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How To: Fabrication of my second hood, Part 1


mistapickles
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Draw out the way you want your vents the way you want them to look

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00305-20110822-0016.jpg

 

Use a thin cut off wheel to make the cuts, a thick one will break your heart

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00307-20110822-1431.jpg

 

When cutting make sure the cutoff wheel is in the hood as deep as it will go, this is too help cutting through the under support...make sure you have a firm grip on the grinder, with the disc that deep it will want to kick out of the hood...if you want to have to fix big gashes in your hood before you even begin fabricating disregard that tip, use two hands if necessary.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00308-20110822-1500.jpg

 

It should look like this underneath when you're done cutting

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00309-20110822-1516.jpg

 

Cut the under supports through

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00310-20110822-1525.jpg

 

Sharpen a putty knife and cut through the adhesive...be careful not to bend the hood separating from the support

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00311-20110822-1531.jpg

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Do not cut away excess under support, my first hood was flimsy because I cut these back too far...leave them as much intact as possible

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00312-20110822-1538.jpg

 

Get a coma dollie and a shrinking hammer...you can use any hard round shape for the dollie BUT you HAVE TO USE A SHRINKING HAMMER. When you hit a smooth hammer against against a smooth dollie it squashes the metal and makes a bulge, if you don't want to use half a gallon of Bondo to make your hood look right spend $20 on a shrinking hammer.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00314-20110822-1629.jpg

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00316-20110822-1630.jpg

 

Take the latch off the hood, lie it on a concrete floor or some other firm hard surface, place the coma dollie under a vent, it should make it bulge up a little, that's fine.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00315-20110822-1629.jpg

 

Lightly tap the hammer a little in front of where the high spot it is coming through on the vent, the metal will gradually bend down. The more time you take doing this process the less body work you will end up doing to make it look right when you are done.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00318-20110822-1811.jpg

 

An hour and a half later and you're done with all the non-welding aspects of the hood. I've been doing body work for 20 years, so it didn't take that long and just like you wouldn't think you could dunk from the free throw line like Kobe because he makes it look easy, you shouldn't do this because it looks easy, it's hard, really hard. If you are patient and artistically inclined you can pull this off. Otherwise you need to contact Burton or somebody to help you.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00320-20110822-2148.jpg

 

Part 2 coming in a little while...it involves welding, if you don't know how to weld or haven't welded sheet metal before, you need to contact somebody to help you.

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I live in southern California, at worst, our rain lasts a couple days. Even when we had a "monsoon" type rain for six days straight I never had a problem. If you put a hose to a hot engine then yeah, that's too much cooling something is going to crack, but rain drops aren't enough water and if you've noticed...all the important electrical stuff is at the side of the engine bay. My engine bay has everything electrical moved to where the fusible links are.

 

 

alp247 - this is my spare, my first practice one looked great but it was flimsy and I used too much heat to weld it so it had a lot of warped areas that I had to use filler on. I'll be looking for another spare though....lol

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A framing hammer (the one with points on it) will also work as a shrinking hammer. If you have one already then you don't need to buy a shrinking hammer. It's heavier so you have to choke up on the grip a bit so you're not hitting the metal too hard but it works. I used a framing hammer to shrink curved copper roofing panels I was making. Worked good. But if you are going to do alot of this type of work then buying a shrinking hammer would be better.
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  • 2 weeks later...
  • 5 months later...

More metal fab, prior to welding....

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00728-20120216-2052.jpg

the hood has some roundness, so in order to match that roundness set the hood on it's side and outline the contour of the hood

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00730-20120216-2102.jpg

the separation between the lines you draw will be how deep the vents at, be careful because you don't want the side pieces too big, it will touch the throttle body and intercooler piping. make four.

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00729-20120216-2054.jpg

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00730-20120216-2102.jpg

cut them out, a tip to cutting smooth round shapes is not to let the blade get too deep

here are your pieces

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00734-20120216-2143.jpg

and they should match the curve of your hood perfectly

http://i383.photobucket.com/albums/oo278/mistapickles/IMG00731-20120216-2102.jpg

welding in part 2 tomorrow

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