Black Beauty Project Build - 06 Ford F-250 Super Duty **1/27/18 - New pics starting on page 41**

[scooter99]

Yeah that's a dangerous place for a guy like you! LOL

[scooter99]

Ok got a little more done tonight. Take a look!

Well it's about that time. New Diablo blade for my chop saw.

Got myself a couple of platforms set up so I have a flat surface for the case to sit on.

Got it all lined up, and everything looks like it's good to go.

But first......"let me take a selfie"! Lol, just kidding, promoting safety first everyone. Remember we're cutting metal with a blade, so hearing protection and eye protection. If you've never had a metal shaving in you're eye, you never want one. Not fun.

Also, hand protection. This service announcement brought to you by S99Creations!

Cut 1, no turning back now!

Cut 2! Now we're getting somewhere.

And this is it. Not sure how I'm going to get the ends black again, but I'll worry about that later. I'm not sure if just paint will work. I have two other pieces to test on though and can cut those if I need to do more testing.

Other end.

And top view. Still need to drill the holes and tap the case for the screws. But she's getting there. This was a big step.

The inside, ready to take on some components.

As far as the case goes, I think I may call a powder coater and see what they would charge to do it. I may still go with a matte black rattle can first and see how that turns out on the test pieces.

The next thing I need to think about is a board of some kind. I need to have something, not metal, to mount the BLD onto, now that the board is exposed. I have a piece of abs, and that may work just fine. But it's not big enough for the whole thing. I'll see if that will work. I also am worried about the rigidity of it. Remember there's going to be lots of vibration in the area, so I want to make sure the movement is at a minimum.

Lots more to do! Plenty more to come! That's all for today.

[jmanjr82]

Damn good work man!!

[scooter99]

Thank you Jmanjr82.

Nothing to really update. Did some little things, figuring out some mounting ideas for the BLD, and some other stuff. Went to Home Depot and got some hardware, screws etc. Also picked up a few different gauges of sheet aluminum to make the ends out of. I did trace out the outline for the ends on a piece of 1/4" mdf I had laying around, and took some pictures of the AA2000.1 to get an idea of how the back plate was mounted as well. So I think I have everything at the moment to make the ends and the back plate. If so, I am just about ready to get this project really moving.

Hopefully this week, I can get my shop cleaned up a little bit. I have no room still from the engine rebuild, and so I have no bench to work on, nor do I have anywhere right now to mount my metal bender. Yes I picked up a metal break to bend the tabs on the unit ends from Harbor Freight.

So more to come soon.

[Wicks]

Ok got a little more done tonight. Take a look!

Well it's about that time. New Diablo blade for my chop saw.

Got myself a couple of platforms set up so I have a flat surface for the case to sit on.

Got it all lined up, and everything looks like it's good to go.

But first......"let me take a selfie"! Lol, just kidding, promoting safety first everyone. Remember we're cutting metal with a blade, so hearing protection and eye protection. If you've never had a metal shaving in you're eye, you never want one. Not fun.

Also, hand protection. This service announcement brought to you by S99Creations!

Cut 1, no turning back now!

Cut 2! Now we're getting somewhere.

And this is it. Not sure how I'm going to get the ends black again, but I'll worry about that later. I'm not sure if just paint will work. I have two other pieces to test on though and can cut those if I need to do more testing.

Other end.

And top view. Still need to drill the holes and tap the case for the screws. But she's getting there. This was a big step.

The inside, ready to take on some components.

As far as the case goes, I think I may call a powder coater and see what they would charge to do it. I may still go with a matte black rattle can first and see how that turns out on the test pieces.

The next thing I need to think about is a board of some kind. I need to have something, not metal, to mount the BLD onto, now that the board is exposed. I have a piece of abs, and that may work just fine. But it's not big enough for the whole thing. I'll see if that will work. I also am worried about the rigidity of it. Remember there's going to be lots of vibration in the area, so I want to make sure the movement is at a minimum.

Lots more to do! Plenty more to come! That's all for today.

Holy shit...

I would have never guessed that chop saw blade could have made such a smooth cut.

I would have thought you'd need a diamond blade or something.

Any water cooling? Bet it got HOTTT?

Ballsy!

[tboorn]

seriously i was thinking the same thing... circular saw on metal. What a bad ass haha. Project looks awesome im excited to see how it turns out.

[scooter99]

Holy shit...

I would have never guessed that chop saw blade could have made such a smooth cut.

I would have thought you'd need a diamond blade or something.

Any water cooling? Bet it got HOTTT?

Ballsy!

seriously i was thinking the same thing... circular saw on metal. What a bad ass haha. Project looks awesome im excited to see how it turns out.

It got a little warm. I have cut my fair share of aluminum on this chop saw, but nothing this thick so I was a little nervous. I also know how much shit it throws off of it when cutting aluminum, hence all of the safety gear.

But this was a brand new blade. Brand new as in the right cut was the first and the left cut was the second.

I just went slow as you would if you were running a router over aluminum. I probably took about 1/8 inch at a time. The benefit of having such a large saw, sliding compound miter. I just went back and forth until the middle was through, and then I slowly went through the back end farthest from the fence, and then once that was through I slowly went through the side closest to the fence.

I was actually shocked that it cut it as easily and quickly as it did. I had to fight myself to do it slower so I didn't eff anything up, including myself! HAHA

So yeah, it went well. Time to get on the rest of it. I bought some new jigsaw blades yesterday. SO when I cut the ends I'll be cutting them with a fresh blade as well. I need to get the lips figured out though so I can bend it all in one piece. I'm thinking a 1/2" lip should do me just fine. Hopefully that will happen in the next few days.

Thanks guys!!

[tboorn]

its just the heat sink catching the blade that would have me scared haha. good shit though,

[scooter99]

I hear you. Thanks. Slow is the key. Drop and lift drop and lift not drop and press it down and cut as fast as you can. At least that's how I did it.

[Twostrokeking]

Your work is insane. Looks great man. Remember if you need any diagrams or anything hit me up on fb