Ok, the cyclone center is half way.
A much bigger PITA then one might imagine. The project of course starts out with that laser cut plate. I knew that I was gonna have to cut each end to match the rounded curve of each tail light. What I didn't consider was how hard it was gonna be to make a frame to follow the same outline.
Nonetheless, I set out with some 1/4" x 1/2" aluminum bar, and bend the two end pieces over varying diameters of tubing. Once I was happy with the end pieces, I made two center spars to build a frame out of. In order to get adequate weld penetration, I beveled each end of the center pieces, and hooked up my aluminum spool gun.
Aluminum burns so hot, all you can do is just trigger that gun, and you'll have a molten mess in a second. The fact that I was trying to do this on the very end pieces complicated the process even more.
After I got the thing welded, I got out a plethora of other hand tools to better be able to grind, file, cut, and blend the excess aluminum weld into the rest of the frame. Afterwards I set the center plate in the frame.
It had gotten out of square.
No problem, it was aluminum, I'll just tweak the frame back into shape. I put one corner on the bench, and press down on the opposite diagonal corner.
it promptly shatters into 4 seperate pieces.
Evidently, I didn't get it as welded as I thought I did.
See the problem is that thick aluminum has to get hot before it'll adequately flow into a weld. That stupid spool gun is pouring so much wire into the weld, and the adjacent pieces being so thick, it
looked like it was doing the job. what I actually did the first time was tantamount to soldering the thing instead of actually welding.
So,...back to the table. This time with a torch.
The torch was used to preheat the metal. When I pointed the spool gun at the target, I ended up with what was a literal hot mess.
At least it wasn't gonna come apart.
It took about an hour to get the frame tolerable enough to move forward, with the next step being the marrying of the center, and frame together. Origionally, I planned to spot weld the thing around its perimeter, but after the disaster that was the ends, I decided to use epoxy putty instead.
* I tell ya,....I should hit up JB weld. As much of this car that is glued together, you'd think they'd consider sponsoring me a paint job or somethin.
Anyway, I digress.
I glued the two pieces together for two reasons actually. One I've already discussed, the other is to seal the plate so light from behind cannot be seen.
Done deal.
Fins go on top of the plate. A 1/2 x 1/8 will cover the screws that serve as mount studs. I wanted to use a 1/4 x 1/8" piece closer to the center after that. Problem is,..that size in aluminum doesn't exist. That leaves me undecided. Since I'm glueing those things on top as well, I could use steel, and steel certainly comes in those sizes. But my intention was/is to paint the the whole thing matte black, then sand/buff off the tops of the fins and expose a raw finish. If it was aluminum, I'd be done. If I use steel however, I gotta spray some clear on top of the bare metal to seal it.
Don't know how well clear will stay on top of un primed bare steel.