25.1E ------- 64 Fairlane

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Post  QKiss on October 25th 2016, 11:03 pm

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SFI helmet pad base plates.


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Hammer forms were made from scrap particle board. Cut out then radiused with a router.    



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The panel is sandwiched in between 2 form boards for shaping.



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The panel is being domed with mallet hammer and dolly.  



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Shaping finished on head clearance blister.



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This is how it fits in the top of the funny car cage


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Plates finished and ready to be shipped to ISP for padding.




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Back from ISP with SFI padding.

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Post  QKiss on October 27th 2016, 11:55 pm

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Time for tin and we start with firewall or I should say the cowl firewall transition piece that will box in the cowl bottom with a 90 degree brake down to receive the firewall.



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The panel has a 90 degree brake made with a 1 1/4" bull nose bar.



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Panel held in place with clamps and welding is started.



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Notice the radiused corner welded in.



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View from the engine bay side. The panel is fit 1/2 way around the tubing so the firewall panels can meet from the other side and make a clean fit.



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View from inside.



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Another shot from outside shows the finished installation.

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Post  res0rli9 on October 29th 2016, 10:36 pm

What thickness poster board do you use.

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Post  QKiss on October 30th 2016, 2:49 am

res0rli9 wrote:What thickness poster board do you use.

The poster board used can be picked up at any art or office supply department in stores such as Walgreens pharmacy or better yet price wise the dollar store. At different times I have ended up with different thicknesses with satisfactory results either way.   One thing to be aware of is that patterns made from flexible poster board can be installed and removed from tight areas that the stiffer tin will not negotiate. Smile  Smile   


Last edited by QKiss on October 30th 2016, 2:53 am; edited 1 time in total (Reason for editing : spelling)

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Post  QKiss on November 7th 2016, 12:40 am

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The cowl grill has been filled in on both the left and right sides of center. The round corner holes and layout lines show center cut out area.  



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The center cut out area is boxed in. The steel strap is used as a hand rest while TIG welding.



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Finished cut out.



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Shot from the under side.



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The engine is set back and the cut out is for ease of rear carburetor access.

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Post  QKiss on November 18th 2016, 1:57 am

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Making up firewall patterns with poster board available at any store carrying art supplies.


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Passenger side firewall pattern from engine side held in place with magnets.  



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Passenger side firewall pattern from inside.




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Pattern cutout around tube extends 1/4" past the tube center line. When done from both sides of the tube leaves a 1/2" flange for rivets or machine screws.



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Patterns can be rough cut around tubes or shapes and the close fit up can be done with small pieces taped on the pattern with masking tape. Keep in mind it is a pattern and can have 4 - 5 or more layers Taped to it without any adverse effect  


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Pattern laid out on a steel blank with magnets.




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The round discs are made up in tube sizes and along with transfer punches pick up the tube center lines in the panel below then a knockout punch the size of the tube is used. 

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Post  QKiss on November 20th 2016, 2:12 am

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Left -- Right -- and -- Center firewall panels.



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The firewall is built with 22 gauge .029 cold rolled steel.



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An inside look of the trans tunnel cut out.



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Trans tunnel opening stiffener tube made with 1/4" 4130 tube and welded to the engine side of the firewall.



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By putting the stiffener tube on the engine side leaves the inside firewall flat for unobstructed trans tunnel nesting.



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3 panel junction around chassis tube. Note lower panel with step down and top panel with leading edge tip in for good clean panel mating.  



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Starting the trans tunnel layout on the inside.

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Post  QKiss on November 23rd 2016, 12:36 am

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Hammer forms for the rear driveshaft tunnel/4 link tubes transition panel.



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Aluminum blank sandwiched in between the hammer form boards.



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Flange worked down over form boards.  



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Forming finished and panel removed from forming boards.



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Transition panel fit and installed with Dzus fasteners.



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The driveshaft tunnel will fit over shaft tube.



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Initial brakes in tunnel panel for first fit up and sizing.  



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Top view of finished removable tunnel installed with Dzus fasteners.



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Side View.



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Tunnel to 4 link transition panel fit.

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Post  QKiss on December 1st 2016, 1:23 am

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Making the firewall transmission tunnel transition flange panel. Picking up the tunnel panel angle to make the flange the same angle on the transition panel.  



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Setting the band saw table angle to match the tunnel panel angle.



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Sawing the flange hammer form.



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Aluminum flange blank.



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Flange blank set up in the hammer form.



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Finished flange after hammer forming.  



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Flange riveted to the firewall panel.



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Counter sunk flat head buck rivets or smash rivets are used so the panel fits flush against the firewall.  



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Finished transition panel installed to firewall with Dzus buttons.

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Post  QKiss on December 2nd 2016, 1:11 am

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Patterns for the trans tunnel. 3 pieces --- two sides --- and a top. The top pattern has a poster board angle taped to the center for support to keep it from sagging in the middle.



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The brake is set up with a 1" radius bull nose to fold the top panel.



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During preliminary set up perimeter lines were drawn around the edges and the lower panels step beaded for flush fit of top panel.  



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Finished trans tunnel with Dzus buttons and springs installed.




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The Dzus buttons spaced for easy access and not obstructed by upright or diagonal tubes.  



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Good fit and all easily removable for trans access.

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Post  BBFTorino on December 2nd 2016, 3:20 am

Looking awesome!!

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Post  QKiss on December 3rd 2016, 12:46 am

BBFTorino wrote:Looking awesome!!


Thanks BBF Torino --------- Your words are appreciated  Smile  Smile  

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Post  slurm on December 3rd 2016, 10:50 am

thank you for posting. I need direction with my own car. looks great please keep up the pics!
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Post  QKiss on December 4th 2016, 12:06 am

slurm wrote:thank you for posting. I need direction with my own car. looks great please keep up the pics!



Thanks -------If you have some questions about your project that I may be able to help with don't hesitate to ask I would be glad to help If I can. ------- Qkiss  

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Post  larry552 on December 4th 2016, 11:05 am

you are doing some great looking work Very Happy
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Post  Wayne Pearce on December 4th 2016, 11:20 am

I only wish that I could work, and form sheet metal to level that you do! Mine turns out okay, but yours is about ten clicks above incredible - love it!

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Post  maverick532 on December 4th 2016, 9:21 pm

outstanding workmanship !!! keep up the excellent work .
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Post  QKiss on December 6th 2016, 1:27 am

Thanks guys for the kind words. A lot of you have the talent to do as well or even better than what I do with sheet metal. It just requires developing your skills. This means doing a part over if you are not satisfied with it. I am working on a small 3 dimensional part right now that I am going through a steep learning curve on and starting on part number 5 as I develop the skill to do this part to my satisfaction. I can make the part in 2 pieces and weld it together but I know it can be made in 1 piece.
------- I like to tell people the only difference between you and me is I have made bigger piles of scrap metal than you. Smile  Smile  Smile  

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Post  bruno on December 6th 2016, 11:13 am

damn you do very nice work !!!
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Post  TravisRice on December 7th 2016, 1:08 pm

QKiss wrote:Thanks guys for the kind words. I like to tell people the only difference between you and me is I have made bigger piles of scrap metal than you. Smile  Smile  Smile  

Excellent fabrication work. Love the motto also. Lot of truth in that.

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Post  Lem Evans on December 7th 2016, 3:36 pm

Cool Deal

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Post  Tomasw on December 7th 2016, 8:32 pm

That is some nice fab work
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Post  QKiss on December 8th 2016, 1:47 am

Thanks guys for the positive comments.  Smile  Smile  Smile  

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Post  QKiss on December 11th 2016, 1:20 am

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This is the solution used to run the shift cable from the shifter to the transmission under the tin work rather than through a hole in the tin that would capture the panel and require unhooking one of the cable ends to free it.  



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Upper and lower dies along with custom made forming tools to form cable trough in lower panel.



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Lower die milled out of a piece of aluminum plate with a ball end mill.



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Lower die held in place with tape until clamped in place with "C" clamps.



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Upper and lower dies "C" clamped in place with aluminum panel sandwiched in between.



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After 2 attempts the second one came out. The first one split out as I was being to timid with it making so many hammer hits it work hardened and became brittle.
The cable trough was the first operation when making up the panel.  




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Finished cable trough under panel. What looks like a blemish is just the clear plastic protective film that is removed when completely done. As seen the cable is not captive in the panel. Very Happy  Very Happy  Very Happy  

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Post  514Fox87 on December 28th 2016, 8:41 pm

Wow your tin work scares the crap out of me knowing whats ahead for my project. Thanks a bunch for the pictures. I'm sure they will help a lot.
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