21st Century Outlaw 997 Project

[Darren C]

Over 2 days while it was hardening properly I cut out some plates and using my bead roller made 2 x closing plates for the pedestal underside.

ped9.JPG

The plan is to attach them with 4 x M4 countersunk bolts using M4 nuts welded to the back of the plates. The swage make everything flush

So with the plates roughed out I took the hardened form tool out the "mold"

ped6.JPG

ped5.JPG

With a little fettling and some small filling of air bubbles etc it was ready.

[Darren C]

Next I VERY carefully rolled the stainless sheet for the RH pedestal around the form tool clamping as I went to form the perfect shape

ped4.JPG

ped3.JPG

Once made, I trial fitted it and worked out the best place for the 4 bolts to fit the closing plate without hitting the spring loaded mirror arms.

For the purpose of the build, I drilled 3.5mm & riveted the plate in place so that I could cut the contour in the closing plate ends and file fit it to the mirror Bullet Cone as a solid object.

[Darren C]

So....following a lot of thought, a post earlier Hollow v Solid, and now that damn bloomin 991 speedster mirror copy

I opted to make my pedestals hollow.

Not because it was easy....but because it is hard

With the pedestal body made I worked out the clearances & angles in combination with the LH cardboard template I made earlier in this thread, tweaked it a bit and took the plunge and cut out my RH pedestal.

I folded up the infill plate and shaped it to suit, making certain the pedestal didn't spring out of shape.

ped2.JPG

ped1.JPG

So it's all ready for Tig welding up later this week

Thats after doing it ALL again to make the LH one.....oh, deep joy

[Berny]

Deep Joy indeed fantastic work Darren

[Darren C]

Thanks Berny

So this last week I've made the second pedestal for the passenger side using the same method.

Using the second Aluminium prototype as a mold

ped2 1.JPG

ped2 2.JPG

So I had two mirror image (no pun intended) bend form tools

ped2 4.JPG

[Darren C]

Next I manipulated the Stainless Steel around the form tool carefully so as not to distort/damage or mark it.

ped2 5.JPG

ped2 6.JPG

And again fitted the closing plate to the underside

ped2 7.JPG

[Darren C]

On to the cut-out section next. VERY carefully making sure it was a mm perfect reverse copy of the drivers side
Cut, folded & fitted ready for welding.

ped2 8.JPG

ped2 9.JPG

So, the next thing to do is weld the insert section into the pedestal so it all looks seamless & appears as a solid stainless block

[Darren C]

Now the cool bit.....Invisibly Micro Tig welding the 1mm stainless plate without distortion.

ped2 10.JPG

And on close up

ped2 11.JPG

If you really, really zoom in you can just about see the weld pool forms But now it looks like one solid part

Next job is to carefully hand polish out any remaining working marks which will be a slow boring task, ideally done while sat watching TV

[KS]

My flabber is well and truly gasted.

[sladey]

So is that just completely amazeballs welding or is there something special going on there?

[Darren C]

Just Plain olde Tig welding Sladey

Heres an under arch shield I made for my Aston, pretty awful as the weld width varies between 1.2mm & 1.8mm in width, but hey its only a wheel arch liner (must try harder)

Aston weld 9.JPG

This corners more consistant at about the same width as the rim edge on a 10p without the dots

Aston weld 17.JPG

No magic here

Okay, who just rummaged in their pockets to find a 10p to see how thin that is?

[smallspeed]

this is exactly the sort of detail i get tied up in - spending hours making it just how you want it vs. purchasing something with 5mins of searching and one or two mouse-clicks that does 85% of the same thing

I LOVE IT!

[sladey]

Just Plain olde Tig welding Sladey

Heres an under arch shield I made for my Aston, pretty awful as the weld width varies between 1.2mm & 1.8mm in width, but hey its only a wheel arch liner (must try harder)

Aston weld 9.JPG

This corners more consistant at about the same width as the rim edge on a 10p without the dots

Aston weld 17.JPG

No magic here

Okay, who just rummaged in their pockets to find a 10p to see how thin that is?

Flash bugger. excellent work.

Can't see your second pic though

[inaglasshouse]

Suitably impressed here. Lovely work.

[Darren C]

Thanks for the kind words guy's

Thought I'd post a few pictures this evening to update the progress.

The Passenger door Mirror pedestal was made & welded as per the Drivers

aug1 pedestals4.JPG

aug1 pedestals2.JPG

aug1 pedestals1.JPG

I spent a good deal of time making them perfect reverse copies of each other