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Old 06-24-2017, 08:02 PM
in33anity's Avatar
in33anity in33anity is offline
Join Date: Dec 2015
Location: Bridgehampton, New York
Posts: 63

Bill, Looks great!!!

Scratch Building Bugatti Atlantic 57SC with BMW S65
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Old 06-24-2017, 08:45 PM
longyard longyard is offline
MetalShaper of the Month September 2013
Join Date: May 2012
Location: Winston-Salem, NC
Posts: 950

Thanks Ira. I'll be up at Wray's class in October. Hope to see you there.
Bill Longyard
Winston-Salem, NC
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Old 06-25-2017, 07:30 AM
hlfuzzball hlfuzzball is offline
Join Date: May 2009
Location: Plymouth, mi
Posts: 131

Bill, you picked the toughest place to shape on your body to begin with. The rest of the project will be easy, well maybe not easy but downhill from here. I admire your guts to take on a project this large and difficult. Good work !
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Old 06-25-2017, 11:57 AM
mastuart mastuart is offline
Join Date: Oct 2016
Location: Mendota Il
Posts: 21

Atta boy Bill! Looks good. Here is a thought for the other side. Make the headlight ring mount a separate piece. Might be more welding but it might be a cure for the coming up short. I hope this link works.

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Old 06-26-2017, 10:39 PM
longyard longyard is offline
MetalShaper of the Month September 2013
Join Date: May 2012
Location: Winston-Salem, NC
Posts: 950

I need to wrap the nose grille panel around the actual steel tubing I will be using in the Superleggera structure. I hadn't originally planned to do this, but thanks to Mark Savory and Rick Mullin I realize I must do it this way.

Here's how I made the tubing...which I ALWAYS find difficult to work.

I made a template out of aluminum 1/2" air conditioner tubing. It is soft and easily formed.

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I used a Pexto stove pipe stake to shape 1/8"x1" hot rolled bar to the inside shape of the template (careful two handed pushing down over many places). After tack welding the upper horizontal of the bar to the bench near the center, I pulled each leg in about 3/4" and tack welded some more. This was absolutely "by guess and by golly" mixed with a bit of previous tube bending experience. I did this to anticipate spring-back of the tubing.

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I welded a short stub of 1 1/4" tubing on the work table near the left side of the steel bar. I used a length of electrical conduit and slowly bent it around the steel bar. I DID NOT pull on the end of the tubing length, but kept my hands as close to the steel form as possible. This kept the shape closer to form without it bowing out.

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On my first attempt, the finish shape was very close, but the spring-back on the right side was more than on the left side. I therefore decided to try it again, but this time I only bent 1/2 at a time, and once I had the first half bent, flipped the tubing over (after careful measuring) and bent the "right side" of the tube in the left side of the steel form. The result was MUCH more symmetrical.

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After trimming the tube to length, note the amount of spring-back. Fortunately, the steel tubing now matched the aluminum template exactly.

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Painful experience has taught me how nearly impossible it is to get a really tight (2" radius?) in electrical conduit without special dies. Instead of fighting the system, I cheated a bit and cut the 90 degree corners out of a base for a halogen lamp. You see the corners on the table ready to be welded and joined by a straight piece of tubing. Another halogen lamp base is in the center of the photo to show where the pieces came from

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Tomorrow I will weld the pieces together; I'll then curve the grille hoop to conform with the curve of the nose; and then I'll begin to carve out the wooden nose to accept this hoop.
Bill Longyard
Winston-Salem, NC
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Old 06-27-2017, 06:58 AM
Gojeep Gojeep is offline
MetalShaper of the Month March 2015
Join Date: Nov 2013
Location: Eastern Melbourne, Australia
Posts: 1,354

Thanks for showing how you did this Bill.
aka. Gojeep
Victoria, Australia

Invention is a combination of brains and materials.
The more brains you use, the less materials you need.
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Old 06-27-2017, 06:20 PM
Charlie Myres Charlie Myres is offline
Join Date: Jun 2013
Location: Narrogin, Western Australia
Posts: 170

A well thought out plan that has come to fruition!

Thank you for showing us the technique and the problems encountered and how you overcame them Bill,

Cheers Charlie
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Old 09-09-2017, 04:57 PM
longyard longyard is offline
MetalShaper of the Month September 2013
Join Date: May 2012
Location: Winston-Salem, NC
Posts: 950

I've been making slow progress on the 166 project. Had the grandkids here for 3 weeks...and then a leaking roof...and then... well, you know the story.

In the last episode I finished with an explanation of how I made the tubular grille opening hoop.

Here I've set the hoop into the solid buck and am about to fair it into the buck using "cat's whiskers" fiberglass resin. The hoop was first wrapped in very thin HVAC aluminum tape so that the fiberglass could be removed from it later.

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I cut out a piece of aluminum to fit into the grille opening and welded in in place.

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I annealed it where I intended to roll it around the hoop.

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Forming the annealed sheet around the hoop into the "mouth".

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Using a Zephyr weld shaver to skim off the weld bead. (Thanks Kent White for introducing me to this tool!)

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Using a hole saw to cut through the solid #2 buck station (1/2" plywood).

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After completely opening the "mouth", I cut slots in the solid buck to join the chassis to the hoop, thus locking the hoop in fixed position. With it locked like this, I can always locate the aluminum nose in an exact position. I joined the chassis to the hoop with 5/8" .049 tubing.

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The hoop is located with 4 tubes, but diagonal bracing will be added as well as aluminum sheet to form a duct to the radiator to prevent airflow reversion.

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Starting to mock up the door shape with thin cardboard.

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I mislocated the primary bulkhead hoop and needed to redo it. I decided to make it out of smaller tubing which is closer to the original Touring style. They used round tubing clad with thin sheet steel.

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Bill Longyard
Winston-Salem, NC
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Old 09-09-2017, 06:32 PM
vroom vroom is offline
Join Date: Feb 2015
Location: SW Wisconsin
Posts: 29

I would say you are rolling right along Bill. Looks great!
Tim Freeman
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Old 09-10-2017, 08:39 AM
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RockHillWill RockHillWill is offline
Join Date: Oct 2009
Location: Rock Hill, South Carolina
Posts: 2,619

Nice progress Bill, keep us informed of your progress. We all learn something

Imagination is more important than knowledge - Albert Einstein

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