Interesting, thanks for that. I think the poms call them waffle boards. Good idea to have other uses for them.Quote:
Originally Posted by workingonit
Interesting, thanks for that. I think the poms call them waffle boards. Good idea to have other uses for them.Quote:
Originally Posted by workingonit
A few more photo's. You can see I've left a gap (where the screwdriver is jamed in) so the plate will flex when bolted up clamping onto the chassis. I'll just weld up to the tack, the bottom bracket is the same, both from 6mm.
https://www.aulro.com/afvb/images/im...14/08/1214.jpg
More gussets for winch
https://www.aulro.com/afvb/images/im...14/08/1215.jpg
The winch cradel is braced right back to the 12mm bolts on both sides, probably overkill but strong.
https://www.aulro.com/afvb/images/im...14/08/1216.jpg
I decided to cut up the original bumper to use for the wings because it was quick and easy, keep a bit of the original look and because I've positioned the bumper about 120mm higher than stock it will give great approach angle. I could've folded up some fancy tapered wings or used tube, but I didn't! If it just looks crap I can always change it later. You can see that I sliced a piece of 100X50 and welded it to the bumper section to box it in and gusset it for strength. I also welded up the two holes so water won't get in.
https://www.aulro.com/afvb/images/im...14/08/1204.jpg
A mate gave me an old bull bar I was going to use for its nice bends, but when I cut it up I found it was only made from thin exhaust tube about 1.6mm. It may have done, but I've just got back from the big smoke (melb) for work, and called into some wereckers and finally found a donor ARB bull bar to cut up. I tried about half a dozern wreckers and panel beaters but all chucked any damaged bars into the scrap bin and had nothing. Finally found a big toyota wrecker who had one which is all twisted and bent and they wanted $150! Dreamin! I ended up getting it for $50, still reckon thats plenty for scrap value but I didn't have time to keep looking. It will hopefully be ok, one bend is a bit overbent and oval from the crash so hopefully I can straighten it out ok. It is much better tube, it's one thing ARB do well, it is specially developed tube for bull bars and is 2.6mm wall thickness and the bends are nice and tight and uniform. So this is where I'm up to.
https://www.aulro.com/afvb/images/im...14/08/1205.jpg
Good Luck, will be watching can't wait to see your Roll Cage:p:p:p:pQuote:
Originally Posted by taylorslandy
Nice find, love how they can be used as table and chairs! Will have to get myself a couple of these.Quote:
Originally Posted by workingonit
If weight and strength are important, you might want to consider honeycomb panels. They are extremely light, strong, insulate well, fire-proof and easy to work with. They make them in aluminium or plastic and they get used in campervans and trucks. Something like this:Quote:
Speaking of light, when it's camper build time I'm going to try my best to keep it light. I am keen to use composite panels but are not sure it will be within my budget. I have some other ideas but havn't setteled on anything yet so are always keen to hear from anyone with some experience in lightweight camper building?
http://polycorecomposites.com/Videos.php
or
Aluminium Honeycomb Composite Panel
Will follow this thread with interest!
Hacked up the ARB bull bar, I was careful to get the max length from the tubes so cut the straps off the posts first. The tube goes through the bumper section so I just roughly cut around it to get it out then cleaned it up later.
https://www.aulro.com/afvb/images/im...14/08/1181.jpg
You can see the tube from the damaged side is a bit over bent, bit of a bugger but should be able to straighten it out.
https://www.aulro.com/afvb/images/im...14/08/1182.jpg
You may be able to straighten it significantly by applying heat on the outside of the bend.
Thanks, but you can't see from the photo that the bend has been squashed to an oval shape so I've straightened it out by welding a couple of bits of RHS to my welding bench to leaver against and positioned a solid block of steel under the bend. I extended the tube with a long lever which I got a mate to apply a good amount of force to but not too much that it started to bend the tube, while I gave the oval shaped bend a good few taps with a sledge hammer. Each tap let the bend return to its original shape, worked very well, no longer oval and back to shape.Quote:
Originally Posted by workingonit
https://www.aulro.com/afvb/images/im...14/08/1167.jpg
The straightened bend sitting on the otherside bend.
https://www.aulro.com/afvb/images/im...14/08/1168.jpg
Tacked the wings on and cut an oval hole in the top so the tube can pass through at an angle and be welded to the bottom of the wing on the inside. This is a much stronger way than just butting the tube to the top of the wing.
https://www.aulro.com/afvb/images/im...14/08/1169.jpg
I welded up the holes it the tube that the scrub bars were bolted to. And wire brushed all the mongral powder coating off, not a big fan of powder coating! Tip, good idea if your using second hand or old steel to clean the bits up as you go before you weld them together.
https://www.aulro.com/afvb/images/im...14/08/1170.jpg
I've just sat the tubes in place so far. Idealy I wanted the lower bend to be closer to the bumper, I could cut and weld a section in but its much better without joins and is more stuffing around. Will sleep on it before welding in. A bar off a defender or troopie would've had better bends, but it's still not too bad.
https://www.aulro.com/afvb/images/im...14/08/1171.jpg
Looking good.
While you're at it - would it be worthwhile adding some brackets for a decent steering guard rather than the standard builder's trestle ;)
Steve
Yeh Steve, are going make an ally bash plate to attach to the bottom of the bull bar and join onto the steering guard. Your right I should make a better one but was hoping the standard builders trestle would be good enough. Everything takes a bit longer! see how I go.Quote:
Originally Posted by steveG