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.
| 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.
| Slowly but surely it drew it in.
| 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.
|
Using the flattening punch to make the bottom smooth again.
| 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.
| Here are the finished parts.
| 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.
|
Pressing into the odd shape cold. I was surprised that it actually did it. I got lucky on this one.
| 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.
| 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.
| Original on left with stage pieces to finish.
|
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.
| 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.
| Blank shown here with finished parts prior to cut off.
| Ready to put on.
|
i used the original brass center hook and slides. I sanded out and polished them. I then powder coated them clear.
| This was a lot of work for these. It was more of a challenge thing when looking back.
| |