at the car on the platform, you can see the laminated foam and the thin layer of clay. That foam is cheap, the clay is about $6/lb. It could have been done with 60lbs, but I used 100lbs because of a mistake.
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  #17  
Old 12-15-2014, 03:08 PM
Mike Motage Mike Motage is online now
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Here are some pics of the viewing cutouts. These also lightened the buck considerably. I made patterns so the buck would be balanced and slightly self leveling. Some additional holes were adding to assist clamping. 1215141405.jpg

1215141410.jpg

1215141407.jpg
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Last edited by Mike Motage; 12-20-2014 at 12:51 PM.
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  #18  
Old 12-15-2014, 03:23 PM
Mike Motage Mike Motage is online now
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The outer spacer blocks were cut from 2x3x6ft boards purchased at half price from the local home improvement store because boards were badly warped. Blocks were cut so that some were slightly shorter and some longer to correct for varying thickness of the plywood. The blocks were placed to help identify contours and again aid in clamping. 0330131731.jpg
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Last edited by Mike Motage; 12-29-2014 at 12:29 AM.
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  #19  
Old 12-15-2014, 03:44 PM
Mike Motage Mike Motage is online now
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Before the ribs are secured to the big box, the height was set by using a long straight extruded bar. The bar is hung from the full width ribs and adjusted to the intended ground clearance. Now the remaining rib heights are set by measuring from the bar up, simulating measuring from the ground up. 0222131154.jpg
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Last edited by Mike Motage; 12-20-2014 at 12:54 PM.
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  #20  
Old 12-15-2014, 07:20 PM
Mike Motage Mike Motage is online now
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The wheel opening ribs were cut leaving extra 1/2" material towards the tire, to be trimmed later. MDF was used to fill the edge of the fenders. Blocks of MDF were made from 3 layers laminated together, one piece being longer to form a tab to screw to a single rib. 1116131431.jpg

0523131532a.jpg
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Last edited by Mike Motage; 12-20-2014 at 12:55 PM.
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