1984 Airstream 345 owner (Newbie) need advice!

[Keyair]

Here it is...
http://duramaxtuner.com/transmission...-kit-1174.html

https://www.youtube.com/watch?v=2PBDeiMeNLE

[Keyair]

Update.
Tough, but productive day on the Banana Wrap project.

Lower part first. Tweaked and smoothed it out on the É-Wheel, to better fit the buck. This is 3003 Aluminum .063”.





Then it was on to the upper part.
Cut a strip, 36x6, and bent it “Around Ma Belly”.... which was about right! [emoji3]



Then thru the BeadRoller it went with the new roll over die....



As I guessed, it flattened out the shape, but a bit of bending and re rollering and it was looking good.

[Keyair]

Looking ok.



Then it was onto the next part.
Made a quick cardboard template.


Transferred it to aluminum and cut that out on my beastly new to me, Rockwell 14” Bandsaw... bought it from a neighbor.... it’d been in the family for 40+ years!


Test fit, which I knew would be rough....


After a clean up, I ran that thru the Beadroller too.

[Keyair]

I knew it would distort the panel, and I was not wrong... should be close to flat....



So into the E-wheel it went....


Better....


And the test fit looked ok.

[Keyair]

So, I’m feeling good about my progress.


Tried to tack these two pieces together only to burn a hole in them!

After checking, and cleaning, and testing, I burned another hole....


Turned out I am out of Argon gas! Ugh.

[Waipio Rim]

That is pretty darn impressive.

[Keyair]

Thanks. Still have to weld it together, which is tricky. Better than MK1 for sure

[Keyair]

Frustration with not being able to TiG the parts together due to lack of Argon, until Monday..,
That boiled over into using up
My CO2 mix gas in my Mig!
Wheeled stand for the Bandsaw....



Then adding wheels and finishing up my “Sheet Metal Station”...
She’s a BEAST!



All that Energy expended needed protein.
BBQ a Tri-Tip!

[Keyair]

Really working hard on stuff for the MH.
I’d decided to put off my next trip out there until I have the wrap tacked together to test fit.
Dang, joining sheet aluminum is tough!
I finally got my TiG adjusted right, or close.
For the record, .063” 3003 Aluminum, super cleaned with a SS Brush and acetone, a 3/32” 2% Thoriated Electrode, and the pedal set at 40 to 80 amps is best so far... but lots to learn...[emoji3]


Hope to have something to show for my efforts today.
While I was waiting for the panel to cool, I got to play with some new tools.

Dimple die set.


Rotabroach set.


Test dimple!



And a prototype shop towel holder for fun. Gonna make another, cos Less will be more.


Decided on new DOT compliant LED headlamps, and they should be here this coming week.... as well as a No-Load LED compliant flasher unit ordered.

[Boom Sounds]

Nice work. Please would you bring me one of those banana wraps when next back in Abingdon.

[Keyair]

Which side shall I bring? [emoji3]

[Keyair]

Seems the TiG Gods we’re smiling on me today.....

[Boom Sounds]

Originally Posted by Keyair

Which side shall I bring? [emoji3]

Both please

[Keyair]

I’ve had a moment of clarity on the wrap project.
I’ve tried and basically failed to get good panel fit, and weld consistency. Realized it’s not gonna be easy to produce a panel, with the methodology, that will fit my quality standards at this time.

I’m not giving up however...
My wraps are broken and warped, and cannot stay on the vehicle. In fact they already fell off.... [emoji3]
Notice the upper, part onboard of the blinker is MIA...


So, with the above statement, and bowed head, I’m changing the plan.... slightly.

I began work on MK3 at the weekend, and am deep into it already. What I’ve learned about shaping sheet aluminum so far has been invaluable, and the tooling I’ve made will be used.
I’m quite amazed at what I have learned and achieved so far in fact.

It might not seem much to anyone else, but I needed to make a consistent radius curve, in a piece of 1/8” steel angle to match the front bumper....
The Motorhome is 50 miles away, I have a few measurements, but I needed it.
The only thing I had to hand was the center part of the front wrap which is partially intact.
I ran the angle thru the Planishing hammer, but it was not man enough. Multiple (10x) passes imparted a minor curve...


Then I put it thru the English Wheel, which, via the “bridge girder” upgrade I did to its frame, imparted a nice curve which matched the wrap curve nicely!



This is how it matches...


This was step 1.
Watch this space....

[Keyair]

No load flasher unit.... for LED bulbs...


And Cree LED headlights arrived.
The seller states they are DOT compliant... but upon arrival there are not marked or stamped in any way! [emoji20]
I have written to them asking for proof of compliance.

The look good tho....


Daylight Running light bar...


Low beam...(lamp is upside down in this pic)


Main beam.... both upper and lower LEDs are lit.


Pair.

[Keyair]

Seller of the lamps is a fraud. No DOT stamp, his responses are barely understandable. Trying to decide if I go with them or return them.

Did buy some new LED tail lamps tho.... more of that later!


Frustrating but somehow, educational time with the wrap project...
Made a new roll over die to suit my 1/2” radius



Works well, and makes a good, consistent 1/2 radius edge that matches the original wrap radius!


Not so fast tho....
What it refuses to do is roll the radius further... i figures out I need maybe 3/8 of flange on top like this...

[Keyair]

However....
what it won’t do is do more than the radius, and I need some flange like this, but maybe a little less....

So I can overlap the upper section like this....


The new tool is not wasted time, as I can use it for other areas.

So, I’m back to hammer, or flow forming this area.
I took some plywood, cut the shape, and routered a 1/2” radius on the edge. Built a jig to clamp, and hold the sheet aluminum, and did a test piece...
The first section, worked good, but as I worked the material around the shape, the .063” aluminum crushed the plywood and distorted/crushed the edge very quickly.
Proof of concept was there, and maybe thinner sheet will be fine, but it’s still never going to last for multiples!

So, I needed to make a stronger hammer form....
Look around the garage.... thinking...
Mmm... 1/2” Schedule 40 pipe has an OD of almost 1”.....
I can bend that to my desired shape in my Hossfeld, I thought, as I have a Die!


I tried, but the Hossfeld is not bolted to the floor as is required, to get the leverage..... and I can’t drill holes in our garage floor because it’s a “Post Tension Concrete Slab”, for Earthquake stability reasons.... ☹️
The only other option is to make it hydraulic powered, so it pushes against itself..... and that is $3000....
Unless you design and make your own setup....

[Keyair]

Been wanting to do this for a while, so many other uses!
Hydraulic Ram attachment brackets done...
The longer one is 24” x 6” x 3/4” and weighs about 50lb ... the holes are all 5/8” and 3/4.... this is kinda over the limit of my drill press, etc but I got it done.



Gotta get some more & longer bolts, maybe drill some more holes, but making progress.

[gaiaenviro]

I used to do a bunch of aluminum welding, and used a Lincoln Square wave tig on AC, with a 100% tungsten electrode. The electrode makes a big difference for what it’s worth. If you have the setup right you can weld beer cans together....

[Keyair]

Cool.
Good info.
I have work to improve my TIG welding for sure.
My rig is a Eastwood, TiG 200, Inverter unit.
I’m trying Langthinated electrodes now.

Working out the angles in my Ram today.
Trying to figure it out!