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  #1151  
Old 03-01-2019, 09:50 PM
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Steve Hamilton Steve Hamilton is offline
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Jack the bumper is coming along nicely. Thanks for sharing the process! You are making it look easy, but I have found that stainless can be a challenge.

Steve
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  #1152  
Old 03-02-2019, 06:13 AM
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Interesting way to go about it Jack. Just wondering though how will you correct distortion from fully welding the main section to the tubing top and bottom? Wont be able to stretch the weld with it being on top of the hollow tubing I would have thought?
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  #1153  
Old 03-05-2019, 09:38 PM
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I transfered the license plate recess to some stainless sheet and cut it out. My friend's sheet metal brake is a pan brake, not a box break so I couldn't use that to bend this. I started the bends on the bead roller, then finished them with the small brake that I have here. This sheet is difficult to work with. I have my reasons for using it but it is fighting me all the way. I will prevail.
Anyway, I got that tacked in and moved on to the outer corners.

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Next is the left outer corner. This little part turned out to be the most difficult part on the whole assembly. It is small and has a few different shapes. I started by stretching a small V shape near the lower edge and up the rear edge to form the shape where two rolled edges meet. I rolled the lower edge and the rear edge in on the E wheel with the PU wheel, then a couple rounds in the planishing hammer. Back on the E wheel with the steel upper wheel. Lots of test fitting and a few more passes in the planishing hammer and E wheel. Some hand manipulation here and there and I got it. Final trim along the edges and I tacked it in.
I have been making these panels with close enough fit to the frame that I can hold them in place with one finger and every edge touches the frame. I don't want to force fit them because they will want to spring back to their original shape. That will put internal stress or load on the frame that will reappear when I start welding. Stainless moves around a lot when welding compared to regular steel. If there's internal stress it can cause all kinds of warpage and twisting problems. It will be tricky enough to get this done right under ideal conditions. I don't want to add more potential problems. To tell the truth, I'm somewhat intimidated by the upcoming welding process. I'll give it everything I've got and hope for the best.

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  #1154  
Old 03-06-2019, 10:41 AM
billfunk29 billfunk29 is offline
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Default Heat dam

I humbly submit some advise to the Master. In past projects with similar, tube/rod edges, I minimized the distortion with a heat dam. A secondary gas purge (top and bottom) can also minimize the clean up of the polished surface.
https://markal.com/products/anti-hea...rbing-compound
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  #1155  
Old 03-06-2019, 12:09 PM
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Quote:
Originally Posted by billfunk29 View Post
I minimized the distortion with a heat dam....
Thanks, Bill. I thought of that. I saw a guy use drywall plaster once. Messy but it worked.
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  #1156  
Old 03-06-2019, 03:54 PM
hillman hillman is offline
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Jack
Masking tape can work really well on the back side, a bit of scrap to practice on to get the amps right, but once again very messy.
Burns away while your welding but works ok with practice.
Cheers
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  #1157  
Old 03-06-2019, 04:54 PM
Charlie Myres Charlie Myres is offline
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I use a wet towel, or wet shredded-paper but the surface needs to be horizontal ideally,

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  #1158  
Old 03-10-2019, 07:45 PM
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Default Jack, Your better than GMC, Ford & Fiat put together!

Title says it all. Fred26T
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  #1159  
Old 03-11-2019, 07:07 PM
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I got the right outer panel finished and tacked to the frame, so this is ready to be welded. I removed the bumper and did some finish welds on the frame and added a temporary brace along the top edge to try to keep the bumper from moving while welding.

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Next, I made 4 foam patterns for the grommets that hold the rear backup sensors. These will be cast in aluminum and polished but I'm not going to have them done right away. The last pieces I'll need cast are two pedestals or perches for the side view mirrors. I'll mess with those when I've finished the bumper.

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  #1160  
Old 03-11-2019, 07:32 PM
AllyBill AllyBill is offline
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Loving this build. Makes me nostalgic for when I messed with cars - almost.
Did a lot of stainless for the yacht-types too as I live on the coast. Best answer I found to the awful distortion problems you get soon as you weld the stuff was infinite patience. Do a tiny stretch then let the heat go away. Getting greedy just heats the job, changes its shape then the next weld goes and captures the shape it twisted itself into because you got it too hot. Even then it'll crack if you give it a hard stare. Stainless is the Devil's material!

Will
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