We're Talkin' A Bunch of Sheet...Metal Fabrication | BANKS BUILT Ep 27
after working late nights and weekends the boys finish up last minute prep work and send lockjaw to empire fabrication for sheet metal work built protected by AMSOIL with support from roadster shop and Nitto square yeah just bring it over to the left the smidge okay straighten it out all right we cranked on it last night uh finally into today into the day it's on the trailer let's get this thing out of here let's get on the road is this is it safe to drive on no sleep i don't think so so all right it's going it's good that's perfect all right guys how's it going man what'd you bring me today all right lockjaw's here uh we got it in it's in the shop finally out of our shop and now it's yours great all right let's open this hood here all right so start front to back yeah front to back let's just go all right so what do we got going on here with this stuff what is this so what we put in here we didn't build headers yet I'm designing those in cad right now okay so in order to get you an idea of where all that's going to land and build them in one night yeah yeah and we had one night to do this so to give you some space claims so you can build the tubs that is our keep out zone for headers all right so I can only go to that or right before that yep exactly and i have one on each side here so that should set you up and uh all right and then can tell by the way we opened the hood this is all so these starfish looking pieces those are the final pieces but as far as these hinges go uh-huh it's all mock-up and um it's going to be redesigned so this is only single shear so we're getting a lot of wobble and these are just plasma where are you going to put your you said you're putting springs in this right yeah we're going to add a spring so yeah these holes here are going to be mounting points and then spring's going to go down this lower hole is going to be a brace and the spring's going to be somewhere down here okay just because when we run the sheet metal down yeah i need to make so like like in this in this zone like here is where I'm going to put it okay all right then and then uh the intakes do you guys have anything from mocking up of the intakes right now we do i think they're in one of our cars they drove here in so this flange is the same as that one over there that was our cutting jig okay so we did is those two bolts or locating pins we drilled the same holes over here so this 14 gauge flange is going to meet up and that cut line is the same profile as this flange here so ultimately we're gonna have a piece of five inch uh tubing here that goes to the headlight and we're gonna have the velocity stack so it's gonna be a real short piece here and this is where the filter drops in so it'll it'll tuck up and in there but we just didn't have time and that clears the tires yeah barely yeah there's there's a gap in there at full turn um and and I don't know if you've seen it yet but we switched from the 66 grille that this thing had into a 60 grill with a dual headlight dual headlights yeah yeah so we're taking the inner headlight out and there's going to be a five inch tube right here okay that meets up with a radiused entry in that headlight all right so um and then your this will be the filter here and that's going to go in through here then yeah filter filter flange sits right on this so then also in this area now here the top this is all cleared open open now all right perfect yep so before when it was rear entry right we switched the supercharger around so that was all going to be everything was going to come up around the floor yeah so now much simpler it's a single bend piece of five inch that's going to dive down into where this filter is going to be okay but it's all off because it doesn't clear the hood yeah it doesn't clear that well the supercharger doesn't clear the hood oh it's going to the front of the supercharger and and into the bed the bends will sweep the hood the hood's getting cut then it's getting cut all right it'll end between the uh the center point so this doubler is going to end up getting cut and we can rework that to add stiffness back but there's like a there's like a little spot right here that needs a notch based on where I've got it what I've seen in cad so far and the supercharger doesn't stick past this flange it does not no we've got you know maybe an inch air gap if not a little bit all right so it looks to me right yeah right it looks to me like you'll be able to do just a flat firewall across this thing all right and we've got the bracket for the brakes mocked up that's ready to be on the firewall plane it's already bolted into two other flush and it's flushed there's some adjustment under the dash okay back if we need to tweak it a little bit all right so it's not welded it's bolted in so the whole thing's just bolted in i don't i don't think we've welded anything to this truck actually anything that is like tapping everything so far is bolted into this truck okay perfect um like these so you saw these when we we had this core support sitting out here floating in space with just the two lower bolts it was just it was we knew it was too movable right it's widely so we made these braces um so these are they clear the tires at full droop uh so you can use them you cannot use them so the spread that we have we put the inner fenders back in at full droop measure is this the cut that's going to be on top is that the final cut this is the piece yeah this is the fight all of this is final geometry all right because it would be cool to match this on this yeah yeah and I'm probably going to do something on this as well that that mimics the geometry that's on the supercharger okay this is kind of roughed in at the moment and then we're going to have a vibrant HD clamp here and a five inch tubing single bend down into the filter well all right uh and then these so when we're laid out we have a real small air gap between this bottom lip and the tire so here why don't we air it out right now okay yeah i don't have enough weight jay uh what are you guys doing for wiring mil-spec we're we're actually talking through that this morning we were thinking we do we have the mil specs yes they are in a box in here so we have three what uh three mil spec connectors okay 18 wire or the 32 or whatever i think they're 32's they're they're in a box in here we can dig them out uh and then we've got uh the ac bolts yeah so over here will be mil-spec and ac bulkhead and then over there we've got you want the wiring over there or behind the motor let's see to get into those military bulkheads I'm not sure how tight of a radius we can do depending on your pin i think this is an 18 pin this is no this is a motor harness this was chassis harness and so we heat shrunk the wraps on them to get so you need three inches yeah so if we do it on the back which this is the one i put on the starlet that's going to SEMA this year we just recessed the back wall back three inches off of the motor so that can go in that's where it is on the starlit you guys hide it right behind and then your ac bulkhead depending on you went with the four way so normally what I've done before depending on how the tub is I'll do the straight four and we can run the straight four and it's hidden behind the tub and then your lines run on the inside of the panel right and then your two lines go forward and then the other two lines you could do another just to get the two bulkhead and we can put that down here and then just the two lines are going back to the pump yeah and the pump's mounted on there where it's going to be okay yeah so it's either we do the four or we can do the vertical the straight inline one I say we hide it yeah and then hide them and just run the lines on the inside of the tub yeah back here as long as like i said if we bring the tub to where the exhaust is and maybe just cut it right short of it uh with the turn radius what is let's turn the wheel I don't know if we're going to be able to with it sitting on that uh trim all the way towards me it won't mess you up too much but we do have a accessory cooler mounting that's going to live underneath this cooling package and mount to the bottom of the frame rails oh and have a duct tape cooler and power steering cooler and ducting built in around it but there is one thing because that the valence that's down here it kind of it kind of dives under the core support and if we can just make that flush with the bottom of the core support it'll force all the air coming through the front through the it's totally we'll have to close the hood to see it well we're gonna have to pull the intake off for that just put it right there ready so we got right up in here so this section of valence here that dives under the yeah core support if we just make it flush with the bottom of the core support okay we're gonna we're gonna grab air underneath here to go through the so just cut it here and then just make a new piece yeah it can be flushed it can be flush with all this stuff you can just okay it can come right across there or whatever it needs to do yeah all right that's not this one yeah this stuff will have to trim out for the air box right here and it's going to pop through roughly I think here through the headlight okay the the latch we should have taken the latch out with the latch it crashes into the condenser fins that's gonna come out but we brought we brought the Mercedes latches for the rear oh okay so we took a quick look at it and we were thinking about coming off perhaps so this is rubbing here yeah right here would probably be perfect right that's what we were thinking just having it slightly inboard off of the uh supports there yeah so if that's going to be here or this way that is probably going to be somewhere right into this which would be good to pocket it ideally right into that guy yeah and then just make this long ways and just go where that's going to fit perfect in that pocket yeah that's what we were thinking that'd be perfect okay so when are you coming back to cut all this stuff out or do i got to do it all it was going to happen at 3am last year it was it was supposed to happen this week but it's been it's been a long week i think we have uh the bezel for this no all right so now we'll just do a nice clean circle to what that is yeah well so i think we can pull this we're gonna make some longer a longer shaft in here and i think we'll pull the pull the column back up a little bit maybe so that the end of the column is flush we haven't we have a mount on the inside there if the firewall goes to here though yeah then it's going to be like an empty pocket yeah it'd be like recessed this would need to come to the very end of the of like the firewall this needs to be at the end of the firewall unless you have like a trim ring or something on it yeah i mean we could put a trim ring on it right now if you look if you look in here at the dash the taper on the column is right oh right yeah right there okay this needs to get angled more because it's a little bit past this and we're going to be mounting on this seam here this bead comes out that step comes out yeah you can you can tweak that thing under the dash okay are you guys using any of like the vic grill on the front of the hood does any air need to go through that still running the air through the grill and the hood does come through the radiator all right it would be nice to have that so if we do anything there still keep it open so the air travels through yeah i would i would think that and we pulled out the turn signal buckets late last night because that new overall shape for the top of the core support will slightly crash into the buckets buckets so we're just going to run some low profiles we're having a couple issues last night but we've got a couple more pieces designed that when this core support gets cut out it's pieces that come back in and follow this shape and then we'll cap over the top of it so that all the strength goes back into the course okay same with the bottom too great so don't make anything on the core support until those are yeah we can send we can send those over to you yeah might need just you can get away with just like a minor notch just to get it to suck up in but we can take care of the rest of doing the overlay and and building it back up okay just the way the air box is set it'll need it'll need a bit of i think right about in here just to get it to suck up yeah just in this area here right just a little bit it comes through like that okay all right so this is a big Allison it's a big boy right there yeah that was a big cut the seat comes to what where does the seat come bench seat buckets we are looking for it's like i guess you could call it a hybrid we don't have it yet though yeah we don't have it but i think that was the thought of kind of a hybrid of the two because we're going to need some serious tunneling in here all right speed sensor I'll fire out does it come uh i will get that over to you because it's uh on my desk and then yeah lines are over there yep okay so we need the just cut offs and pops in to see like how far out they come yep we'll need those and i think that's pretty much it for this yeah driveshaft we're gonna run is uh right now it's looking like it's going to be a qa one three and a quarter carbon fiber okay you need to trim this more or is this all should be good it was a fairly minimal cut okay um that's three 750 on a 3200 drive shaft okay so it's not a whole lot of air gap there and here how much uh vibration do you think you're going to get out of this thing the uh amounts are pretty pretty stiff yeah okay so like normal we'll put like we'll do like a half inch of clearance just because some of these transmissions are getting up there in size yeah okay so if i gave you guys a half inch clearance all the way around of everything and then we came back here and just dropped it down right behind this and came down just minimal around this that way whatever the seat is here yeah it doesn't interfere too much then yeah yeah and we're doing a drive-by wire okay so you can put the pedal where you're gonna do wherever um so we'll have a few things we'll have the vintage air under the dash we'll have our ECM our TCM I need to make sure i get my tetanus shut that's why it's called lockjaw I know jeez that's a nice hole yeah what's your time frame guys see you later two weeks about two weeks two weeks all right put them yeah so you guys want to take care of the holes on the roof yeah all right and there's like this side has a couple like this guy right here i don't know if there's anything on that side yeah all right so well it looks pretty clean under here yeah this doesn't look too bad yeah just in the floor right here where it started going through okay well i got my hands full for a while before i even get the bed so you want to get you want to see the new grill we saw it in the video i mean we can take care of the tubing add the tubing to the air boxes and do anything that's grilled to air box related if it comes to it we can take care of that but yeah air box will be pretty in yeah air boxes are built now uh we might need you've got all this bitchin metal shaping equipment around here so we might need a hand forming some of the compound curves okay pieces so all of our bends were just slip rolled so the pieces we left were there what is this getting made out of 14 gauge 16. 16 gauge yeah you want me to shape 16 gauge no you can shape whatever you want in there yeah this was a terrible decision just make it out of aluminum we might yeah nothing's all right i mean if we make it out of aluminum i could shape 3003 and we could just dome those bottoms and the tops or whatever needs to be taped and then just weld them in yeah yeah we made that like two nights ago everything's been a flurry here so okay yeah I mean because right now as what i have i can't do the engine bay but I could do the firewall the transmission tunnel uh and the drive shaft tunnel and so that's that's as high as it needs to be how much is that exact cutout for the drive shaft with the truck laid out that is from uh or is that sitting on the drive shaft with the truck laid out that's got some clearance in it the what i did on this was i did all this in cad we don't have we're trying to get a slip shaft for this Allison this qa1 does not do a slip shaft in the drive shaft oh they have to have a slip yoke all right uh so this thing is straight piped right wait no you're coming exhausted yeah we're doing four into one headers all right so and we're we're gonna squirt under the body mount so that is gonna go under the body all the way across on outside of the frame outside of the frame the thought is to have a v-banded straight section so if we want to put in a straight through muffler or just have a straight pipe depending on yeah because compared to a normal Duramax diesel that's turbocharged with a straight pipe all the way to the back this thing is going to have no turbo to muffle it it's supercharged yeah so straight pipe is going to really leak it's going to be uh get your attention the early testing of our super turbo engine before we added the two turbos was it was a supercharger that was the five liter or was it for the i can't remember it had zoomies on it and that shook the whole warehouse okay then uh you might have already mentioned but the fiat is basically everything but idlers and tensioners because those are all inboard of our pieces yeah the fiat just has the alternator and the ac compressor and the power steering pump uh in place uh and we're probably gonna end up with a power steering reservoir fabricated this thing right here it comes with it has a plastic one factory but it's it's not the most uh aesthetically pleasing shall we say all right there's a charge air cooler in the intake manifold that's going to have rear exit lines to it so i sink it three inches behind the motor for the plug is that going to be enough for those fittings too I'll tell you what I'll do is I'll early next week I'll draw up all the fittings in cad and make print something that you can glue onto the back of the manifold all right I'll have a laundry list next week yeah all right well this hood's coming off first so it's yeah once you pull off those just four nuts two guys can get it yeah perfect all right so timeline on this thing we're pretty busy so we're gonna have to really bust it out i mean i have a lot of stuff going on right now yeah I can kind of show you what we got going on yeah the shop looks pretty full i know Erik's going to geek out on this I'm going to geek out on it can you go over some of the metal working tools you have machinery here well we can start with this one since we're right here yeah all right I don't even notice this one oh man this is getting good make sure to like 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2021-07-24 16:17
