1999 4Runner 4x4 Streamlining

[aerohead]

Originally Posted by aardvarcus

Freebeard,

Using the aluminum tape is a great idea! I had been contemplating riveting some metal to the shell and fiberglassing over it, but the tape would work even better.

Really it should be ok even if the tape only was acting like a form, as once the fiberglass set up it should be rigid. I will try to give that a go this weekend.

If you ever need to consider a release mechanism when laying up,the tape can also be triple-waxed, and fogged with polyvinyl acetate,providing good release.I've used it on concrete tooling.

[aardvarcus]

I have mainly just been using the 4Runner, not a lot of mods since my last post, but this week (in preparation for a off-roading trip) I got the urge to finish the nose to radiator skid plate/belly pan. This also partially acts as the bottom half of a lower grill block, the upper grill is already ducted to the radiator, so the lower grill serves no present purpose. The holes are for fog lights and a center removable license plate to access the hidden receiver. The outer edges of the lower plastic valence were trimmed back in preparation for two large conveyor belt tire spats.

[M_a_t_t]

Did you roll that corner or did you just find a scrap piece and make it work?

[aardvarcus]

My press brake i built has a round bar for the upper die that puts radius in the bends.

[M_a_t_t]

Could you post pictures of the brake? The "Metal shaping technique showcase/discussion for ecomodders" thread might benefit from the same pics.

I've seen DIY press brakes using angle iron, but never with a radius attachment.

[aardvarcus]

Matt, I understand and support information sharing, hence all of my posts, however I feel I must refrain from posting pictures of a dangerous tool built from scrap metal as I would not want others to attempt to copy its design... the forces (80,000 lbs) here are no joke... there are plenty of well engineered designs to glean from.

But to not be an entire buzzkill, it is similar to most press brake designs with a double angle lower "W" die, and the upper die has a piece of 1 3/8" solid bar as the pressing point instead of a sharp v. The tonnage required is a function of the spacing of the lower die when "air bending" vs bottoming out. Air bending doesn't result in a perfect sharp 90 anyway. The radius helps the air bend form a nicely curved profile. Also reduces stress and weakening when bending thicker pieces.

[freebeard]

Trying to make a brake do a rollers job?

[aardvarcus]

Freebeard, more like trying to make do in my garage. It just helps define the curve that you inevitably get with lower tonnage press brake designs. Plus from an aero standpoint I would rather have the radiuses than sharp bends anyway.

Edit: oh and I don't have a roller...

[aardvarcus]

The 4runner did great today at Windrock OHV park. Didn't get stuck or break, the same can't be said of all vehicles on the trip. It was a long day. The skids did their job. And then it drove home, unlike most which went home on a trailer. I am very happy with the onroad to offroad balance of this vehicle.

[M_a_t_t]

I didn't realize it was hydraulic. I also didn't really pay attention to the thickness of that aluminum. Same concept with thinner metal and a manual brake should work then right?