might as well get this thread back up there...
this one isn't truck stuff,but it's some kinda interesting aluminum fab.
i'll start with my fancy blueprint.it's an engine pod for a boat that's being converted from inboard to outboard.the owner is mounting one engine now,but may want twins on it later so this had to be taken into consideration in the design.
i got my measurements figured out on the transom first,making sure all my angles were correct.i did a structural rebuild on this transom,but since most of it will be covered by the pod i'm not too worried about it's appearance at this point.
all my layout,bend allowances,and cuts are figured out using a neural cognitive software system.everything is marked out onto 1/8'' marine grade aluminum sheet.
as this material is a little too heavy for the shear,all the cutting was done with my trusty circular saw.i've been cutting metal(and sometimes wood)with this saw for almost 20 years now.it's old enough that it has a metal chassis,not like the plastic crap being made these days.
the windex is used as a cutting fluid,i used to use wd-40,but this works just as well,and is cheaper plus it doesn't remove the sharpie marks on the metal.
the welding helmel is for face protection,there is a huge amount of sharp,hot aluminum chips being thrown off the saw at high speed.a good coverup is vital.
all the parts formed up and ready for assembly.
anywhere i can substitute a bend for a weld leads to a neater assembly,and is cheaper to do.welding,especially aluminum tig welding is kind of expensive.
i'll get back to this after doing some welding.