Outer Limits 4x4 Board

its booty fab time

The skunkworks workshop




The victim and the plan


Time to get the 35 off the back door and get rid of those stupid lights in the plastic bumper




First scribbles




to be continued......

AJ wrote:and get rid of those stupid lights in the plastic bumper
to be continued......

Kewl.. I need the left bar light

what thickness is the C channel, it looks thin?

the c channel looks like a bit of leftover from his shed. i think he is just using for an idea. well i hope he is.

dont worry about the c channel...im drooling at his shed ...hes got all the bits for building big boys toys....

ozy1 wrote:what thickness is the C channel, it looks thin?

The C is 1.5mm which will be plenty for the bumpers. Its ideal because its lightweight and has nice preformed radiussed corners.
There will be a 100x100x10 angle running full width to support the bumper and to mount the wheel carrier. The aluminium rear step will slip over the angle for a factory like look.

Thats the plan at this stage anyway

I want a bigger shed

Todays progress, limited by multiple visitors. Damn christmas season. Bah humbug. They werent even the useful type that could swing an angle grinder.

The view behind the bumper section. Far more substantial than the crap plastic bumper itself






The bar section on the bench




Checking, checking

continuing....

Rear angle view


Wing added




Upper side wing

One more from tonight

1.5/1.6 is pretty thin. You can dent it with a little hammer tap............with a little hammer. Design is looking good though

Looking good.

2-4mm would be better material choices because the 1.5mm will fod lit a tin can if it hits anything.

Love the welding table, and cannot believe how clean the shed is.

- David.

Dirty wrote:Looking good.

2-4mm would be better material choices because the 1.5mm will fod lit a tin can if it hits anything.

Love the welding table, and cannot believe how clean the shed is.

- David.

No shit thats what i was thinking wish i could keep my shed that clean

steve

Dirty wrote:Looking good.

2-4mm would be better material choices because the 1.5mm will fod lit a tin can if it hits anything.

Love the welding table, and cannot believe how clean the shed is.

- David.

Double checked it teh other night and its actually 1.9mm base metal thickness.

Easier to keep the workshop clean and free of crap when you have 2 sheds.
Other shed has cars, trailers, kids crap, camping gear, etc.
Patrol would normally be in the other shed but it was handy to have it next to the job.

That's gotta be a brand new shed. No workshop outside F1 can stay that clean.

KiwiBacon wrote:That's gotta be a brand new shed. No workshop outside F1 can stay that clean.

Sheds are about a year old now http://www.outerlimits4x4.com/ftopic114974

AJ wrote:

KiwiBacon wrote:That's gotta be a brand new shed. No workshop outside F1 can stay that clean.

Sheds are about a year old now http://www.outerlimits4x4.com/ftopic114974

Very nice, I'm as jealous as everyone else.
Apart from the living in a flat place.

Cut up the 100x100x10 equal angle tonight.
Prepped it, put it together, tacked it then welded the inside with a couple of passes.
Will flip it over tomorrow and back grind and fully weld it from the outside.

Once its been all fitted up and trialled I'll be drilling a heap of 35mm along the neutral axii to get some of the weight out of it.

Piccies:

Placed in position on the previously used layout






Tack welded to the bench and tack welded together to help prevent movement/distortion/twisiting




Just enough penetration but OK as I'll be backgrinding it. A bit more root gap would have helped.






A reminder of the bumper.

This afternoons efforts:

Prep'd for welding


Welded - 3 passes


Cleaned up




Making a big hole with a small drill (if you call 10mm small)




Mr.Bosch got rid of that "chewed by a rat" look. Now it just looks like a bad circle. LOL


The reason for the big hole.




The donor for the hub. Got two of these for $24 each at a Supercheap sale.

was he buiding something ,i was still lookin at the shed. great thread and build looks great as well , keep em cumin

any more progress on this bar???