This is an ongoing project I've been working on since October 2019, things got slowed down by the jewdemic, the owner & his engineer living in 2 different provinces 40 mins away from eachother was a nightmare for a while.
I had to make new teardrop wingtips out of 3/4" o.d. cromoly tube, going from 3/4" thick to 1/4" towards the back of the wing. Here's one of the fusted out originals (Not my messy workshop!).
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Made a pattern to follow
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Then I shaped the teardrop using a pipe bender die welded onto a worktable, didn't take many pics of that because I had reverse nigger hands. This is what the taper looked like once pressed.
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Matched up on the pattern it looked decent.
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Successful fitting (Yes, there is a shameful bump, shhhh).
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Then came the light holders for these 500$ LEDs.
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I started out with .050" chromoly sheet metal.
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Roughly shaped the teardrop form & hammered the edge round.
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Then I started tacking on the top plate.
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Quickly welded before a rough finish.
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After that I had to fit those onto the wingtips.
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Then I installed riveted threaded thingies & prepped it for welding.
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Freshly welded on
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Top view
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Side view
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Rotteuxx 1 points 3.7 years ago
I just stuck a piece of round stock bar in the vise, extended the sheet metal over the edge about 1/16th & hammered it, 3 or 4 passes extending it a bit more every time. Cromoly is extremely hard, it's not like hammering soft steel...
Including jig fabrication, about 15 hours for the wingtips, another 11 or 12 for the light holders to be made & fitted on. It took as long to fabricate the pressing jig than it did to shape & press the tips into the tapered form.