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RockHillWill · 09-20-2017, 08:26 PM

More pics of the speedster project with Bob Kolenda. We were fortunate to get overnight processing of the two surround fabrications for the mere cost of four assorted fresh made donuts. We decided to make a test panel/process out of an earlier panel that I had labeled a 'learning' project. It wasn't finished as nicely as the powder coated pieces, but served the purpose of evaluating fit of the surround to the panel cutout and the remaining tab that is to be turned over the previous wire edged 'strip'. We annealed the panel, trimmed the excess interior portion away and began turning the remaining aluminum portion over the black surround test piece.

Before hammering over the aluminum, Bob measured the existing (slightly) variable extension, so that we can more accurately trim the aluminum prior to the forming. The area at the curves is not the same as at the straight section and we are trying to account for that. So far, we have been able to keep the aluminum tight against the surround piece. We used a contoured wooden mallet backed up by a piece of scrap white oak setting against the top of the rivet heads. Once we got half way around it was very strong on it's own.

We began to metal finish the 4 main side panels and plan to be ready to rivet them on some time tomorrow. Bob did a lot of detail work at the ends of the character line and we finally decided on a process that gave the difference of reflectivity that am looking for. Bob did a nice job of working that all out. It was very similar to the advice given me by Jim Hery, and I could not be happier with what we have come up with.

The surround pieces were sheered here in the shop and we used the P7 and the 'P' die set to form them in four foot sections. They were trimmed again with the Beverly shear to a constant width after inserting a #9 wire and setting them with tool that I made for the P5. I think that they turned out quite nice, straight and uniform in width. Thanks for all your help.

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09-20-2017, 08:26 PM	#133
RockHillWill Senior Member Join Date: May 2010 Location: Rock Hill, S.C. Posts: 985	Re: I could not sit idle, have a new project More pics of the speedster project with Bob Kolenda. We were fortunate to get overnight processing of the two surround fabrications for the mere cost of four assorted fresh made donuts. We decided to make a test panel/process out of an earlier panel that I had labeled a 'learning' project. It wasn't finished as nicely as the powder coated pieces, but served the purpose of evaluating fit of the surround to the panel cutout and the remaining tab that is to be turned over the previous wire edged 'strip'. We annealed the panel, trimmed the excess interior portion away and began turning the remaining aluminum portion over the black surround test piece. Before hammering over the aluminum, Bob measured the existing (slightly) variable extension, so that we can more accurately trim the aluminum prior to the forming. The area at the curves is not the same as at the straight section and we are trying to account for that. So far, we have been able to keep the aluminum tight against the surround piece. We used a contoured wooden mallet backed up by a piece of scrap white oak setting against the top of the rivet heads. Once we got half way around it was very strong on it's own. We began to metal finish the 4 main side panels and plan to be ready to rivet them on some time tomorrow. Bob did a lot of detail work at the ends of the character line and we finally decided on a process that gave the difference of reflectivity that am looking for. Bob did a nice job of working that all out. It was very similar to the advice given me by Jim Hery, and I could not be happier with what we have come up with. The surround pieces were sheered here in the shop and we used the P7 and the 'P' die set to form them in four foot sections. They were trimmed again with the Beverly shear to a constant width after inserting a #9 wire and setting them with tool that I made for the P5. I think that they turned out quite nice, straight and uniform in width. Thanks for all your help. BobWednesday2 005.jpg BobWednesday 002.jpg BobWednesday 003.jpg BobWednesday 011.jpg BobWednesday 010.jpg BobWednesday 006.jpg BobWednesday 007.jpg __________________ Uncle Bud says "too soon old, too late smart!"