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chevynut
05-31-2015, 06:10 PM
I have been working on the design of my dash valence, and this is what I've come up with so far. I think I'm going to put 4 oval A/C vents in it, and it's going to flow into the console, which will have a trim piece on the top of it. It's 3" wide at the outboard ends and 5 1/2" wide by the console.

The two side long sections will be made out of aluminum and there needs to be a 1 3/4" flange at the top and bottom. I'm trying to figure out the best way to fab this part. I think I need to bend the top flange on my brake and cut the shape on the bottom, then weld the entire bottom flange to it. Any other ideas how to make this? I think the bottom flange is too wide to try to bend over with a hammer form or a tipping wheel and hammer and dolly. Even the top flange will have to be cut a little and welded to shape it to the bottom of the dash, as it's not completely straight.

4464

MP&C
05-31-2015, 07:08 PM
To make the radius along the length, you should be able to use the bead roller with a skateboard wheel....



http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture061-1.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture063.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture064.jpg

A few passes with some 18 ga......

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture065.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture067-1.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture066-1.jpg

MP&C
05-31-2015, 07:11 PM
That was a variation on using the go kart slick on the English wheel....



http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture066.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture067.jpg

Slick is partially inflated (deflated?)

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture069-1.jpg

It keeps the panel nice and flat lengthwise..


http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture070-1.jpg

chevynut
05-31-2015, 08:24 PM
Robert, thanks for the help but I'm not sure where you're referring to a radius. The face is flat, as is the top flange that bolts to the lower dash. The lower flange will also be flat but curved to match the shape you see. I may need to radius it where it meets the trim on the side of the console, though.

I think I need to fit the piece to the dash first. That means I need to bend the top flange, then cut and weld it so it matches the lower dash which is mostly straight, but has some slight curves to it. I may be able to work some of it with a hammer and dolly or other forming tool. It's going to be .063" aluminum.

After I get it fitted to the dash and the angle of the face right, I need to create the curvature you see as the bottom approaches the console. Then the two side pieces will bolt to the console sides. I'm not sure how I'm going to trim the top of the console sides yet.

MP&C
06-01-2015, 03:51 AM
Goes back to this drawing, a radius or "roll" at the bottom... Also, with your aluminum, if you have any shaping to do at the transition to the console, 3003 alloy may be the best choice, less annealing to contend with..



http://i5.photobucket.com/albums/y167/rmccartney/Misc/Valence2.jpg

chevynut
06-01-2015, 09:59 AM
Gotcha Robert. I think I plan to make mine bent at 90 degrees to the face on the bottom, not rounded like the one you showed. If I make it rounded, it will have to be wider and I don't know if I want it any wider. I'm unsure about the details and whether I want to add some recesses on my bead roller or something else.

If you made it with a 90 degree bend at the bottom and top flange, how would you fab this?

chevynut
06-01-2015, 12:08 PM
Thinking about how this will look finished I think I may radius the bottom edge after all. I am thinking that I need to cut out the overall shape and leave enough material at the bottom to form the radius using a hammer and a wooden or metal form with the correct radius. So first I would draw the radius setback, then add the material for the forming from there. For a 1/4" radius that should be about .39" and for a 3/8" radius it would be about .59". Once I form it, I can weld the lower flange onto it. Then I would bend the top flange last in my brake and make any necessary adjustments to it to fit the dash.

I would bend the long section in my press brake using a radiused die, but it's not long enough to accommodate the whole piece, so I'd have to make it in sections and weld them together. Maybe that wouldn't be such a bad idea either. This is a pretty complex part to make.

I'm pretty sure the aluminum I've been buying is 5052 since they don't sell any 3003 locally. 5052 seems to form well too.

Rick_L
06-01-2015, 04:16 PM
I think I'd try to get some 3003 for the project. You can buy it online, though if you want a single piece across the car, shipping is going to be a problem.

Surely you could find a supplier in Denver?

chevynut
06-01-2015, 06:02 PM
Yeah Rick I probably could find a supplier in Denver but most of they guys want you to buy a 5x10 foot sheet. I've never used 3003 and 5052 seems to form pretty well. I used it on my air intake.

I made one side today. Formed it over a 3/4" bar along the bottom curve and it turned out pretty good. I'm trying to figure out how I want it to look when finished, whether to roll a step or leave it flat. To me, the design of this stuff is sometimes harder than the fab.

chevynut
06-02-2015, 12:22 PM
Here's a pic of the driver's side so far. I think I decided not to form any more detail in it at this point. Next step is to bend the top flange and fit it to the dash, then trim the lower flange to the correct width.


4467

chevynut
06-02-2015, 02:56 PM
Here's the first fitting with the top flange bent. The dash isn't straight on the bottom so I'll probably make a piece of trim that fits there. I still haven't figured out how to terminate it at the console, but I'll get there. You can kinda see how I plan to integrate it into the trim I plan to make for the side of the console.

4468 4469

MP&C
06-03-2015, 12:09 PM
I was suggesting the radius at the bottom to more closely match the bottom of the dash. Your rounded dash bottom now goes into a square-ish extension panel..

chevynut
06-03-2015, 02:59 PM
I was suggesting the radius at the bottom to more closely match the bottom of the dash. You rounded dash bottom now goes into a square-ish extension panel..

Thanks for the suggestion, and I changed my plan in response to it. That's partly why I rounded the bottom with a 3/8" radius. I have about a 2 3/4" flat area for my A/C vents now and I plan to put about a 1/2" to 3/4" piece of trim at the bottom of the dash. Maybe it's too wide but I'm not sure. I think the vents I want to use are 1.6" and others are larger.

It's a lot more complicated to make the part you posted, and I don't believe I have the skill, equipment, desire, or patience to make it like that. :) This car is taking far too much time already and I gotta get it done. :(

I wanted to make the valence blend into the console, not butt up to it like others I've seen. I'm having a hard time imagining how I'd make a large radius blend into the small radius I need for the top of the console edge. I would pretty much have to make it out of fiberglass using a foam core to get those shapes because I don't think I could stretch the metal like that.

Here's a car that has something like your valence design that I grabbed the pic of some time ago.

http://www.trifivechevys.com/attachment.php?attachmentid=4470&stc=1

Complete Auto Upholstery
04-20-2016, 03:50 PM
http://www.trifivechevys.com/attachment.php?attachmentid=5981&stc=1http://www.trifivechevys.com/attachment.php?attachmentid=5980&stc=1

http://www.completeautoupholstery.com/store/#!/1955-56-Chevrolet-Dash-Extension/p/57553107/category=15652007

Here is possibly another option or idea. We used to make them out of steel, but then we pulled a mold off of the last steel one and make them in fiberglass.

DocHarley
04-20-2016, 04:16 PM
CAU, Awesome look. Do you make and sell the center console?

BBPanel
04-20-2016, 05:25 PM
That does look nice. Is it flat where the vents are in the center so that gauges could be mounted there instead?

races14
04-21-2016, 09:22 AM
Mine is fairly similar to that!!
http://www.trifivechevys.com/attachment.php?attachmentid=5982&stc=1

Allen

rockytopper R.I.P 5-13-2017
04-21-2016, 10:02 AM
Mine is fairly similar to that!!
http://www.trifivechevys.com/attachment.php?attachmentid=5982&stc=1

Allen

I tried to push Cnut to use larger radius were the console blends into the valance to mimic the existing curves in the dash like you have but he didn't bite. Both these examples you guys posted look good curve or no curve.

DocHarley
04-21-2016, 02:27 PM
Complete Auto, you out of stock? Says product not available.

Complete Auto Upholstery
04-21-2016, 05:25 PM
Complete Auto, you out of stock? Says product not available.


I have just recently put them up on the website. I just had an order today so I am in the process of making one right now. I didn't make a bunch of them until I saw there may be some sort of demand for them. I just put it back up on the website if you are interested. If you ordered one you would probably see it sometime middle to end of next week. I think I am going to make about a half dozen of them during the rest of this week and next week. Thanks.

http://www.completeautoupholstery.com/store/#!/1955-56-Chevrolet-Dash-Extension/p/57553107/category=15652007

Complete Auto Upholstery
04-21-2016, 05:26 PM
Mine is fairly similar to that!!
http://www.trifivechevys.com/attachment.php?attachmentid=5982&stc=1

Allen

Yes, that is a beautiful car! Nice looking interior work. I think I saw that at the Goodguys Kissimmee show. I just tried to come up with something fairly universal that could be used with or without a console. Nice job!

Complete Auto Upholstery
04-21-2016, 05:29 PM
CAU, Awesome look. Do you make and sell the center console?

We made that center console, it was a one off to that car. They are all slightly different, for example that car had a raised trans tunnel to clear the Tremec transmission. We don't have any patterns from that console unfortunately, but since the floor wasn't stock, it probably wouldn't be a good idea to pattern from that car. We would need another 55-56 Chevy in the shop to be able to make some sort of console again and to keep templates for it. So, to answer your question, no, we do not currently have any consoles that we sell.

Complete Auto Upholstery
04-21-2016, 05:30 PM
That does look nice. Is it flat where the vents are in the center so that gauges could be mounted there instead?

It is fairly flat right until it starts to roll under. I think you could certainly mount some smaller gauges into it, not sure about anything over 2 inches though. Although, you could use some body filler and flatten it and feather that out if you needed it a little flatter. There are some better images of it here: http://www.completeautoupholstery.co...egory=15652007 (http://www.completeautoupholstery.com/store/#!/1955-56-Chevrolet-Dash-Extension/p/57553107/category=15652007)