The BAD AST Project - Faze II

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I got the lower panel made this morning. Cut a piece of 22ga and laid out the hole patterns for the plug welds and lightening holes.

I used the bench mounted hole punch to make the weld holes and my 1 1/2" diameter rotobroach to cut the lightening holes.
I clamped the piece to the table and used the Milwaukee drill to cut them.

The thin sheet cut real quick and I had all six holes cut in about 10 minutes.

After I did a bit of de-burring I broke out the Mittler Bros. flaring tool. These are sweet!



I had these all flared in just a few minutes.

Putting on the first bend. The piece was pretty flimsy until I put this first bend in. It got pretty strong with this and even stronger with the second bend.

I had to sweeten up the middle of the bends with a hand seamer but it didn't take much.

Now that all of the pieces are made I mocked them up for a look see

This is the right hand side

An overall shot

I ran out of time today so I'll get the pieces blasted tomorrow, welded together and at least a coat of primer on them. I have tomorrow off so I can play in the shop.
Mark