Alex01 Silver Sport Build Thread

The one other attempt at this that I am aware of used a large die to form the bend and the result was cracking. The compromise here is that the bend isn't as clean as might be desired or required. But for a one off home project, the multiple bends with the little steps might become more acceptable when there is no longer another option.

For all I know getting to the final bend on the second piece will do the same. I feel like I pulled off a miracle the first time so I'm extremely hopeful the second bend will work out as well but at the same time very nervous for the final bit.

For an experiment I may take some of the extra length, the area where the trunk hinge goes, and put it in the press and keep cranking till it breaks. Not sure if it'd make me feel more confident though or make me realize my margin of error is zero. I'm assuming I'm playing with fire though given the thickness and the bend radius.
 
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Heating it would obviously make it easier but then I'd lose the temper.
 
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I'm curious to see what you're going to do around the hinges. I have the stock hinges and don't see how this will work around it.

I have some aftermarket hinges that I haven't had a chance to install yet.
 
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I'm curious to see what you're going to do around the hinges. I have the stock hinges and don't see how this will work around it.

I have some aftermarket hinges that I haven't had a chance to install yet.
If all goes to plan I'll terminate it right at the hinge and attempt to use the rear bolt as a anchor.

If it goes mildly wrong I'll leave the last bolt unattached to the slider but have it make the bend.

Worse case I'll chop off the bend.
 
If all goes to plan I'll terminate it right at the hinge and attempt to use the rear bolt as a anchor.

If it goes mildly wrong I'll leave the last bolt unattached to the slider but have it make the bend.

Worse case I'll chop off the bend.

Very impressive work!
 
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Looks like I'm going with the option of making the bend but not integrating the rear bolt.

Durning bending I had a catastrophic crack. Fortunately I was able to move a bit up the piece so I had enough material to get to the hinge. It could use another crank or so on the press but I'm too gun shy at this point.

I haven't tested opening the tailgate yet but I assume I'll need to remove some material in order for it to function.

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Looks like I'm going with the option of making the bend but not integrating the rear bolt.

Durning bending I had a catastrophic crack. Fortunately I was able to move a bit up the piece so I had enough material to get to the hinge. It could use another crank or so on the press but I'm too gun shy at this point.

I haven't tested opening the tailgate yet but I assume I'll need to remove some material in order for it to function.

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What in the Wildman is that?
 
FYI Alex, if you’re going to bend any more 6061 aluminum, you can ease the cracking issue by heating the aluminum prior to bending . It doesn’t need to be bent hot, only de-tempered before bending.

The heat will take the temper out of the material, but too much heat will remove it all. If you heat it until it has a golden tinge when cooled, you’ve gone too far.

I use an oxy-acetylene torch to do it. I’ve never used propane or MAP, but I suppose it would work. It’ll just take longer.

I’d give you a specific temperature, but I’ve just guesstimated it as a rule.

And BTW, nice work dude! 😸
 
I got the tub sliders rounded off a bit with a router and drilled/countersunk all the holes. For the front I used button heads like savvy. (Still waiting on the longer bolts for final install)

I'm not really happy with the rear near the hinge but for a DIY it's not horrible. I certainly wouldn't be thrilled though if I bought them lol. I found I had a tiny bit of meat near the last mounting point so I drilled it though and added a bolt so it'd pull the slider better into shape.


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I got the tub sliders rounded off a bit with a router and drilled/countersunk all the holes. For the front I used button heads like savvy. (Still waiting on the longer bolts for final install)

I'm not really happy with the rear near the hinge but for a DIY it's not horrible. I certainly wouldn't be thrilled though if I bought them lol. I found I had a tiny bit of meat near the last mounting point so I drilled it though and added a bolt so it'd pull the slider better into shape.


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Looks DARN good. Thanks for giving me more SHIT to do. Are you going to add a bolt to the rear near the hinge?
 
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Looks DARN good. Thanks for giving me more SHIT to do. Are you going to add a bolt to the rear near the hinge?

I did but it's a bit cringe. The angle was off so the hole is bigger than it should be, and too far to the right, but it affectively pulled the corner in closer.

I may buy another piece to try and redo that side in the future.

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I got the tub sliders rounded off a bit with a router and drilled/countersunk all the holes. For the front I used button heads like savvy. (Still waiting on the longer bolts for final install)

I'm not really happy with the rear near the hinge but for a DIY it's not horrible. I certainly wouldn't be thrilled though if I bought them lol. I found I had a tiny bit of meat near the last mounting point so I drilled it though and added a bolt so it'd pull the slider better into shape.


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Turned out awesome, you've got the gears turning for something similar on my jeep
 
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I have a call out to Revolution to replace the shaft. Assuming they don't want it back what's the best method to get this thing straight again so I can keep it in the spare pile? Heat and a vice?
 
The press is coming in handy lately. I borrowed @Midnight LJR's inner shaft and salvaged the stub shaft with a bit of work on the press. Revolution will send me a new inner and stub but it won't arrive before moab. @Midnight LJR will also bring an oem shaft to be safe.

Thanks, Mike for getting me out of a pickle.

Also, I noticed the hub was grinding badly. I replaced it while I had everything apart.

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