Thread: Bad Ast Astro Van Build

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I got the lower panel made this morning. Cut a piece of 22ga and laid out the hole patterns for the plug welds and lightening holes.
http://images108.fotki.com/v1623/pho...00_5314-vi.jpg
I used the bench mounted hole punch to make the weld holes and my 1 1/2" diameter rotobroach to cut the lightening holes.
I clamped the piece to the table and used the Milwaukee drill to cut them.
http://images59.fotki.com/v683/photo...00_5324-vi.jpg
The thin sheet cut real quick and I had all six holes cut in about 10 minutes.
http://images51.fotki.com/v423/photo...00_5331-vi.jpg
After I did a bit of de-burring I broke out the Mittler Bros. flaring tool. These are sweet!
http://images107.fotki.com/v780/phot...00_5325-vi.jpg
http://images60.fotki.com/v778/photo...00_5327-vi.jpg
http://images18.fotki.com/v60/photos...00_5328-vi.jpg
I had these all flared in just a few minutes.
http://images9.fotki.com/v174/photos...00_5330-vi.jpg
Putting on the first bend. The piece was pretty flimsy until I put this first bend in. It got pretty strong with this and even stronger with the second bend.
http://images52.fotki.com/v726/photo...00_5334-vi.jpg
I had to sweeten up the middle of the bends with a hand seamer but it didn't take much.
http://images9.fotki.com/v174/photos...00_5337-vi.jpg
Now that all of the pieces are made I mocked them up for a look see
http://images108.fotki.com/v1623/pho...00_5341-vi.jpg
This is the right hand side
http://images107.fotki.com/v780/phot...00_5342-vi.jpg
An overall shot
http://images107.fotki.com/v70/photo...00_5343-vi.jpg
I ran out of time today so I'll get the pieces blasted tomorrow, welded together and at least a coat of primer on them. I have tomorrow off so I can play in the shop.
Mark