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  #581  
Old 04-19-2020, 06:15 PM
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Steve Hamilton Steve Hamilton is offline
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Kerry
Good to see progress on the roadster. The trim is coming out very nice.
All the small stuff seems to take forever. Keep plugging along and it will eventually all get completed.

Steve
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  #582  
Old 04-19-2020, 07:33 PM
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Kerry Pinkerton Kerry Pinkerton is offline
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Yeah, small steps take forever. I can see the light at the end of the tunnel though. Hopefully it's not a train.

Today, I needed to build a return for the grill opening.

But first, I needed to address a possible symmetry issue that I thought I could see...maybe...perhaps. The upper left looks a bitter less radius than the right....

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The only way I know of to check is to make a template. I took a piece of cardboard and taped it over the opening. Once it was secure, I tapped around the opening and it left a mark on the inside. Once it was trimmed to the mark it fit the opening perfectly. When I flipped it over, I saw that, indeed, the radius was off a little. After marking and trimming it looks good to me.

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Now it was time to make the flange. It's an odd shape. Again, using CAD (Cardboard Aided Design) I marked the cardboard and made a 2" parallel mark which I then cut out.

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Doesn't look like it will be right but it is. Centuries ago, I took a Descriptive Geometry class and learned about laying out the true length of an intersection of an complex shape. Loved that stuff! One of the few classes I finished with a 100%.

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Blurry photo of it tacked in place

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And welded.

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Other side.

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Not totally filed yet but close. I've got arthritis in my right thumb and it's really bugging me this year. When elective surgery opens up in a couple months, I'm probably going to get it done. It's a 6 week recovery but we're not going to be traveling so it's as good a time as any. I'm happy with the look and symmetry. This flange has stiffened the grill opening enormously and will provide a place to mount the actual grill...which is next.

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  #583  
Old 04-20-2020, 08:23 AM
NEB Alan NEB Alan is offline
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Default Retaining Trim

Kerry, I used Elevator Bolts from McMaster Carr to retain trim on my International truck. Replaced the broken spring clips. This may save you the work of making your own.
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  #584  
Old 04-20-2020, 09:31 AM
Mike Rouse Mike Rouse is offline
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Choose the side of the grill opening that you like, find center line ,trace good side,flip temples to new cardboard. I m sure you understand that way the opening will be the same on both sides.
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  #585  
Old 04-21-2020, 07:54 PM
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Beautiful spring weather in Alabama this week. This is one of the two months of the year that folks want to be in the South. Yesterday I pressure washed the house and while that only took a few hours it pretty much did me in so I made no progress.

Today I started back and wanted to prototype my grill bars. My opening is on the small size and I want to keep the grill bars skinny.

I sheared a piece of the mirror stainless 2.5" wide in the shear. Although this stainless is probably 22 gauge my shear cut it ok. I then tightened up the gap on my crappy brake and bent it it over to about 120 degrees. To give it a bit more body, I taped a stainless TIG rod in the bottom of the bend.

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I then took it to my ewheel with a flat anvil and slowly pushed the gap flat.

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It came out great.

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I wanted to see if I could shrink the bar on the Eckold with NOMAR tooling.

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It actually came out really well. It takes a lot more pressure but it's bending two pieces of metal. Just after one pass, it had a definite bend.

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After a little more work, I had the profile pretty close.

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I had pulled the left fender to do some work and just put this trial piece in place for a look.

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The reason I pulled the fender was to install some 'NUT SERTS' instead of the temporary self drilling sheet metal screws. These are pretty neat. As you apply pressure with the tool, the nutsert deforms kind of like a pop rivet and it stays in place and won't rotate. I use #12-32tpi screws for these but have used 1/4-20 in other places.

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One thing I learned is that the Eckold will wad the stainless up if it's left too long in one spot. Gotta keep it moving.

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So I now know what I'm going to do and I'll start doing it. It will be a slow process.
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  #586  
Old 04-22-2020, 01:29 AM
Jaroslav Jaroslav is online now
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Kerry, great result.
The stainless steel wire remained in the bend?

"One thing I learned is that the Eckold will wad the stainless up if it's left too long in one spot. Gotta keep it moving."

My experience: If you start shaping stainless steel, you must not stop, it must always be in motion. It's like moving the burden of moving and keeping it moving. If you stop pushing to keep moving, new starts moving again with more force. In my big Eckold, the first speed is 150 rpm. At this speed you can hear the sheet loudly creak. Soft sheet steel cannot be heard.
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  #587  
Old 04-22-2020, 08:14 AM
Mike Motage Mike Motage is offline
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Your project is really starting to show it's character. Looking really nice!
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  #588  
Old 04-22-2020, 08:44 AM
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Nice progress Kerry!
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  #589  
Old 04-22-2020, 09:06 AM
billfunk29 billfunk29 is offline
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Default Headlights

Am I seeing early VW beetle headlights?
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  #590  
Old 04-22-2020, 01:48 PM
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Kerry Pinkerton Kerry Pinkerton is offline
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Quote:
Originally Posted by billfunk29 View Post
Am I seeing early VW beetle headlights?
Yes. They are vw
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