Fabrication Work - Post it here!

[the_engineers]

Over the last few years, I've seen some really creative solutions for issues.  While I enjoy seeing the sheetmetal replacement that so many of us have been engulfed in at one time or another, I think the projects that really impress me are the ones where someone is solving "from scratch" to create new.

A recent example of what I'm talking about is Brads70's LCA sway bar brackets.  I consider myself a decent fabricator, but never would've thought to start with box tube...I would've started with flat and then gone looking for a way to bend or weld.  Take a look at what I'm talking about if you're not following his thread...http://www.cuda-challenger.com/cc/index.php?topic=74858.15

Anyway, the jist of what I'm posting about is that I'd like to see a central thread that concentrates on "how I fabricated this" pictures.  Looking for innovative solutions, not parts swapping...although it certainly wouldn't be limited to mechanical projects.

Post up your proudest efforts...mechanical, electrical, etc.  Let's see the creativity!

 

[Challenger III]

O.K. I'll jump. I've seen some pretty cool coilover suspension installs where the torsion bar socket was abandoned in the transmission crossmember. Here's what I did, not only to get rid of some rust, but to also get rid of the torsion bar socket.....

[Barracudadan]

At work i`m usually fabricating the truth! 

[IMNCARN82]

My first little welding project. Other than sheetmetal and a 4 link.  I worked as a prototype industrial model maker for John Deere,Polaris,And new Holland. This was close to road america.The boss had lots of cars. Indy,Porsche,Corvette,Ect... I was always installing custom front valences and screens. Not to mention All the other usual stuff. It was a great job,But pretty toxic. And in the same building every day. But it was extremely fun for me. So these old cars are a total blast! There's some really talented people here!! can't wait to see more posts! R/T

[ShelbyDogg]

Allows you to drop a 68-70 B-body 8-3/4 or Dana into your E-body, without cutting then rewelding the spring perches.
I run a 10" rear wheel with a 5.5" backspacing. Using 295/50/15 tires without jacking up the rear.

I made my own 1" offset front spring hangers, then modified the sway bar mounts to have a second hole 1" away. I used 2 sets of rear shackles to make my offset shackles but didn't take any pictures. Dr Diff sells offset kits for $185, Get his and get on with your resto.

Take your stock hangers and cut off the sides, cutting one side flush so that the second on lays flat against it. I left a lip on the right side for strength. This one will be for the PASSENGER SIDE.


Knock out the 2 studs on the flush side. Remove all 4 studs from a second hanger and lay it on top of the first piece. Slide it 1" over from the stock holes. Flip it over and mark the location of the new holes.
Drill the 2 holes on the second bracket so that the first 2 mounting studs now go through both brackets, when laying on top of each other. I drill a small hole then use a die grinder to open the hole in the exact location and size to hold the stud.



    I notched the top bracket to allow changing of the studs.


Here it is on the right, ready to weld.
I weld all 4 sides including inside that big hole


Here it is in primer next to the finished one, on the right.




For My convertible, I had to cut the top corner at an angle to clear some metal at the bracket mount. I don't remember cutting the corner for my hardtop.



Offset sway bar mounts




I slice down the sides with a cut-off wheel.


Bend out the sides.


Make a piece out of cardboard to fit in the holes, transfer it to metal plate, then welded them in front and back.



I drill a pilot hole then use a carbide tipped die grinder to form the final hole.


Ground down, etch primed then painted.


Finished product, READY TO INSTALL!

[72rtchallenger]

great topic 

[brads70]

Subframe connectors. I drilled holes and welded in light tubing, it really made a difference when I put it in a vice before and after twisting it with a big adjustable wrench. Total cost....$10

[brads70]

I made this gauge bracket. I drilled it for either 2 or 3 gauges.

[brads70]

Overflow bottle made from two GM air conditioning dryers. Cost...free

[mopar12372]

i removed the mini tubs from my car and had to make a peace out of sheet metal with a plasma cutter . i traced the area with carboard transfered it to the metal 

[brads70]

ShelbyDogg   nice work on the sway bar brackets!

[ShelbyDogg]

Thanks Brad.

     I needed a rear jack mount and had to make one.They do sell these new though.

 
Hammered it flat
 
Cut a new piece of metal
laid it under the old one to mark it
 
 

drilled the 2 holes.
bent it on the floor with a piece of wood
and various pieces of metal to hammer against,
then used my cut-off wheel to carefully reach inside and grind of the middle area.
 
 

[mopar12372]

You need to modify your post to just include the photobucket "IMG" code.  I quoted you above but I changed this for your picture code.

[!mg]http://s1133.photobucket.com/albums/m593/mopar12372/DSC01029.jpg[/!mg]

I changed the "i" to "!" so it wouldn't display the picture again.

Thanks for posting

thankyou !! now i know what to look for when i host pictures..

[ShelbyDogg]

I know this is kind of goofy.     It started after I bought a chrome cover at a swap meet for $15.  I  like the looks of a Dana cover, but love the ease of swapping pigs when I want a gear change.

I carved this out of high density foam then painted it. I was going to weld 4 stand-offs on the back of the housing to hold it on.   

 I never installed it becuase I got too busy.

[dutch]