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25.1E ------- 64 Fairlane

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Post  QKiss October 25th 2016, 11:03 pm

25.1E ------- 64 Fairlane - Page 3 IMG_0658_zps59fca2d8
SFI helmet pad base plates.


25.1E ------- 64 Fairlane - Page 3 IMG_0668_zps86d67e38
Hammer forms were made from scrap particle board. Cut out then radiused with a router.    



25.1E ------- 64 Fairlane - Page 3 IMG_0667_zps6aeb9e0e
The panel is sandwiched in between 2 form boards for shaping.



25.1E ------- 64 Fairlane - Page 3 IMG_0666_zpsaec220a8
The panel is being domed with mallet hammer and dolly.  



25.1E ------- 64 Fairlane - Page 3 IMG_0670_zpscfd17ce8
Shaping finished on head clearance blister.



25.1E ------- 64 Fairlane - Page 3 IMG_0669_zpscefbc19f



25.1E ------- 64 Fairlane - Page 3 IMG_0661_zps682681b4
This is how it fits in the top of the funny car cage


25.1E ------- 64 Fairlane - Page 3 IMG_0671_zpsf5346d68
Plates finished and ready to be shipped to ISP for padding.




25.1E ------- 64 Fairlane - Page 3 003_zps3f4330aa
Back from ISP with SFI padding.

QKiss

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Join date : 2012-08-05
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Post  QKiss October 27th 2016, 11:55 pm

25.1E ------- 64 Fairlane - Page 3 IMG_0718_zps5090c6d2
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.



25.1E ------- 64 Fairlane - Page 3 IMG_0717_zps048ae772
The panel has a 90 degree brake made with a 1 1/4" bull nose bar.



25.1E ------- 64 Fairlane - Page 3 IMG_0725_zps3fb9547f
Panel held in place with clamps and welding is started.



25.1E ------- 64 Fairlane - Page 3 IMG_0726_zps4528a500
Notice the radiused corner welded in.



25.1E ------- 64 Fairlane - Page 3 IMG_0733_zpsb9127f94
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.



25.1E ------- 64 Fairlane - Page 3 IMG_0731_zpsdb7b29f3
View from inside.



25.1E ------- 64 Fairlane - Page 3 IMG_0737_zpseae82837
Another shot from outside shows the finished installation.

QKiss

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Post  res0rli9 October 29th 2016, 10:36 pm

What thickness poster board do you use.

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Post  QKiss 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)

QKiss

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Post  QKiss November 7th 2016, 12:40 am

25.1E ------- 64 Fairlane - Page 3 IMG_0729_zpsa3d38bcc
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.  



25.1E ------- 64 Fairlane - Page 3 IMG_0738_zps3f01505d
The center cut out area is boxed in. The steel strap is used as a hand rest while TIG welding.



25.1E ------- 64 Fairlane - Page 3 IMG_0744_zps0414dfc1
Finished cut out.



25.1E ------- 64 Fairlane - Page 3 IMG_0742_zpsc0203a0f
Shot from the under side.



25.1E ------- 64 Fairlane - Page 3 IMG_0739_zpse455c976
The engine is set back and the cut out is for ease of rear carburetor access.

QKiss

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Post  QKiss November 18th 2016, 1:57 am

25.1E ------- 64 Fairlane - Page 3 IMG_0758_zps29318f9f
Making up firewall patterns with poster board available at any store carrying art supplies.


25.1E ------- 64 Fairlane - Page 3 IMG_0750_zps6edc3f5c
Passenger side firewall pattern from engine side held in place with magnets.  



25.1E ------- 64 Fairlane - Page 3 IMG_0752_zps923bb4aa
Passenger side firewall pattern from inside.




25.1E ------- 64 Fairlane - Page 3 IMG_0756_zpsdf851978
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.



25.1E ------- 64 Fairlane - Page 3 IMG_0755_zpsc5e71778
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  


25.1E ------- 64 Fairlane - Page 3 IMG_0762_zpsc382997c
Pattern laid out on a steel blank with magnets.




25.1E ------- 64 Fairlane - Page 3 IMG_0759_zps840ea111
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. 

QKiss

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Post  QKiss November 20th 2016, 2:12 am

25.1E ------- 64 Fairlane - Page 3 IMG_0769_zps0ff6fd13
Left -- Right -- and -- Center firewall panels.



25.1E ------- 64 Fairlane - Page 3 IMG_0770_zps39d79e10
The firewall is built with 22 gauge .029 cold rolled steel.



25.1E ------- 64 Fairlane - Page 3 IMG_0777_zps908ea020trans tunnel
An inside look of the trans tunnel cut out.



25.1E ------- 64 Fairlane - Page 3 IMG_0779_zpsd6287a17
Trans tunnel opening stiffener tube made with 1/4" 4130 tube and welded to the engine side of the firewall.



25.1E ------- 64 Fairlane - Page 3 IMG_0773_zpsb7ad8ee0
By putting the stiffener tube on the engine side leaves the inside firewall flat for unobstructed trans tunnel nesting.



25.1E ------- 64 Fairlane - Page 3 IMG_0775_zps532a6363
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.  



25.1E ------- 64 Fairlane - Page 3 IMG_0781_zpsf1bffa03
Starting the trans tunnel layout on the inside.

QKiss

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Post  QKiss November 23rd 2016, 12:36 am

25.1E ------- 64 Fairlane - Page 3 IMG_0809_zpse0c1eafa
Hammer forms for the rear driveshaft tunnel/4 link tubes transition panel.



25.1E ------- 64 Fairlane - Page 3 IMG_0810_zpsd96ddfcf
Aluminum blank sandwiched in between the hammer form boards.



25.1E ------- 64 Fairlane - Page 3 IMG_0811_zps979ba36a
Flange worked down over form boards.  



25.1E ------- 64 Fairlane - Page 3 IMG_0812_zpsd84a1d83
Forming finished and panel removed from forming boards.



25.1E ------- 64 Fairlane - Page 3 IMG_0813_zpsa3e5d0be
Transition panel fit and installed with Dzus fasteners.



25.1E ------- 64 Fairlane - Page 3 IMG_0814_zps9cecb5ad
The driveshaft tunnel will fit over shaft tube.



25.1E ------- 64 Fairlane - Page 3 IMG_0815_zps3fd368d8
Initial brakes in tunnel panel for first fit up and sizing.  



25.1E ------- 64 Fairlane - Page 3 IMG_0817_zps668ef7a2
Top view of finished removable tunnel installed with Dzus fasteners.



25.1E ------- 64 Fairlane - Page 3 IMG_0818_zpsaf1f72d4
Side View.



25.1E ------- 64 Fairlane - Page 3 IMG_0820_zps96532f23
Tunnel to 4 link transition panel fit.

QKiss

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Post  QKiss December 1st 2016, 1:23 am

25.1E ------- 64 Fairlane - Page 3 IMG_0823_zpsdbcaed5e
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.  



25.1E ------- 64 Fairlane - Page 3 IMG_0824_zps2d0d84c9
Setting the band saw table angle to match the tunnel panel angle.



25.1E ------- 64 Fairlane - Page 3 IMG_0825_zpse5a75db9
Sawing the flange hammer form.



25.1E ------- 64 Fairlane - Page 3 IMG_0827_zpse7b027b4
Aluminum flange blank.



25.1E ------- 64 Fairlane - Page 3 IMG_0828_zpsba609b05
Flange blank set up in the hammer form.



25.1E ------- 64 Fairlane - Page 3 IMG_0830_zpsec8337d7
Finished flange after hammer forming.  



25.1E ------- 64 Fairlane - Page 3 IMG_0831_zps53d8d4e3
Flange riveted to the firewall panel.



25.1E ------- 64 Fairlane - Page 3 IMG_0833_zpsfabc6341
Counter sunk flat head buck rivets or smash rivets are used so the panel fits flush against the firewall.  



25.1E ------- 64 Fairlane - Page 3 IMG_0834_zps48cf6521
Finished transition panel installed to firewall with Dzus buttons.

QKiss

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Post  QKiss December 2nd 2016, 1:11 am

25.1E ------- 64 Fairlane - Page 3 IMG_0870_zps888102bc
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.



25.1E ------- 64 Fairlane - Page 3 IMG_0856_zpsb45d4912
The brake is set up with a 1" radius bull nose to fold the top panel.



25.1E ------- 64 Fairlane - Page 3 IMG_0860_zps23dcc8ff
During preliminary set up perimeter lines were drawn around the edges and the lower panels step beaded for flush fit of top panel.  



25.1E ------- 64 Fairlane - Page 3 IMG_0862_zps08cff51a
Finished trans tunnel with Dzus buttons and springs installed.




25.1E ------- 64 Fairlane - Page 3 IMG_0868_zps4122b0a6




25.1E ------- 64 Fairlane - Page 3 IMG_0866_zps115fda8a
The Dzus buttons spaced for easy access and not obstructed by upright or diagonal tubes.  



25.1E ------- 64 Fairlane - Page 3 IMG_0865_zpsb215a333
Good fit and all easily removable for trans access.

QKiss

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Post  BBFTorino December 2nd 2016, 3:20 am

Looking awesome!!

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Post  QKiss 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 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 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 December 4th 2016, 11:05 am

you are doing some great looking work Very Happy
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Post  Wayne Pearce 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!

Wayne (SAWDOFF) Pearce

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Post  maverick532 December 4th 2016, 9:21 pm

outstanding workmanship !!! keep up the excellent work .

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Post  QKiss 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 December 6th 2016, 11:13 am

damn you do very nice work !!!

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Post  TravisRice 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 December 7th 2016, 3:36 pm

Cool Deal

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Post  Tomasw December 7th 2016, 8:32 pm

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

Thanks guys for the positive comments.  Smile  Smile  Smile  

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Post  QKiss December 11th 2016, 1:20 am

25.1E ------- 64 Fairlane - Page 3 IMG_0852_zps48ffc18c
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.  



25.1E ------- 64 Fairlane - Page 3 IMG_0839_zpsa2dcabf1
Upper and lower dies along with custom made forming tools to form cable trough in lower panel.



25.1E ------- 64 Fairlane - Page 3 IMG_0840_zpsc85f1428
Lower die milled out of a piece of aluminum plate with a ball end mill.



25.1E ------- 64 Fairlane - Page 3 IMG_0841_zpsc64c5446
Lower die held in place with tape until clamped in place with "C" clamps.



25.1E ------- 64 Fairlane - Page 3 IMG_0842_zpsd4780f4d
Upper and lower dies "C" clamped in place with aluminum panel sandwiched in between.



25.1E ------- 64 Fairlane - Page 3 IMG_0846_zps238a48b3
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.  




25.1E ------- 64 Fairlane - Page 3 IMG_0850_zpsa6ac34c7
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 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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