BUILD-OFF CHALLENGE: Tygaboy's '75 LS3, It seemed a good idea at the time... Options

[Morph914]

Great news Chris! Can’t wait to see what you have in store for us next year.

Happy New Year (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/beerchug.gif)

John

[tygaboy]

All - I really appreciate the kind words. Thanks so much.

Now, let's get back to work!

Today was knocking a few items off the to-do list:
- I needed to replace a few of the 6mm threaded inserts in the replacement outer longs, those that hold on the underside of the rockers. One had a rusted in/broken off bolt, the two middle ones had to be added as the replacement outers don't come with them installed.

So boring I didn't even take pics!

[tygaboy]

Next, it was on to the flares. Those that have done this know how poorly the "ends" are formed (mine actually have spots where the metal was folded over onto itself and is now three layers!) and how they don't match the shape of the chassis.

So today I went after the rear part of the rear flares. Let me start with a pic of the essentially complete driver's side. Car is upside down, obviously!

[tygaboy]

To match things side to side, I made a quick card board template of the driver side. I've found that the large size Post Grape Nuts boxes work really well for this! (IMG:style_emoticons/default/biggrin.gif)

I used that rear-most part of the curved lip and cut it to length and width at the wheel well opening.

[tygaboy]

Here's an example of how the flares come. You can see one of the "folded over on itself" areas and how not quite paint ready they are.

Ignore those Sharpie lines. They were initial guestimates from before I did the driver side.

[tygaboy]

Let's do this.
- flip the template over and get it positioned
- find a suitable dolly and clamp it in place to set the line where the flange needs to be

You can see how I set the dolly against the factory flange to ensure the flare's flange coincides with it.

[tygaboy]

Start hammering the flange up (down? (IMG:style_emoticons/default/blink.gif) ). Go slowly, working a bend along the entire length of the flare material.

Go back and add a little more angle to the entire flange.

Repeat until the flange is tipped to where it needs to be.

[tygaboy]

Like this! (IMG:style_emoticons/default/cheer.gif)

Yes, I swapped the position of the dolly and clamps. I did this to allow the hammering angle I needed and to get to the entire flange.

Really though, once you get the flange started, it's no big deal to move the dolly around. Just be sure it's clamped fast and firm into the corner you started before you continue tipping the flange.

[tygaboy]

I did a quick, rough trim, just to get the excess material out of the way.
Next, I'll weld up that seam and final trim the flange.

On to the next thing...

[tygaboy]

Corner welded and flange trimmed to final shape.

[Andyrew]

Boy thats some pretty metal work!!

[Krieger]

Looks awesome Chris! Better than Porsche would've done!

[tygaboy]

@Andyrew @Krieger Thanks for the positive comments. There are certainly areas that could be improved but I'm not yet capable of delivering a 100% metal finished result. Filler will cover/correct my imperfect fab work. Not that I'm NOT giving it all I have!

In keeping with the "finish the flares" effort, I moved to start on one of the front flares, rear section.

I cut the corner areas off the factory wheel openings figuring I could add them back on and merge them with the flares. Here's how the first one went.

Note that that hole for the rocker mount has to be in the correct location so I mounted the rocker and eyeballed where this piece needs to be, clamped it in place and roughly tacked it in.

[tygaboy]

I did my best to get everything lined up...

[tygaboy]

(IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)
Tack, weld a bit, grind, hammer/dolly, check for alignment, tweak as needed. Repeat until done.

[tygaboy]

Trim things to shape, final grind with 80 grit then hit things with a conditioning disc. It turned out pretty well.

[914forme]

Looking great Chris, keep up the awesome work.

[tygaboy]

Final check that the rocker mount hole is where it needs to be. Yep. (IMG:style_emoticons/default/beerchug.gif)

On to the next corner...

[Mayne]

I love the fabrication work and your determination to produce high quality final results. Someday, I’ll do flares. I just have to remember to use your thread as inspiration!

[tygaboy]

I figured I may as well work on the other "hard" part of the flares. This is the front edge of the rear flare. You can see how the flare has essentially just a radius curved edge where the chassis has the two flat planes with crisp breaks as it wraps around under the car.