Locost 11 R1

[B85]

What I have learned. I can't weld .030 Alum. I have proof.

But I am moving forward a little.
Think I have worked out the door.
I will bound the door supports in after fitting or during ?

Thanks for the input Red. Trying to stay with the Alum. them until it does not work.
Doing it in glass could be cheating ?

[B85]

In 2 days I will see if it worked ?
Sikaflex 221.

Going to move over to the other side and give the 221, 2 days to fully set up.

[B85]

Just bending metal !

Will pull the clamps after 3;00 and see how it fit's

[B85]

.032 is too dam thin. That is for bending on a edge. A 180 fold.
Oh well, guess I took the "add lightness" to far ?

So I will pickup another sheet of .062 and start over. Easy !

But I did play with the inside wall mounts. Working out the how to do's.

Oh, the bounding works but only so far. I will use it between panels but not just by itself. Welding ,rivets or something.

[B85]

Cut the .062" for the new doors.
More tomorrow.

Had to do yard work today .

[B85]

Just a start but the new left door skin in moving ahead.
The 062 is harder to shape.
But more forming to do.

[B85]

Does this look like 4 hours work ?
But I'm slow.

[B85]

If you will look their are some cut lines.
This will be the next step.
And maybe I will need to bake another one ?

[B85]

Took today off.
Did some TAX stuff and washed the car. ( i am scared to cut the panel )

[B85]

The Boxster is a old girl with 175,000 + but still fun.

So , I'm back on the door's.
Here are some photos of the process I used.
Map out the bend line. Then heat the aluminum at the bend line. ( maybe no cracks ? )
Then on to the bender. I put some tape ( x2 ) on the bend line then bend.
Then on to fitting. Easy ?

[B85]

The big black strips are marker then I heat the up until their gone.

[B85]

Major F-up.
I cut the wrong line.
Now I get to test my welding skills. And some sanding and wheeling.
Or, make a new panel.
The little panel is testing and training.

[B85]

Tacked and will weld up tomorrow !
The bend will be almost in the middle of the flat.

[B85]

Well. It worked but didn't work.
The weld is to hard after trying to add some radius.
But I welded it up again and re-bent it again. Need to do a little repair but should be good.
This will be painted so I can make it all good.

DON'T bend Aluminum welds or even close to it ! Ask me how I know ? LOL

[seattletom]

After cutting on the wrong line, wouldn't it have been easier to scrap the part and wheel up another panel?
(Don't ask me how I know )