Sunday, July 17, 2016

Hand-Fabricating Custom Air Cleaners (with how-to photos)

Note to Readers:I just love this do it yourself blog post of making car parts by the Hot Rod Network and had to share.  Given the tools and the time, I would love to do more of this type of car restoration on my 1957 Chevy.  
Back in the day, I subscribe to several Vintage and Classic Car Magazines, but alas those day have gone the way of the dodo bird.  Everything you would want is on the internet today.  If you can't waste several hours on a Saturday surfing car blogs such as Hot Rod Magazine Beta and Texas Classic Chevy Experience you are just not trying.  
Here is a link to Hot Rod's web page,  Check it out and I'm convinced you'll enjoy the site:  http://beta.hotrod.com/
Link to the post copied: http://beta.hotrod.com/articles/hand-fabricating-custom-two-barrel-air-cleaners/


24 PHOTOS
 STREET RODDER ENGINE

Hand-Fabricating Custom Two-Barrel Air Cleaners

- Author
Picture a 1959 Chrysler 300E, its 413 Wedge adorned with paralleled ham can-style air cleaners atop a pair of dual quads. Now wipe that mental slate clean and picture the same air cleaners, inline, atop a quartet of Stromberg two-barrels feeding a vintage Hemi in a 1932 Ford roadster. Same … but different … different in a good way!
To formally “induce” the 1957 392 in his Deuce roadster project that Austin Speed Shop is currently undertaking, Dr. Dan Peterson chose a somewhat rare Horne 4×2 intake, for which a quartet of Stromberg 97s affixed. But rather than the average aluminum snorkels or standard paper-element air cleaners, he wanted something unique to top things off. That’s where the dual-quad Wedge inspiration came from—but with a 90-degree twist.
Seeing as the investment in purchasing an OE air cleaner setup would not be so cost-effective, say nothing about further modifications required to re-quip them for “quad-dual” service, the answer was simple: have Austin Speed Shop’s lead fabricator, Eric Anderson, custom-fabricate a fresh set.
While the solution may have been simple, the forthcoming process took a little effort and ingenuity, to say the least. Our following documentation of the procedure should give you some good insight on the process.
The custom quad-dual air cleaners started life as a template … then a layered ply buck … then a strip of 18-gauge sheetmetal, as shown, where we picked up on the fabrication process at Austin Speed Shop with Eric Anderson.
The custom quad-dual air cleaners started life as a template … then a layered ply buck … then a strip of 18-gauge sheetmetal, as shown, where we picked up on the fabrication process at Austin Speed Shop with Eric Anderson.
The top edge of the metal strip is left long; the buck’s upper perimeter rounded. Anderson starts the reshaping by hammering the edge over.
The top edge of the metal strip is left long; the buck’s upper perimeter rounded. Anderson starts the reshaping by hammering the edge over.
The rough edge is then pulled back taught beginning with a shrinker/stretcher.
The rough edge is then pulled back taught beginning with a shrinker/stretcher.
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High spots are hammered back down onto the buck before the shell is taken to the planishing hammer for finishing.
High spots are hammered back down onto the buck before the shell is taken to the planishing hammer for finishing.
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For the lid portion, Anderson created a template for which he used to scribe the accent detail lines that were bead-rolled into the sheetmetal.
For the lid portion, Anderson created a template for which he used to scribe the accent detail lines that were bead-rolled into the sheetmetal.
Since the bead roller slightly distorted the panel, Anderson uses the skrinker/stretcher to pull it back into shape.
Since the bead roller slightly distorted the panel, Anderson uses the skrinker/stretcher to pull it back into shape.
Nice and flat, the first OE Chrysler–looking accent is complete; now for the perimeter bead.
Nice and flat, the first OE Chrysler–looking accent is complete; now for the perimeter bead.
Back to the roller, Anderson ran a nice reverse bead (concave) along the exterior edge of the lid. Again, the outer edge is pulled in to make the panel flat and uniform.
Back to the roller, Anderson ran a nice reverse bead (concave) along the exterior edge of the lid. Again, the outer edge is pulled in to make the panel flat and uniform.
Now for the lid’s “skirt”—a thin section of sheetmetal that will join and stand the top off the main portion of the air cleaner body. Two pieces of channel-shaped 18-gauge will do the trick.
Now for the lid’s “skirt”—a thin section of sheetmetal that will join and stand the top off the main portion of the air cleaner body. Two pieces of channel-shaped 18-gauge will do the trick.
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Each half is bent on the shrinker/stretcher until its shape is uniform with the contour of lid. Inconsistencies in the flange edge are hammered out.
Each half is bent on the shrinker/stretcher until its shape is uniform with the contour of lid. Inconsistencies in the flange edge are hammered out.
Once shaped, the two halves are TIG-welded together.
Once shaped, the two halves are TIG-welded together.
The lid needed one more detail first—the recess for the attachment hole was hammered in using a wooden die Anderson whittled out.
The lid needed one more detail first—the recess for the attachment hole was hammered in using a wooden die Anderson whittled out.
Now the lid and skirt get fitted prior to being welded together— Anderson used shears to trim off excess material.
Now the lid and skirt get fitted prior to being welded together— Anderson used shears to trim off excess material.
The two pieces were set up and sandwiched together using vise grip clamps for the welding process.
The two pieces were set up and sandwiched together using vise grip clamps for the welding process.
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Once joined, the perimeter weld bead was hammered outward prior to being ground and sanded flush and subsequently metal-finished.
Once joined, the perimeter weld bead was hammered outward prior to being ground and sanded flush and subsequently metal-finished.
Now the lid is united with the main body of the air cleaner—welding is done from the outside and finished with a cutoff wheel and file.
Now the lid is united with the main body of the air cleaner—welding is done from the outside and finished with a cutoff wheel and file.
Lastly, Anderson adds a detail strip of sheetmetal to the lower edge of the air cleaner—this portion is done by welding the bottom-most joint and fishing off the weld.
Lastly, Anderson adds a detail strip of sheetmetal to the lower edge of the air cleaner—this portion is done by welding the bottom-most joint and fishing off the weld.
Save for a bit of additional metal-finishing and paint, the custom fabrication ham cans are complete!
Save for a bit of additional metal-finishing and paint, the custom fabrication ham cans are complete!
 MUST READ FROM STREET RODDER

ALL PHOTOS

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