Darksider's Realm

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DARKSIDER In the world of automotive hobbyists a Darksider is one who modifies and or customizes any and all sorts of vehicles. The Darksiders are in a class of their own simply because they endeavor to be different and do things that others would not attempt for a number of reasons mostly being related to a lack of ability and fear of non conformity.

This is a forum for people who think outside the box in everything they do. It doesn’t matter if you are modifying or building from scratch. It doesn’t matter what brand or brands of vehicles or components you are using. It doesn’t matter if you are working on a mini car or a bus.

We will not be asking you for donations or any kind of monetary payments. We will be asking for help in terms moderators and encouraging you to spread the word and add to our membership.

Darksider's Realm

A message board & forum for automotive builders, fabricators and customizers who think outside the box.


    Chopped 55 F100

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    Darkside Dave
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    Age : 72
    Location : Marietta, Ohio

    Re: Chopped 55 F100

    Post  Darkside Dave on Mon Mar 26, 2012 8:47 pm


    Cool Man !!!
    Until I saw you post I hadnot considered the size press you would need for that job. Did it really have to be that big or was that what was available?

    BTW, on another subject, machining aluminum, a good machinist friend of mine turned me onto something interesting. He said he has been very successful at using 1/2" shank Carbide router bits to machine aluminum on his Bridgeport mill. I had a few and tried it. It works. The point is that they are cheap and you can get about any style and shape you want from Grizzly.

    Later Man...



    Darkside Dave



    Last edited by Darkside Dave on Wed Mar 28, 2012 6:31 pm; edited 1 time in total
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    Duke55

    Posts : 36
    Join date : 2011-05-03
    Age : 37
    Location : Utah

    Re: Chopped 55 F100

    Post  Duke55 on Tue Mar 27, 2012 9:33 pm

    Darkside Dave wrote:
    Cool Man !!!
    Until I saw you post I hadnot considered the size press you would need for that job. Did it really have to be that big or was that what was available?

    BTW, on another subject, machining aluminum, a good machinist friend of mine turned me onto something interesting. He said he has been very successful at using 1/2" shank Carbide router bits to machine aluminum on his Bridgeport mill. I had a few and tried it. It works. The point is that they are cheap and you can get about any style and shape you want from Grizzly.

    Later Man...



    Darkside Dave


    I definitely did not need a press this big. For 18 gauge steel it take 1.8 tons per inch of shear, so about 22 tons to press my 12" louvers. A 22 ton press is easy to come by but one that can accept a 4-5' wide sheet with precision placement of the dies is not. The smallest precision press brake I have seen is a 6' wide 50 or 100 ton press. Prior to locating this monster press I was seriously considering building my own press to get the job done (glad I found one to use instead).

    As for using router bits on aluminum I hadn't thought of that. I will definitely dream up a couple of uses for them. Thanks for the idea.
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    Darkside Dave
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    Re: Chopped 55 F100

    Post  Darkside Dave on Wed Mar 28, 2012 6:49 pm


    If I remember correctly, you use a mist type coolant. I can't say if that will work well with the aluminum and the router bits as I use liquid coolant. However, that may not be a concern as you have used the mist system to machine aluminum. As for building a press, I think you are better off doing it the way you did. A one time use would probably nor justify building one.




    Darkside Dave
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    Duke55

    Posts : 36
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    Age : 37
    Location : Utah

    LOTS OF LOUVERS

    Post  Duke55 on Sat Apr 14, 2012 10:52 pm

    True Mom and Pop shop. The first picture shows me the owner of the shop and his wife pressing louvers (great people). There are 85 louvers each spaced 1" apart. All the other pictures show the sheet setting on the truck.













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    Darkside Dave
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    Re: Chopped 55 F100

    Post  Darkside Dave on Sun Apr 15, 2012 9:54 am


    I'm guessing the nerve racking part is bending it down over the back and hoping something doesn't bow or kink.


    Darkside Dave
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    Duke55

    Posts : 36
    Join date : 2011-05-03
    Age : 37
    Location : Utah

    Excuses

    Post  Duke55 on Mon Jul 23, 2012 11:35 pm

    3 months later and no progress on the truck. I feel bad for not posting so I will post what I have been doing. I decided to stop working on the truck to finish my shop. I was in the process of building the shop when my dad passed away, then I lost all ambition on the shop and decided to finish this chopped 55 for him. Originally I planned to use my dads shop to paint the truck but after thinking through the project I decided the number of trips I would have to take to his shop that is 2.5hrs away was just too much. In the last 3 months I have completed the wiring, insulation, siding, hanging drywall, ran water/power and started mud and taping (also put in curbing and sod between my house and shop). The shop is 44' wide x 32' deep x 11.5' ceiling it has 2 10x10' and 1 10x12' overhead doors. I framed a 15x26' semi down draft paint booth in one of the bays. Other than that, I picked up a Logan 11x36 Powermatic lathe that I am just starting to play with. Definitely anxious to start working on the truck again.
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    Darkside Dave
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    Re: Chopped 55 F100

    Post  Darkside Dave on Tue Jul 24, 2012 9:12 pm


    Hey Man...

    I too have not done a damn thing for three months. I just haven't been in the mood I guess. However, I'm starting to get the itch. You'll get no criticism from me.

    Later Man...





    Darkside Dave

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    58 ford

    Posts : 81
    Join date : 2009-06-21
    Age : 53
    Location : canada

    Doing???

    Post  58 ford on Sun Jul 29, 2012 8:01 am

    I to have been busy with other peoples projects,So mine has been lacking also!!
    I have been watching a few of the builds and this one is going quite well.
    Thats the thing about this HOBBY we forget sometimes that it is, and when it becomes a job it is time to take a break!! I still have plans to have my 65 running by the end of september will see how it goes lol!!
    Later Andrew


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    Duke55

    Posts : 36
    Join date : 2011-05-03
    Age : 37
    Location : Utah

    Wheel spikes

    Post  Duke55 on Mon Sep 03, 2012 7:24 pm

    Finally worked on the truck for a day and it felt good. Yesterday would have been my dad's 56th birthday, so it just felt right to work on his truck. I picked up some 2.75" aluminum bar stock to make some new center caps for the wheels. This is what I came up with.







    I still need to make the mounting plates for the back side and sand a polish them, but I think they fit the truck well.

    I need to find 3-4 good days to work on my shop then it will be ready for paint. After paint i need to install the electrical fixtures, finalize the ventilation system on the paint booth, install the gas furnace and plumb the air lines. Never a dull moment.
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    Duke55

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    Location : Utah

    Shops finally done and I am back to work on the chop truck

    Post  Duke55 on Fri Jan 04, 2013 5:00 pm

    Shop and paint booth are finally finished, truck moved out of the garage and into the shop and I am back working on it (this took much longer then I ever expected, but it is going to be nice).

    Few pictures of the semi-downdraft paint booth:

    Exhaust filters in front wall



    Intake filters is rear ceiling



    Recessed wall lights behind glass



    24" Tube-axial exhaust fan



    Outside of booth front wall, exhaust ducting/mixing bench



    Front wall of work bays



    Front wall of work bays



    I then designed and built a metal roller to roll some angle iron for the paint booth ducting and the square tubing needed for the tonneau cover.





    One of the completed rails for the tonneau cover



    The original tonneau cover frame



    Modified tonneau cover frame for louvers



    Modified frame and louvered panel primed.





    Tonneau cover panel tack welded in place. It rolled very smooth with no buckling at the louvers.





    First paint job out of the booth. I built it for my daughter for Xmas and gave it a lace paint job (fabricated everything except the door).







    2nd paint job 2 days later (7 degrees outside and no issues keeping the booth warm). Shell for my truck.





    Sorry for the long post, but I think I am all caught up now and will try to post more regularly. Also, did'nt want anyone to think I have just been slacking off.




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    Duke55

    Posts : 36
    Join date : 2011-05-03
    Age : 37
    Location : Utah

    Re: Chopped 55 F100

    Post  Duke55 on Mon Mar 04, 2013 12:31 am

    To see the latest progress on the truck click on the following link.

    http://www.garagejournal.com/forum/showthread.php?t=183844

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