The BAD AST Project - Faze II

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Thanks Will, that's the plan. Got a four day coming up this weekend. I promised one to my wife and I hope to get the right front wheel well installed and the left front well on it's way.
last weekend I worked on the rear tubs. They are about 80% welded right now. I will get those finished up this coming weekend and get them installed also. This will be a big deal. getting the tin work wrapped up means we can start moving forward with the doghouse reconstruction and actusally slinging some sealer and paint!
Last weekend was spent tack welding and building the Right Front wheel well.
While I was welding Mel made a pattern out of the last of the green cardboard. We laid that out on a sheet of 22ga and stomp sheared it to shape. After getting it to fit well in the opening we taped a piece of 1 inch heater hose to the tire and spun it to check clearances. We had a close condition at full jounce/right lock as you can see by the witness marks inside the black marker "oval".

We cut this out with the plasma cutter and decided to make a "bicycle fender" to improve the clearance.
The clearance pocket from inside the van

From underneath

Sunday we made a hammer form out of a piece of 1 x 12. We cut a slot out to duplicate the clearance pocket, routed the edge with a round over bit, clamped a piece of 22ga in place and went to town with the BFH and numerous forming tools made from chunks of lumber and a few body dollies ...



After a few minutes we had the shape well on it's way.

Drawing out the corners with a body dollie.

Fairly complete at this point. Took about 10 minutes to make this piece.

Pulled the "die" apart to check the damages... Of course the parts are flat as we made them in a flat die. Here I am trimming off the flanges.

To get the "fender" to match the contourof the inner well we ran it through the shrinker.

A little shrinking on both sides pulled it into a perfect arch to match the wheel well radius.


Still have a lot of fitting to do but the hard part is done...

Have to do a little more trimming on the old structure to get the pocket where it needs to go.

This will work very well. A lot of work for something you won't even see. right?

Thanks for looking
Mark