I'm back at doing custom work. Glad to be out of an apartment and back in a house again. Nothing beats having your own garage 
. First order of business, get the accord ready for some serious autoX. That means slimming her down and lighten the load the Euro R H22 has to carry.
The first custom part to build, the front bumper support beam. The stock piece is fairly heavy, and the mounts are pretty thin sheet metal. In addition, it's HUGE!! Anyone boosting the accord knows the difficulty of fitting a good size intercooler in there. Not saying i'm going boost any time soon........
On to some pics and some design decisions
Material's of choice:
Mounting brackets will be made of A36 steel. 0.1875" thick
Support beam will be made of rectangular tubing. Specifically A513 steel. 1" x 2.5" @ 0.12" thick
Fabrication process:
All components are prototyped out of cardboard (CAD or cardboard aided design), and then metal templates are created by plasma cutting around the cardboard. This creates a concave template which can be reused to create identical parts with a good degree of accuracy and repeatability. After all the parts are templated out, they are TIG welded together using the stock piece and Accord as the jig to ensure proper fit.
Pictures of the work so far:
. First order of business, get the accord ready for some serious autoX. That means slimming her down and lighten the load the Euro R H22 has to carry.The first custom part to build, the front bumper support beam. The stock piece is fairly heavy, and the mounts are pretty thin sheet metal. In addition, it's HUGE!! Anyone boosting the accord knows the difficulty of fitting a good size intercooler in there. Not saying i'm going boost any time soon.......
.On to some pics and some design decisions
Material's of choice:
Mounting brackets will be made of A36 steel. 0.1875" thick
Support beam will be made of rectangular tubing. Specifically A513 steel. 1" x 2.5" @ 0.12" thick
Fabrication process:
All components are prototyped out of cardboard (CAD or cardboard aided design
), and then metal templates are created by plasma cutting around the cardboard. This creates a concave template which can be reused to create identical parts with a good degree of accuracy and repeatability. After all the parts are templated out, they are TIG welded together using the stock piece and Accord as the jig to ensure proper fit.Pictures of the work so far:
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