(Author: ikom Saturday April 17, 2004,
Apr,17,2004Apr,17,2004
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Saturday April 17, 2004
Cold but bearable weather today. I get up early to tackle the firewall panels. I still have to bend the pieces at the lower point of the cabin (I have a puny 20" metal brake) and will have to rig up something custom and more substantial to accomplish this.
The desire to have a custom double panel firewall will require that I pay the price of admission. The 0.063" aluminum will also be much harder to lap over the chassis hoops but I guess nothing is ever easy.
I use the air shear to make initial cuts to the outer engine side firewall (the factory calls this an engine bulkhead) and the metal cuts like a charm. Smooth unbroken flowing cuts, close to the marked line; very little if any filing will be required. I also have a nibbler and an air hacksaw. I am not too fond of the nibbler though, since it is very hard to make controlled cuts with it and it leaves an unsightly scalloped edge that requires massive amounts of filing to get to a smooth unbroken finish. I use it sparingly and only where nothing else can reach. My favorite tool is my air die grinder equipped with a high-speed carbide cutter. It just chews up aluminum and with a good steady hand; precise accurate controlled clean cuts can be made in order to clear welds or chassis obstructions. The next "must have" tool in my repertoire is the "Nicholson" 14" flexible flat file with curved teeth; it was recommended by an aerospace/aircraft fabricator and is the best file for rapid removal of aluminum from sheet stock. This file is the equivalent of a woodworker's plane and will true up an aluminum edge like nothing else that I know of. It is an expensive tool but will pay for itself in productivity. Together, these tools make for a very good ensemble for achieving a high quality build.
