Hand Crafted End Caps. A HOW TOO.

[ctriverfish]

I have received some requests on how I fabricated the end caps. Would any one in Starcraft land be interested in me posting a how in pictures. There are a lot of great welder fabricators out there that people can show this to and have them fabricated if replacements are required.

Bruce

 

[InMotion]

Re: Hand Crafted End Caps. A HOW TOO.

Absolutely! You never know when this would come in handy!

IM

 

[Raystownboater]

Re: Hand Crafted End Caps. A HOW TOO.

+1 ^^^^^^^

A definite candidate for a sticky.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

Good Morning all.

To start with all alum will work with this project but 5052 is what should be used because it will not crack when forming. The material I used was 6061-T6 X 3/16 thick only to show you what can or should I say will happen when forming the strip around the radius. As you will see my strip did crack. (“Damn you Murphy”) All was not lost I just welded the crack inside and out. The grinding and sanding will make it look like the crack was never there and the welding will assure the integrity / strength of the material.

More to come

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

To start I took measurements prior to starting my end caps and then made a sketch. With sketch is in hand I made a material list and then headed to the scrap yard for a sheet of material that will do the job.
I used a metal shear to cut my stock but a band saw or even a hacksaw will do the job.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

Then I laid out my paces and cut everything. I left the strip long and will trim it at the band saw later. Then on to welding.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

Welding: I used the weld wire for the material I was using (6061-T6) if the wrong weld wire is used the weld will be brittle and in time the weld will crack. Your welder will know the right wire to use or if you are attempting this yourself your local welding supply house will have the correct weld wire. I start buy tacking welding the strip to the plate then welding to the first corner. Weld inside and out.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

As I stated when I made my first bend the strip cracked. I just welded the crack inside and out and kept going. After forming the strip I welded the outside then the inside, stopping the weld just before the radius.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

Now the radius can be a little tricky. I formed a little and then welded and then formed a little more then more welding. I found doing it this way the strip conforms to the radius better. Then I re-welded the out side making sure there was a good build up of weld so I can grind/sand in the contours later. Then I tack welded the strip where I was going to stop welding.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

Then weld the inside of the radius. Then weld the outside. Then back to the inside. Now the strip is ready to be cut to length at the band saw. It's time for me to get some paying work done in the shop. I will post more in the morning. Have a great Day all.

 

[cj8mule]

Re: Hand Crafted End Caps. A HOW TOO.

Those are some fine looking welds. It's quite amazing the skill set and craftmanship we have in this forum

 

[InMotion]

Re: Hand Crafted End Caps. A HOW TOO.

Nice work CT and thank-you for sharing... this is great info even for those who are not able to weld... as you mentioned, this is a step by step process that someone else could follow to get the job done!

J.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.



Sorry no work on the end caps but I did machine up 4 caps for my bumper strip. Will finish the end caps and post soon.

 

[ctriverfish]

Re: Hand Crafted End Caps. A HOW TOO.

InMotion;

I have hade people bring me things just for weld. Just lay out the plats cut with a jig saw give it to the welder.