I decided to try and make all the slide hardware for the windshield frame. I say try as this would take some pretty serious tooling to get done. Some of this stuff was uncharted territory for me as I had never tried what I guess is called draw forming. All the sheet stainless shown here is 1/8 inch thick and takes some serious force to get it to move around.
Learned a lot here as well and mirror polishing these small pieces wasn't fun.
Album by Kevin Foust. Photos by Kevin Foust. 1 - 18 of 18 Total. 1868 Visits.
1 Up first to try was the pillar side stud mount. The original is 2nd from the left. I 1st tried pushing the steel in the center and came close till it went bang and punch a hole. I then tried laying it close to an edge and this allowed the metal a relief to flow from. Forming die in the middle and first stage punch next to it. Final flattening punch is on the right.
2 I stacked washer above it and would allow it to bottom out, this kept the surface flat as it pulled the metal into the bubble shape. Took a washer out and repeated it.
3 Slowly but surely it drew it in.
4 Here you can see how deep it needed to go. The original parts had this same relief so I guess I found out what they did in making them.
5 Using the flattening punch to make the bottom smooth again.
6 These were both square shaped when cut out and it shows how the metal pulled in. Drilled a hole in the center and the 3 on the outer edge, welded a stud in the middle and recessed the 3 for flush mount machine screws.
7 Here are the finished parts.
8 Next was the windshield frame side mount. Forming die and punch on left, Jig to bend the small , hard 90 degree bent tab on the right. Finished part and original on the far right.
9 Pressing into the odd shape cold. I was surprised that it actually did it. I got lucky on this one.
10 I made the far edge of the die high so it would act like a backstop. The 3 side V side was rounded so the metal wouldn't catch or mar so bad. All I can say is it worked.
11 Once the bracket was formed it was time to bend the tab. VERY hard 90 degree bend with hardly any radius. I cut where the tab would be. Made a jig to hold the piece and then had a die button cut to align the bending punch exactly in position. Bending punch has an angle and portion radius on it to keep marring down, This work as planned too.
12 Original on left with stage pieces to finish.
13 Made up a threaded collar for slide to be trapped on and riveted it on. Other than that is is from a single piece of stainless. Smoothed it out and polished them out.
14 Next was the knobs. Mine were gone so I had nothing to go by. I got some bar stock and Mike C. got them blind hole tapped and knurled for me. I then had Chris C. spin the inner cone for me. Then I ground reliefs on them. Sand out, polish and then cut off.
15 Blank shown here with finished parts prior to cut off.
16 Ready to put on.
17 i used the original brass center hook and slides. I sanded out and polished them. I then powder coated them clear.
18 This was a lot of work for these. It was more of a challenge thing when looking back.
