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Post by ap40rocktruck on Jun 19, 2012 13:01:37 GMT -8
This is a step by step "How 2" for adding curved tip polished aluminum exhaust tips to your truck models. Or anything else for that matter. this photo is one that i had made for another project, so we will use it as our pattern. it is 3/16" diameter aluminum rod. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:03:05 GMT -8
Next we have a section of solid aluminum rod stock, 3/16" diameter, this is a cut off from a 24" piece from K&S. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:05:25 GMT -8
Now we put the solid rod into a tubing bender. I picked this one up at Harbor Junk about 10 years ago " 1/4" brake line bender". You don't need to worry about the excess here, we are just looking for the curve. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:07:05 GMT -8
This is the result in bending the rod on the bender. easy, solid rod will not kink or tear. you can do this cold or room temp, no need to heat at all. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:09:06 GMT -8
Now we take a zona or razor saw and cut the end to desired shape & with the amount of curve. For this how 2, i chose the Mack 3-diameter bend, used by Mack from the 1930's thru to the middle of the 80's. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:12:28 GMT -8
Next i use the flex drill & a small center drill bit to drill a shallow hole into the end of the pipe. this will be ground out next to resemble a tube. The reason for the drill first is give the grinding cutter a hole to follow & it will minimize the problem of the cutter sliding off the aluminum rod & grinding in to your finger. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:14:33 GMT -8
This is the carbide burr type cutter i use to gently hollow out the tip of the pipe. These are very sharp and take a light touch, only a few minuets to complete the grind out. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:17:06 GMT -8
this just before grinding out the hole, showing the hole made by the center drill. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:17:45 GMT -8
This is after grinding out the exhaust tip opening. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:20:25 GMT -8
next, I very carefully use a fresh #11 knife blade to thin the outer edge of the pipe to near paper thin. In 1/24 scale the thickness of a exhaust pipe is .002" at best. so we want to get close with out cutting thru the ultra thin aluminum. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:22:14 GMT -8
now that the bore is done, I smooth out the pipe with a bit os maroon scotch-brite pad. only takes a few minuets, and it makes seeing any imperfections very easy for correcting. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:25:04 GMT -8
next step is to use a soft cotton cloth (old T-shirts are the best) and your favorite metal polish. I use Flitz (Micro-Mark), or in this case a bulk tube of tool steel polish that was on the bench. Use a pea sized dollop, and rub the pipe. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:26:02 GMT -8
work the polishing compound into the aluminum until it turns dark gray or black. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:27:03 GMT -8
Now with a clean bit of T-shirt, polish the pipe to a chrome finish. Ap40 Attachments:
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Post by ap40rocktruck on Jun 19, 2012 13:28:34 GMT -8
Now compare this to the original, if making dual exhaust, now is the time to cut the long vertical ends to the same length. Ap40 Attachments:
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