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Thread: Blender, My LX450/FZJ80 + FJ45esk + GM + Land Rover crazy concoction

  1. #551
    Join Date
    Dec 2005
    Location
    Southwest Colorado
    Posts
    3,451
    Part 3 of 4 for the front fender....



    It felt like more of a step backwards cutting out a big chunk of my new fender. I was also able to drill the mounting holes so the fender holds itself in place! Mini-Win.

    Forming this little panel wasn't too bad. I just used a drop of material that was a bit big to whittle down to the right shape. That is always easier than adding material.



    Clamping the little panel into place for tack welding was the hardest part I think....



    This was my super complicated bending jig for the radius I needed....

  2. #552
    Join Date
    Sep 2013
    Location
    Delta, BC, Canada
    Posts
    27
    Epic work as usual!!! It always brightens my day seeing how you’re making this beautiful beast!


    Sent from my iPhone using Tapatalk Pro

  3. #553
    Join Date
    Dec 2005
    Location
    Southwest Colorado
    Posts
    3,451
    Tonight's update....



    I made the last big part for the drivers front fender. Overall I am really happy with how it turned out so far. Now I just need to glue it all together and dress all the visible welds down.



    I was able to fold this forward 'bill' in one part using my homemade press brake with the laminated tooling. The 1/4" wide tools let me dial in the bend width. I am also make new tooling pretty easy if I have more crazy ideas in the future.

    The part got root clearance holes at the corners. I saw cut the clearance for the multiple tabs to fold together.



    Not the best shot, but I also have a laminated bottom die. This lets me run the part off the end so the next tab didn't get in the way.



    Here is the top die reset to the correct width for the final bend. It was basically done to match the other two folds. The machine also has a way to have a bend stop, but I haven't got that dialed in completely yet. I just usually bend with a small test part to match the angle.



    Fitting the 'bill' in place. Overall pretty happy! I will be able to weld a lot of the back seams also.



    I do have to add one more little part here. It will just be a little triangle. I could have added it to the 4th part, the 'bill', but I just decided to weld it in later. I am going to pay with a few designs for that last triangle by changing the leg length on the grill side.....

    Now to weld it all up, dress down the visible seams, and then start on the other side....

  4. #554
    Join Date
    Dec 2005
    Location
    Southwest Colorado
    Posts
    3,451
    Much welding and sanding today...





    I still have a few details to button up, but overall the fender is basically done. I am still on the fence on what to do with the rear open corner between the cowl, fender, and hood. I think I will just do a basic fill panel that is welded to the fender, but I don't know for sure....



    Sometimes you have to get a little creative to make a 5th or 6th hand. I use this little jack bolts for a few things. They are handy to make out of coupling nuts.



    Shot from the rear. You can see the area I need to fill still.



    Before I sanded down the welds. I think I had about two hours on the TIG to get this all welded up. I did both sides of all the seams I could. Only the outside seams got sanded to give the seams some extra strength.

  5. #555
    Join Date
    Jan 2006
    Location
    Reno, NV
    Posts
    1,498
    Amazing work as usual.
    .
    Jack
    2007 2500hd, Max/Alli, Hawk FWC (the new explorer)
    Build thread: http://www.expeditionportal.com/foru...07-Chevy-Build
    2006 Jeep LJ Rubicon-Sold
    1985 4Runner 22rte-Project...
    KE7NCK

  6. #556
    Join Date
    Feb 2007
    Location
    Colorado Springs, CO
    Posts
    709
    Very cool. I really like this build.

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