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  #251  
Old 06-15-2019, 12:20 PM
heinke's Avatar
heinke heinke is offline
MetalShaper of the Month Jan 2018
 
Join Date: Nov 2009
Location: Livermore, CA
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Post Fresh air intake/air filter box (cont.)

I had to remove all the parts of the fresh air intake so they could get final deburring and polishing. Here’s what it looks like with all the pieces attached.





Then it was on to the finishing/polishing part. This just should have been a laborious, boring task but somehow I found a way to add some excitement to it. One of the rounded corners on the air box top didn’t look quite right so I decided to clean it up with a sanding block. In my zeal to make it look just right, I turned the already thin aluminum into aluminum foil

I should have re-shaped the corner with a body hammer and shot bag instead of sandpaper. My first thought was to add back some thickness by welding some filler on the back side. The thin areas just melted away into holes.



I now had a choice to make; it was either remake the whole lid or weld in a patch panel for the corner. I decided to try the patch panel just to see if I could do it. Using a T-dolly, I formed the rounded corner for the patch panel. I did this with a body hammer to shrink the metal over the T-dolly and give it a nice round shape. The metal thickness went from .063 up to .110 in the area with the most shrink.

After cutting out the corner, welding in the patch and metal finishing, here’s what I got. I used parent metal for the weld filler to minimize the weld seam visibility in this now very visible area of the lid.





After a bunch of metal polishing, I now had a finished fresh air system/air box. I also made some clips out of thin stainless steel to keep the MAF wiring from getting caught up in the belts.







All in all, I’m really happy with how this part turned out. It was also a confidence booster that I could repair my mistake on the lid
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  #252  
Old 06-15-2019, 12:34 PM
blue62 blue62 is offline
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Very nice save
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  #253  
Old 06-15-2019, 01:35 PM
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Steve Hamilton Steve Hamilton is offline
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Looks Great Joel!

Thanks for showing both the good and the oops😬
We all make mistakes, so we all need to learn how to repair them.

I always enjoy following your projects!
steve
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  #254  
Old 06-15-2019, 06:46 PM
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Gojeep Gojeep is offline
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Great save. I have had many an occasion where I thought what do I have to lose but some time. Least I will know the limits of what can be brought back to right again and have been surprised more often than not.
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  #255  
Old 06-17-2019, 10:28 PM
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heinke heinke is offline
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Quote:
Originally Posted by blue62 View Post
Very nice save
Quote:
Originally Posted by Steve Hamilton View Post
Looks Great Joel!

Thanks for showing both the good and the oops😬
We all make mistakes, so we all need to learn how to repair them.

I always enjoy following your projects!
steve
Quote:
Originally Posted by Gojeep View Post
Great save. I have had many an occasion where I thought what do I have to lose but some time. Least I will know the limits of what can be brought back to right again and have been surprised more often than not.
Thanks for following and the appreciation for my oops. I can smile about it now but at the time I sure wasn't smiling.
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  #256  
Old 07-01-2019, 11:37 AM
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heinke heinke is offline
MetalShaper of the Month Jan 2018
 
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Location: Livermore, CA
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Post Headlight Fairing Aerodynamics

On the GTO, Lexan covers were used on the headlights to increase high speed aerodynamics. While these covers make for a real nice look, they are very time consuming and tedious to make.

I had made the aluminum rings that hold the covers in place prior ( http://www.allmetalshaping.com/showp...&postcount=222 ) but found they still need “fine tuning” once fitted together with the Lexan covers. I found a football dolly and rubber hammer most useful for adding some “dome” into the rings such that the edges fit up nice to the surrounding body. I used some 1/16” EPDM sheet rubber to make gaskets to go on backside of the rings. The purpose of the gaskets is to minimize stress on the Lexan covers and chaffing on painted body surfaces.

I sourced the formed Lexan covers from John Washington at VR Engineering. These were carefully cut to rough shape on a bandsaw where I purposely left them a little bit big. I used a body file around the edges to bring them to the final shape. It took lots of filing, trial fitting, more filing, etc. before I was satisfied. A 5/16” tall, adhesive back rubber strip was used under the covers to seal them. I’m hoping for a good seal as any moisture under the covers could lead to condensation and fogging.

After final polishing of the rings and installation, here’s the result.





The assembly for the GTO nose is now complete with all lighting and trim items in place.



I’m now working to get a headliner installed as this must be done prior to windshield and rear window installation. Not quite ready for the road but getting close
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  #257  
Old 07-01-2019, 11:51 AM
blue62 blue62 is offline
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Very nice work as always
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  #258  
Old 07-02-2019, 04:46 AM
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Gojeep Gojeep is offline
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So close now!
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The more brains you use, the less materials you need.
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  #259  
Old 07-02-2019, 05:13 AM
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123pugsy 123pugsy is offline
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Good stuff.
When will she be on the road?
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my project:
http://www.allmetalshaping.com/showthread.php?t=154
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  #260  
Old 07-02-2019, 08:16 AM
Onorius Onorius is offline
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fantastic result, congratulations
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