My cat is earning his keep. Resident fly catcher! I managed to snag this picture while he was still in the air and thought it was cool enough to share.
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Figured I would show my CAD setup. I do all the math on a notepad and then I draw it all out on cardboard.
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I then cut it out with a razor blade. The trick is to not cut it in one stroke. Several lighter strokes will cut cleanly without mangling the cardboard. Bend the cardboard using a ruler as a straight edge to get nice sharp bends.
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AAAAANNNDDDDD it didn't work. HAHAHAHA. I did account for radius', but bending them evenly so that everything ends up planar is hard. One side will fit perfectly and the other side will be twisted a few degrees out. I gave up, sectioned it, and welded it all nicely. Sooo, lesson learned. If it's complicated, multi-planar surface; do it in many smaller pieces.
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This is a piece of 18g I tacked in to block off the rail above the trailing arms. It has a slight crease and a slope towards the weep hole. The other end of the rail is open right now. I'll tape off all the holes, pour in the phos-prep stuff if I can find it, drain it out. Let it dry. Then repeat with primer and thinned down rustoleum paint. I'm hoping this gives a nice coat inside that will prevent corrosion issues. I'm trying to decide if I want to rattle can or brush the paint on the outside. I think it will be cheaper, and perhaps provide better coverage to bush on the primer and paint.
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I found out that these plates, as shown on my last post, contact the toe arms. I cut a split down the middle, hammered it into a curve, then patched it up and ground out any protruding metal. I'll need to do another test fit tomorrow and see if this did the trick.
If it all fits nicely, I will be painting it in the coming days. I'll then cut into the driver side of the trunk and frame and perhaps be fitting it next weekend.