Rookie wanna-be weldor starting to make some cool things!

Discussion in 'The Garage' started by kirkster70, Oct 3, 2010.

  1. kirkster70

    kirkster70 moto junkie

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    Good idea. I'm keeping detailed notes on everything. I may be able to shear off the corners ahead of time, but the insets will still need to be manually cut. I'm guessing the big boy's have their patterns laser cut or stamped out...
  2. kirkster70

    kirkster70 moto junkie

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    I met with a local powdercoater yesterday. Very nice guy. He loved my front bumper and wants one for his shop truck!!! :lol3
  3. kirkster70

    kirkster70 moto junkie

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    [​IMG]

    All seams TIG welded.

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    Now I get fancy with the lids. 3rd time's a charm. Try one and two in the background. :D 1/8" wrong makes a huge difference here. I had to make a 1:1 scale drawing to measure the length of the angles to get them just right. My original 1/4" : 1" drawing had the width of a penstroke messing me all up.

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    Ends bent and sheared. The whole purpose of a finger brake is to do all this in one single piece. Not gonna' happen here. Maybe on a simple lid with no bevels. I had a heck of a time just doing this.

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    Bevel cuts and miter cuts on corners laid out. I'm letting the kiddos get their beauty sleep before I fire up the grinders at 4am. :lol3

    DAD!!!!!!!!!!!!!! :D
  4. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Looking great Kirk! I really like the lids too!:deal

    I can hardly wait to see them done!:clap

    Jim :brow
  5. DirtyDog

    DirtyDog Lust for dust.

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    Beautiful work so far. As usual, us on-lookers have questions...

    Why the "canyon cut" on the aft edge of the boxes? I understand that the sides are cut for lean angle and the front edges are cut for ankle protection. Is the back just replicated for symmetry or aesthetics?
    :ear
  6. CaptTeach

    CaptTeach Been here awhile

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    Kirk

    May I suggest two books, Sheet Metal Fabrication and Advanced Sheet Metal Fabrication. They can be found in the Transportation section of Barnes and Noble. In the books they make templates from a NON corrugated cardboard but you could do the same with posterboard. Once you get all the angles figured out you lay the paper version out on the aluminum, trace, cut and bend Then weld up the small places Lots of kewl projects in there from oil tanks to building a monocoque chassis for a GTP car. One book even shows a guy repairing a Ferrari 250 GTO - one of my favorite cars!!
  7. kirkster70

    kirkster70 moto junkie

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    Thanks, Jim!

    It's getting there!
  8. kirkster70

    kirkster70 moto junkie

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    Thanks!

    :deal Working from customer suppied specs. :evil
  9. kirkster70

    kirkster70 moto junkie

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    I think I was looking at those. Ron Covell maybe? Yep. On the want list - with a whole bunch of other things.

    The more tools I amass, the more I realize I don't have. :lol3 Books are definately tools. Most things I have learned in the garage have been from reading books and frequenting sites just like this one. :clap ...and by screwing up and NOT doing it that way again. :D
  10. bwalsh

    bwalsh UUU, UUU!!!

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    Ah! My preferred method! :lol3

    Those Panniers look great!

    I haven't had a chance to skim thru this thread yet to see if this has already been posted...What TIG welder do you have? Got any pics of it? Any chance I could stop by one day and check out your welder and pic your brain? I'm starting to look a little harder at TIG welders and am thinking of pulling the trigger sometime in the near future.
  11. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Exhaust is on the left, but the bags look better if they have similar tops and overall symetry, and it adds a bit of space. Lastly, the full top allows for better mounting surfaces.

    Similar to these, but better looking and more functional.

    [​IMG]

    Jim :brow
  12. NoVa Rider

    NoVa Rider Long timer

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    Wowsers! :clap :clap :clap
  13. kirkster70

    kirkster70 moto junkie

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    Thanks, Bob!

    Sure thing! You're welcome to come by and have a look. It's a Dynasty 200DX with Coolmate 1.

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    Cart is made of scrap and spraypaint. I did have to break down and buy the rear wheels. :D

    I just ditched the 2" PVC tubes for filler wire today and upsized to 3" PVC. I'm starting to buy filler in 10lb boxes, and it wouldn't fit in the 2". Now it looks like a mortar launcher. :rofl
  14. xcflyn

    xcflyn Long timer

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    :thumb I have used construction paper also. Tons of little tricks to be learned over time with sequence of bends and allowance of material for bends. There is specific math to figure out a lot of this, but on a manual brake it will be a little more guess work. Looks like you are getting your head wrapped around this a lot faster then most ( a lot faster then I did thats for sure)
  15. kirkster70

    kirkster70 moto junkie

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    :lol3 Yeah, I'm having fun figuring it all out!

    more piccys incoming....
  16. kirkster70

    kirkster70 moto junkie

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    [​IMG]

    Scud missle launcher upgrade. :D

    It's a whole lot cheaper buying 10lb filler wire qtys. online than buying 2lbs local. :huh Talk about markup. Same manufacturer of filler, even. I'm all for buying local, but these guys are doing it to themselves.

    Also, when I first started TIG welding, I bought some 18" long filler from HTP. That's an oddball size, though I didn't realize it at the time. So, the tubes had to be larger diameter and longer to accept the 10lbs. As I run the oddball sizes out, I just upgrade my most common used filler...

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    10lbs of filler ^.

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    Lid trimmed and ends TIGged in place...

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    One down, one to go. After some QC, it will be off to the powdercoater! :clap

    Hmmm.... now all I need is a bike to mount them on...
  17. defib

    defib Portly Paranurse

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    I don't even have a dual sport yet and want a set of those boxes!:D

    As usual your craftsmanship amazes me. Keep it up!

    Btw. I had to subscribe to this thread, so I wouldnt miss what project you might be working on.

    I thought the bumper was amazing then you build a tool to help you unload another tool. Freaking amazing!:clap
  18. JimVonBaden

    JimVonBaden "Cool" Aid!

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    I got that covered!

    See you tomorrow!

    Jim :brow

    PS Looking great!:clap
  19. bwalsh

    bwalsh UUU, UUU!!!

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    I stopped by and met Kirk today, talked about steel, welding, bikes, etc., and saw those boxes. They are SWEET! You're going to love them Jim.

    Nice meeting you Kirk. :freaky

    I'll be keeping in contact.
  20. kirkster70

    kirkster70 moto junkie

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    We can zap screw a set to the side of your car! :D

    Thank you very much!