V8 Cheesegrate Valance Redesigned!

[superdave]

A few have you know already that I've fitted the 2002 rear round light conversion to my V8. I've been trying to get fitted a centre exit exhaust in time for the factory visit but no joy. So instead I've redesigned the cheesegrater valance which had the exits in the middle and taken it back to the drawing board. I've redesigned it to have the eixts on the sides to fit a standard exhaust. I've sent the plans off the a laser cutting company who have cut it out in stainless (prototype veriosn). The only problem i have now is finding a company who has rollers small enough to roll to the radius I want. So Iam stuck at the moment.
Here's some pictures so far and the drawings and also the flat piece of stainless ready to roll.

http://good-times.webshots.com/photo/

http://good-times.webshots.com/photo/

[teigan]

once cut that close to taeget size, you can no longer roll the edges. you need to die stamp it on a form fit plug. the tooling would be uneconomical for small runs, so i would CNC mill a frame for what you have already. it can be made in four segments and cut from matched stainless steel.

[superdave]

Hi there,

I've already made a sample piece using rollers then folding the sides up. It does work, it's just that the rollers we used were too big.
Iam not really understanding what you are trying to say?


Dave

[kylie]

Nice pics Dave, keep up the great work.

[teigan]

i haven't had good luck rolling edges. what size are you using, and what size do you need? i was suggesting you make the side rails as assembly pieces, and leave the grate flat to nestle inside a groove. it's extra work, but if you are stuck then that may be a way to finish up quicker.

[superdave]

Hi all,

I decided to bend this up myself in 6mm increments using a power folder. I drew all the marking on the CAd and printed them 1:1. I stuck these onto the back of the flat plate to save time in marking the 18 bends I need to form the radius.
I've offered it to my car but the old valance is in the way but you get the idea.
So what do you think, yes, no?
I haven't bead blasted it yet as I don't know whether to fit it or not. If it looks crap then I'll go centre exit.

Your opinions please.



http://rides.webshots.com/photo/27693



http://rides.webshots.com/photo/23682

[andecorp]

superdave said:

Hi all,

I decided to bend this up myself in 6mm increments using a power folder. I drew all the marking on the CAd and printed them 1:1. I stuck these onto the back of the flat plate to save time in marking the 18 bends I need to form the radius.
I've offered it to my car but the old valance is in the way but you get the idea.
So what do you think, yes, no?
I haven't bead blasted it yet as I don't know whether to fit it or not. If it looks crap then I'll go centre exit.

Your opinions please.



http://rides.webshots.com/photo/27693



http://rides.webshots.com/photo/23682

I like it a lot.

[fflyingdog]

Looks good Dave i would be intersted in fitting one onto my S4s ,but would it be possible to loose the left hand exit area and make the cheese grater fit all the way ?

Cheers
Nick S4s

[superdave]

Hi Nick,

It would but this would mean a one off. I was thinking of making 10 off of the V8 to keep costs down to around £100. The stamping out alone costs £60 as a one off. This is for a flat piece of stainless. Someone else has just asked me for a GT3. When I worked out the cost, it would come to around £120-150 as a one off. This is the problem about custom parts and low volume. There's no profit and also no time added for drawing it and picking it up from one supplier and taking to other which is a 70 mile round trip. This would all be off my own back.
If you are still interesting then email me.

[superdave]

Nick,

Did you receive my email the other day, it's come back as undelivered for some reason?


Dave Walters

[fflyingdog]

Hi Dave
Yeah i recieved and i replied about 2 days a go,PH seems to have a few gremlins,maybe b y now you have my reply? If not will try ending through Lew.