In another post in the welding form I made an aux fuel tank for my RAM 2500 pickup truck with 6.7 Cummins engine. The problem is how to access the fuel filler when the cap is on the truck? Crawling through the back and over stuff when I travel is a problem. The solution is to make the front glass window open for access when I am fueling the truck.
I had great ideas that well, were ideas and then complication set in and I had to settle for what you see. More explaining as the post continues.
For working access I placed my truck cap on my car trailer with a few 2x4's and backed it into the work bay of the shop.
First step is to make a template from card board for the size of the window frame.
Using the template I laid out the 2 ends of the frame. Holes were to allow for change in direction of my band saw.
2" x 1/8" flat stock is TIG welded to the end sections.
A stiffener is bent from 6061 1/2" x 1/8" flat stock. To do the bends the stock is heated with a propane torch. Without heating the stock will crack and break.
Clamps are used to position the stock for welding.
The back side is welded as well.
With a bit of practice welds like these are obtainable.
And here is where things started to go wrong. I wanted a flush hinge but the glass panel is larger than the opening. Not seeing this I bent up a hinge from 1/8" x 2" stainless steel. Here the 6" Record vise and the Lee Valley vise break are working to their maximums with cold forming.
I had to look up how aircraft can swing a door out of the way. Well, they use 2 pivot hinges with rollers and trackways, Not going to happen so I cut the hinges and now made the exposed. Maybe some day someone with some engineering background will send me a sketch to contemplate. Here is how it is going to have to happen.
Not sure on this form how many pictures I can post. Some other forms only allow 10 pictures, so I will add another post to this one.
TonyK.
Grimsby Ontario Canada.
I had great ideas that well, were ideas and then complication set in and I had to settle for what you see. More explaining as the post continues.
For working access I placed my truck cap on my car trailer with a few 2x4's and backed it into the work bay of the shop.
First step is to make a template from card board for the size of the window frame.
Using the template I laid out the 2 ends of the frame. Holes were to allow for change in direction of my band saw.
2" x 1/8" flat stock is TIG welded to the end sections.
A stiffener is bent from 6061 1/2" x 1/8" flat stock. To do the bends the stock is heated with a propane torch. Without heating the stock will crack and break.
Clamps are used to position the stock for welding.
The back side is welded as well.
With a bit of practice welds like these are obtainable.
And here is where things started to go wrong. I wanted a flush hinge but the glass panel is larger than the opening. Not seeing this I bent up a hinge from 1/8" x 2" stainless steel. Here the 6" Record vise and the Lee Valley vise break are working to their maximums with cold forming.
I had to look up how aircraft can swing a door out of the way. Well, they use 2 pivot hinges with rollers and trackways, Not going to happen so I cut the hinges and now made the exposed. Maybe some day someone with some engineering background will send me a sketch to contemplate. Here is how it is going to have to happen.
Not sure on this form how many pictures I can post. Some other forms only allow 10 pictures, so I will add another post to this one.
TonyK.
Grimsby Ontario Canada.
