2015 Chevy Sonic/Wall/4 PSI 15's/SA 6K/Active/Arc/CDT/Singer/US Alt/XS

[BP1Fanatic]

I like the kerfing too!

[WalledSonic]

Went to Metals Supermarket today, this was their steel tube rack

Grabbed some 1"x2" hollow tube and a drop of 2"x0.25" rectangular bar for gussets

Still need to cut the bar

Downward view

Ordered the turnbuckle and jam nuts from McMaster Carr today too. Pics of that forthcoming.  Also, the metal store had a community board with a bunch of business cards for fab/welders.  Hopefully get everything welded up next week.

[WalledSonic]

Also, those cabin pressure equalization flaps are apparently needed.  This mustve happened on the freeway

And a wall shot

[BP1Fanatic]

Awesome brace!

[WalledSonic]

Still waiting on the turnbuckle to arrive so I can get the pole welded up.  More on the pole soon.  Moved on to other things this weekend.

Wood ceiling:

Me trying to hold it up for the pic

[WalledSonic]

All the parts are in for the windshield brace.  This turnbuckle is so much larger than I imagined:

Ordered lefthand and righthand nuts so I can tension the pole:

The pole will generally look like this:

Sketched up some details on how to prep the turnbuckle.  Just downloaded the image from the website and drew over it.

Suggestions on how to secure the turnbuckle to the pole and the pole to the top brace.

Need to meet with the welder to see what he thinks.

 

[nkrell11]

That turnbuckle is definitely an interesting idea, for future reference your kerfs will bend much easier if you make your cuts deeper it looks like you could have went about two layers of ply deeper. If you're blade isn't set deep enough you get the telltale lines out the outside. If you already know these things I apologize, these pictures kind of show what I'm talking about but these are the best ones I had in my photobucket library.

[tboorn]

just read this hole build and i must say awesome work so far! looks really sick, hopefully i get to hear this some day.

[WalledSonic]

11 hours ago, nkrell11 said:

That turnbuckle is definitely an interesting idea, for future reference your kerfs will bend much easier if you make your cuts deeper it looks like you could have went about two layers of ply deeper. If you're blade isn't set deep enough you get the telltale lines out the outside. If you already know these things I apologize, these pictures kind of show what I'm talking about but these are the best ones I had in my photobucket library.

That port is SICKKK man.  Damn.  Thanks for the input, I was scared to cut too deep.  I saw on Wicks' build log that he used a slide-pull miter saw to quickly make a bunch of straight kerfs.  My miter is not a slide-pull, so I dont know if I want to cut all those kerfs with a circ saw and a guide, as that was a PITA last time.  Im also trying to make a 9.25" diameter kerfed curve, which may not be reasonable.  Thanks for the input, though.  So just leave a single or maybe two plies?

[WalledSonic]

9 hours ago, tboorn said:

just read this hole build and i must say awesome work so far! looks really sick, hopefully i get to hear this some day.

Heck yeah man, I go to Austin occasionally.  I'd also like to go to a meet over there just bc I love visiting the Hill Country!  So. Much. Beeeeer.  Thanks for looking!