How would you make this?

[chevynut]

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.

CCF05312015_00002.jpg

[MP&C]

To make the radius along the length, you should be able to use the bead roller with a skateboard wheel....








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

[MP&C]

That was a variation on using the go kart slick on the English wheel....







Slick is partially inflated (deflated?)



It keeps the panel nice and flat lengthwise..

[chevynut]

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]

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..

[chevynut]

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]

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]

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]

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]

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.


20150602_001.jpg