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  #321  
Old 01-17-2018, 10:46 AM
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juicedz4 juicedz4 is offline
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Good progress last night. Finished shaving the badge holes. Which went pretty smooth and turned out good. They probably wont even need any filler.





Then it was time to tackle the lock hole. I needed to remove the step, but wanted it round and centered if possible. Puzzled it for a bit until I remembered I had this hole saw arbor that lets you expand existing holes. Luckily I had the perfect size saw for the existing hole (just had to go around it like 20x with a deburring tool for a slip fit).





Then carefully cut a circle of steel to fill the hole.



Skipping a bunch of steps, but basically i did a bunch of tacks a few times around to get it fully welded. Then ground, sanded, hammered, sanded, hammered, until we get to here. Its def not perfect and will certainly need some filler, but Im pretty pleased.









Up next is the third brake light. Im either going to shave it completely or shave it but add a thin flush mount LED. I cant find a good pic of what Id like to do, but basically youd just see the lens which would be a piece of lexan sanded flush to the contour of the lid.

Dan
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  #322  
Old 01-17-2018, 12:12 PM
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entropy entropy is offline
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Logging away the stacked hole saw trick!


E
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When did empirical knowledge get replaced by a theoretical education?

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  #323  
Old 01-17-2018, 12:14 PM
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Quote:
Originally Posted by entropy View Post
Logging away the stacked hole saw trick!


E
This is what I have:

https://www.mcmaster.com/#hole-saw-e...uides/=1b61ggh
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  #324  
Old 01-17-2018, 12:53 PM
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Graham08 Graham08 is online now
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Quote:
Originally Posted by juicedz4 View Post
Thanks for the tip! I just added one to my next McMaster order.

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