Billet Aluminum Dash Bezel
 

Got the gauges picked out I think for the dash project. . I downloaded the ones I want off the net, sized em' to the specs on the site & printed the faces out on the printer. Then I cut some PVC gauge housings on the CNC. They are a little deeper than the actual gauges but that'll insure I have ample room for the real deals down the road. Now I can make a bezel. That outta' keep me busy for awhile.
http://img.photobucket.com/albums/v2...8/429c9698.jpg

Cut the bezel out on the CNC. There's a bunch of steps to get this thing cut. I keep thinkin' one BooBoo & it's scrap. :shock:
http://img.photobucket.com/albums/v2...8/a295844e.jpg


Got the bezel off the table. Now comes the task of bending it in the right places & at the correct angles to fit the dash.
http://img.photobucket.com/albums/v2...8/df067abb.jpg


Got it roughed into the dash cover. Still rough but close enough that I know it will fit. The right wing is 1/2" longer than the left wing, so angles are different. I think I got it purdy' close though. Next is to cut the contour in the fiberglass for the oversized tach & speedo.
{that's a relief}


http://img.photobucket.com/albums/v2...BendBezel2.jpg

http://img.photobucket.com/albums/v2...stFitBezel.jpg

http://img.photobucket.com/albums/v2...hBezelBent.jpg

Re: Billet Aluminum Dash Bezel
 

Got a little further on the dash today. I made plugs out of PVC to form the gauge wells, since these gauges are too big for the original bezel opening.
http://img.photobucket.com/albums/v2...sh14-19-08.jpg
I did the kitty hair "form the bezel to the dash deal" again. Used vinyl & spray Pam as a release agent.
http://img.photobucket.com/albums/v2...sh24-19-08.jpg
One last big hurtle for me. TIG welding on the bezel w/o ruining it. I welded some strap aluminum to the top & bottom to stiffen up the bezel & to provide a place for rubber mounting grommets.
http://img.photobucket.com/albums/v2...sh34-19-08.jpg
Got the bezel just setting in place. It's being held in by the dash bar. Close enough to see what it'll look like.
http://img.photobucket.com/albums/v2...ash4-19-08.jpg

Re: Billet Aluminum Dash Bezel
 

very nice work...

go into business for yourself and sale one to me. i got a 79 camaro it would look great. the cost of gauges would be preety high to. but, hell if you had to ask how much you should not be here.

Re: Billet Aluminum Dash Bezel
 

If I told you how many hours I had in that thing you would laugh.....http://skins.hotbar.com/skins/mailsk.../emoti_462.gif

Re: Billet Aluminum Dash Bezel
 

man, that does look good, nice to see someone take pride in their work.

Re: Billet Aluminum Dash Bezel
 

Thanks Keith

Re: Billet Aluminum Dash Bezel
 

That is a super job. I wish I had that talent. If I can't make it with Duct tape and J B Weld then I'mn toast.

Re: Billet Aluminum Dash Bezel
 

Thanks CPOlesen

Re: Billet Aluminum Dash Bezel
 

Got the bearing housing for the steering column (firewall) done this weekend. Now all I need are those back ordered steering column parts.

http://img.photobucket.com/albums/v2...gFirewall1.jpg

http://img.photobucket.com/albums/v2...gFirewall2.jpg



I got one last thing done this weekend. I pulled the old dash out & used the glove box as a plug to make this mold. Got a couple little places to touch up and then I can make up a couple fiberglass glove boxes to finish off around the intercooler. The door has that imitation leather pattern, & the Camaro logo. They came out O.K. so far.
http://img.photobucket.com/albums/v2...shglovebox.jpg

Re: Billet Aluminum Dash Bezel
 

Little steering column mock-up tonight. The Mark Williams quick release hub came today.
http://img.photobucket.com/albums/v2...umnmock-up.jpg

Re: Billet Aluminum Dash Bezel
 

Got the brake pedal ready to go in. Rule book says it has to be covered with a non-slip surface so I cut the center out .018" and inserted a pc. of mud flap from Big "R" Hey, it works.
http://img.photobucket.com/albums/v2...8/c287091f.jpg

http://img.photobucket.com/albums/v2...8/78c89a10.jpg :wink:

Re: Billet Aluminum Dash Bezel
 

At first I wasn't going to post a pic of the clevis for the B-R-A-K-E pedal. But..... I'm workin' on a billboard for a spa today and ....well......I just couldn't resist the irony. HEHEHEHE
http://img.photobucket.com/albums/v2...8/572c8b36.jpg
http://img.photobucket.com/albums/v2...8/3636c974.jpg
http://img.photobucket.com/albums/v2...8/9a0df938.jpg

Re: Billet Aluminum Dash Bezel
 

Bearing hub.
http://img.photobucket.com/albums/v2...8/8511d05e.jpg

Re: Billet Aluminum Dash Bezel
 

i for one, am glad to see these pics. you do good work! :)

Re: Billet Aluminum Dash Bezel
 

Thanks Keith. I'm having fun.

Re: Billet Aluminum Dash Bezel
 

Pushed the "Z" outside to clean the shop today. BUT, this time I didn't have to kick the front tires to keep it str8. I used the STEERING WHEEL. WooHoo.


BTW: I had a weak moment today. There is some spy footage in the link below. Make sure you turn up the volume before you click on the link. This doesn't happen often in the "Z" shop, so don't miss it.

http://media.putfile.com/Camaro-Spy-Video-5-26-08

Re: Billet Aluminum Dash Bezel
 

Well, it's another small step but I figured I better dust this thread off. The mold I made for the glove box way back when finally produced a part.

http://img.photobucket.com/albums/v2...DoorPulled.jpg

I cut the bottom of the glove box to the contour of the intercooler and glassed it in place.

http://img.photobucket.com/albums/v2.../glovebox4.jpg

http://img.photobucket.com/albums/v2...veboxfront.jpg

Flipped it over, cleaned up all the overlaps & danglin' tabs and gave it a couple layers of cloth to hold it together.

http://img.photobucket.com/albums/v2...oveboxback.jpg

Got it roughed in to a 100 grit state & gave it a light coat of primer

http://img.photobucket.com/albums/v2...BoxPrimer1.jpg

I think I'm going to stop here. I'll do the finish work later when I'm ready for final paint. This little project took months (a few minutes here and there). I think I'll work on the engine compartment for my next project. I have a header tube clearance problem to address and then I'll start reconstruction of the firewall. Hopefully I can pick up the pace some on that deal.....

http://img.photobucket.com/albums/v2...ashPrimer2.jpg

The more I LQQK at the intercooler in this pic. I'm thinking I might change the outlet tube connection to a bolt together joint instead of the hose clamp set-up. I can see that thing blowing off taking the dash with it. That might be bad for me knee & ears too. :-[

Re: Billet Aluminum Dash Bezel
 

http://img.photobucket.com/albums/v2...28/flange1.jpg
So, I had some time this weekend & I decided I'd get the hose & clamp set-up replaced. I pulled out the old slab of aluminum and started whittlin' away.


http://img.photobucket.com/albums/v2...28/flange4.jpg
Flipped one over & cut an o-ring groove

http://img.photobucket.com/albums/v2...28/flange3.jpg
cleaned them up on the lathe & cut the mating surfaces for a nice air tight fit.

http://img.photobucket.com/albums/v2...28/flange5.jpg
Finished and ready to install.

Re: Billet Aluminum Dash Bezel
 

http://img.photobucket.com/albums/v2...28/flange6.jpg
My aluminum welding skills aren't the best, but I got 'em melted together.

http://img.photobucket.com/albums/v2...28/flange7.jpg
Intercooler side with o-ring

http://img.photobucket.com/albums/v2...28/flange8.jpg
all bolted together and back in the caah.

http://img.photobucket.com/albums/v2...28/flange9.jpg
dash cover back in. No more hose & clamps. I feel safer with this set-up by my shin. I've seen some ugly footage of those clamps letting go.

That's what I did this weekend.

Re: Billet Aluminum Dash Bezel
 

You have a real talent, you should pursue it in some way. your having fun doing it. Why not make $$ while doing it. Good luck with the rest of your project. Best Regards

Re: Billet Aluminum Dash Bezel
 

Thanks Bob.
I have a one man sign shop that keeps me pretty busy & is something I like to do also.
The fab work is a nice change of pace.*Something to do to relax on those rare occasions when I have nothing to do.

Re: Billet Aluminum Dash Bezel
 

I had a couple hours yesterday afternoon & a couple more this afternoon, so I thought I'd get organized for the upcoming "Z" firewall build. I've got some sheet metal tools that have been under the bench for a good long while now. So, I chopped up an old attachment I had for my first track loader that was just collecting dust in the corner. It had some slip tubes on it (like a receiver for the hitch). I used some angle iron I had in the shed and made this deal up. I put it on an outside corner of the shop so I'd have plenty of workin' room.

http://img.photobucket.com/albums/v2...ntreceiver.jpgå

I bought a stretcher/shrinker at a car show a couple years ago. No mount so it hasn't been used yet.

http://img.photobucket.com/albums/v2...8/Shrinker.jpg

Harbor Freight Planishing hammer. Might call it new old stock. I've had it for a long time too, but never used it.

http://img.photobucket.com/albums/v2...hingHammer.jpg

http://img.photobucket.com/albums/v2...eadroller1.jpg

I've used the bead roller a couple times. Clamped it in the band saw when I DID use it.

http://img.photobucket.com/albums/v2...eadRoller2.jpg

I'm wondering about a wing (table top) on each side of the bead roller to help feed the stock through? or maybe it would just get in the way? Any thoughts?

I still plan to make an attachment to hold the bench vise, and one for a small welding table. I'm gettin' tired of saw horses......... :oops:

that's what I've been up to this weekend.

Re: Billet Aluminum Dash Bezel
 

I welded up the welding table tonight. I cut the supplies kinda' close. I have 1/2 pc. of filler rod left, 20 PSI of argon in the second tank & the 20''x20'' table top was the biggest pc. I could get out of what's left of a 4'x4'x3/16'' sheet of steel.

http://img.photobucket.com/albums/v2...ngtabletop.jpg

Bracing under the table. Gettin' low on that stuff too, but I got er' done.

http://img.photobucket.com/albums/v2...ablebottom.jpg

Re: Billet Aluminum Dash Bezel
 

Worked on the bead roller today. I got rid of the hand crank and put a bicycle wheel in its place. Local bike shop gave it to me, it's a little bent, but it works for this deal. I figured the bigger the wheel the better control. I had to try it out, works a whole lot better now. . I made an aluminum table for the exit side. Loosen 1 thumb screw at the bottom and it lifts off a couple pins on the top. I scribed some lines every 2" as guides. no fence yet. I think I'll use it this way first and add a fence later.

http://img.photobucket.com/albums/v2...lertable-1.jpg

Got the Vice mount done. I made a knee brace for those times when I feel the need to beat on the vise. Same brace will work on all the attachments.

http://img.photobucket.com/albums/v2...70z28/Vise.jpg

....and I got the rack finished up tonight. Everything in easy reach, tucked away behind the door. Oh, I bent up some scrap sign aluminum also, to protect the wall.

http://img.photobucket.com/albums/v2...chmentrack.jpg

I think I'm ready to start on the "Z" firewall now. I have to put a quick disconnect in the planishing hammer air line so I don't have to drag the foot pedal around. It's a pain in the hose this way.

Re: Billet Aluminum Dash Bezel
 

Before I start the firewall I wanted to get the English Wheel built. Ran into a little snag though. I made up the bottom anvil assembly last night. Cut the frame parts out today. Got a couple pcs. clamped together to weld.......and then stripped the threads out of the torch head on the TIG. and it's saturday.
There goes the weekend. ...............


http://img.photobucket.com/albums/v2...lishwheel1.jpg

http://img.photobucket.com/albums/v2...lishwheel2.jpg

http://img.photobucket.com/albums/v2...lishwheel3.jpg

http://img.photobucket.com/albums/v2...lishwheel4.jpg

Re: Billet Aluminum Dash Bezel
 

I drew up & cut out the adjuster wheel for the E-Wheel.

Cut the hand grips out of 1/2" PVC.
http://img.photobucket.com/albums/v2...28/EWheel1.jpg

1/4" aluminum for the wheel itself.
http://img.photobucket.com/albums/v2...28/Ewheel2.jpg

Used fusor auto body panel adhesive to glue it all together.
http://img.photobucket.com/albums/v2...28/Ewheel3.jpg

Like Norm Abram says ''I'll let it cook in the clamps overnight''.
http://img.photobucket.com/albums/v2...28/Ewheel4.jpg

Re: Billet Aluminum Dash Bezel
 

Got a little more done tonight.

Cutting out the backing plate. The slots are to index the backing plate to the adjuster assembly.
http://img.photobucket.com/albums/v2...ckingplate.jpg

Cutting out the top cap that connects the ready rod to the rams.
http://img.photobucket.com/albums/v2...mcapEwheel.jpg

Top cap completed. The brass thrust bushings are pressed in from the top and bottom. They come about .020 short of touching each other. This allows grease to be pumped in from the grease fitting.
http://img.photobucket.com/albums/v2...apfinished.jpg

Assembly is pretty close to done. This shows the index slots that align the backing plate to the assembly.
http://img.photobucket.com/albums/v2...ntassembly.jpg

I also added a grease fitting to each ram cylinder just to keep everything workin' smooth.
http://img.photobucket.com/albums/v2...tassembly2.jpg

Re: Billet Aluminum Dash Bezel
 

Got a little more done last night. Parts for the top anvil.

http://img.photobucket.com/albums/v2...pAnvilYoke.jpg

Re: Billet Aluminum Dash Bezel
 

man, i said it before, very nice, hope u don't mind, i'm going to make a multi tool receiver like that, nice idea, please keep them comming!

Re: Billet Aluminum Dash Bezel
 

Thanks Kieth. I don't mind. I actually got the idea from a welding site. I finished the top anvil assembly tonight. Time to start welding up the frame.

http://img.photobucket.com/albums/v2...lyfinished.jpg

Re: Billet Aluminum Dash Bezel
 

Tonight I cut a jig to align the top & bottom anvils. Next is to cut the frame tube & match it up to the flange on the back of the top wheel assembly.

http://img.photobucket.com/albums/v2...eelwoodjig.jpg

http://img.photobucket.com/albums/v2...ginstalled.jpg

Re: Billet Aluminum Dash Bezel
 

http://img.photobucket.com/albums/v2...elBracket1.jpg

I got the frame built. I knew when I decided to built an English Wheel light enough to easily mount to the wall receiver it would be a challenge. Deflection is not a good thing, so I am hoping to make up for the light frame with some triangulated bracing. Only time will tell if it works or becomes lawn art. I figure if it doesn't work I can always build a steel frame since the top & bottom anvil yokes are bolt ons.

http://img.photobucket.com/albums/v2...mebracket2.jpg

Re: Billet Aluminum Dash Bezel
 

Just about done with this deal. Got all the steel parts painted black & made a plywood rack for the lower anvils. All that's left is to dial in the top anvil. Seems to have pulled the bottom in a little during the welding. A shim ought to bring it back into alignment. I tried it out and I'll be if it doesn't work. Time to get back on the "Z" now.

The plan was to make it light enough to carry around. Weighs 84 Lbs. including a set of anvils. My shoulder fits under the top arm so it's not bad taking it out & putting it in the wall receivers. I planned to put struts on the bottom arm but it seems to be pretty stable the way it is. If it becomes a problem I'll add that later. Don't want it any heavier than it has to be.

http://img.photobucket.com/albums/v2.../AnvilRack.jpg

http://img.photobucket.com/albums/v2...elFinished.jpg

Re: Billet Aluminum Dash Bezel
 

I tried a scrap pc. of .080 aluminum just to see what it would do. Bare in mind I've never used one of these contraptions before so I'm sure it would turn out better with practice. I'm surprised how easy they are to use. I figured I'd get a workout pulling & pushin' the workpiece back & forth but it's so easy a caveman could do it. :lol:

http://img.photobucket.com/albums/v2...numwheeled.jpg

Re: Billet Aluminum Dash Bezel
 

And, it fits in the void behind the door with the Bead Roller, Shrinker/Stretcher, Plannishing Hammer & Welding table when they aren't in use. So, I'm hardly loosing any floor space at all when it's all put away. I have to add one more receiver on the storage rack for the vise since I now have one more attachment than I do storage rack receivers. On normal days this space is just more or less a hallway to the back room where the CNC is (where I normally do sign work). I need this space open so I can get materials into the room and signs back out.

http://img.photobucket.com/albums/v2...oolstorage.jpg

http://img.photobucket.com/albums/v2...lsStorage2.jpg

Re: Billet Aluminum Dash Bezel
 

O.K. Now I'm done. For sure. I'm in the sign biz' ..... I had to do it.....what can I say? lol.

http://img.photobucket.com/albums/v2...heeldecals.jpg

Re: Billet Aluminum Dash Bezel
 

Gary

I like both the fabrication work and the sign art! Nice job!:)

P.S Did your brother Dave teach you how to weld aluminum?

Re: Billet Aluminum Dash Bezel
 

Gary,

Great thread! You are one handy dude! An artist no matter what the medium.

LOL, first time I have seen Norm's name on a site like this.

Keep up the good work and keep us posted.

Bill Lamb

Re: Billet Aluminum Dash Bezel
 

Thanks Bill L.
Bill B. you didn't work with Dave by chance?
To answer your question I watched Dave lay a bead once or twice but he moved to Georgia before he had much time to teach me. I don't really weld aluminum I just melt it together. lol.

Re: Billet Aluminum Dash Bezel
 

Gary
Yes I did and I have inspected dozens and dozens of his welds and he was one of the best! I can't weld aluminum worth a damn fortunately T-Roy can!
I believe Rick Elberts introduced me to you at RT-66?
Are you going to finish that turbo charged bad boy this winter?