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The curve of the running board is very gradual, so I made several reference marks on the wood and steel with a green marker to make sure the steel is positioned in the right place. |
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When it was in the right spot, I clamped the steel to the wood buck, and then clamped another piece of wood on top as close to the edge as possible, to reduce the amount of warping on the top flat side while I hammered the edge down. |
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I had to carefully measure the amount of overhang that would be beat down 90 degrees. It seems that the curved line I traced onto the steel using the edge of the running board was just a little off. The center of the curve was a little narrower than I would have liked. |
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I used my paper to measure the width of the running board at the spot where my
sheet metal was the narrowest. Then I measured the folded lip on the rear fender
as a reference to see
how much extra I would have to leave on the outer edge to get that folded edge
in the running board. My sheet metal was just about a quarter inch too narrow. I
had to find a way to save at least a quarter inch. After some more measuring, I
found that the original boards have a 1" lip on the back side, next to the car.
Since I will be welding that side to the long skinny piece (not sure what's it's
called), I could make that side less than 1 inch, and then there would be enough
room for the 180 degree folded edge on the front. I also had to factor in a
little for the bead rolled detail edge on the front, plus the bend radius on the
back. Let's see, add...subtract that.... looks like the narrowest part of the
sheet metal should be sticking out over the wood buck 7/16", and bent down 90
degrees. Whew. That's a lot of calculating just to bend an edge. I'll leave a
little extra room next time! So in the 3rd picture above, everything is clamped
down and ready to be hammered.
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Here's the final bent edge. It came out surprisingly smooth. I used a 5 pound hammer to beat it down, and it worked great, with very minimal warping on the top flat side. |
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Here's a test fit up against the long skinny piece. It matches perfectly! Those 2 edges will eventually be welded together, and then welded to the front fender to make one big smooth piece with no seams. Should be pretty cool! |
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