...project post continues.
Sheet metal fab always starts with looking over the options and some cardboard + tape mockups. Sheet metal can be tricky, as you can't always make what you envision. I only have a finger brake, no press brake so was slightly limited (which i'll explain more later).
Looking at placement option ...rear most like other kit options I've seen ...
...didn't really like that option although I could have used the stock plate light with this config. Steals the visual show from the pipe and tail section lines. Middle, where there is a stock cross brace ...much better
So got out the marker, cardboard, scissors, and duct tape and worked out a design that was low profile, complimented factory lines, and got the job done.
..there was a little lacking I felt, and the back plastic pipe shroud was still not fastened in place, so I added a little tail piece that visually terminated the tail section and kept crap from splashing up under the muffler. Sorta compliments the wedge'y naked headlamp also.
Next came the fab. The Aluminum is 3/16" sheet, T something grade, as it's very stiff stuff (came from our misc workshop stock pile). Cardboard mockup was laid flat onto the metal and traced with a marker. All holes and radii were drilled at this stage. Note use of the hole saw for a large radius. After drilling use the jigsaw to cut out the part. I did this for both parts.
Next came bending on the finger brake. A little fore thought helps makes sure you bend in the correct sequence ...as sometimes you can bend tabs etc that screw you up for future bends. These parts not to tricky, except, that I did have to end up cutting the outer round edges off the plate mount tab as they were in the way of bending up the blinker mount tabs. If I had a
press brake, I wouldn't have needed work around this. Minor.
Good use of a metal file and coarse aluminum oxide sandpaper and things were ready for automotive quality flat black. I also taped a fake frame around the plate and painted the backside black as well. Scotchbrite and clean off each with pure alcohol before painting.
Some solder work and electrical tape while paint dried. I cut the stock wires off about two inches from the stock turns ...then stripped back the cover. See how these are soldered offset so I can just tape in one pass.
Turn signals were
off eBay $40 I think these were wayyy overpriced in hind-site. Came with generic male connector ends, but didn't even come with female connector ends so useless and gave them the chop. They are very bright and have a nice led array inside otherwise. LED's don't care about vibration, so having them rubber mounted is stupid IMO ...but they are.
Next came mounting. Pretty straightforward. I turned the LED flashers at a slight upward angle to make them more visible to other drivers. The splash panel just sits on-top off the license plate, no bolts. Zip tie off the wires to the frame ( I couldn't get that stock plastic wire-cover piece to go back in place). Will see if the exhaust melts the wires in time haha
Another shot of the stinger
Final checkout ...works :rockon:
Questions? ...hit me up
