Quote:
Originally Posted by BajaSportsmobile
I'd probably use 6061 and would not worry about any heat treating.
Cut it yourself with a Carbide Skill Saw and use a Router to clean up the edges before and or after welding. Treat it just like wood...
You can rent a Spool Gun and weld it yourself quickly and easily. Any voids in welded seams can be re-welded or filled with All Metal filler and then Powder Coated.
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Ramsey: Yes I've been toying with the idea of cutting the sheets....my non ferrous blade will cut this stuff like butter. There are a couple of shallow bends...thinking of kerfing/scoring the sheet on the tablesaw and then bending with 2x4's and clamps or vice, etc.
I'm also thinking about a couple of pieces of 2x8" AL channel for the support that bolts to the van. I don't really need a full length channel although if I find a rem at IMS.......that would give the top and bottom something significant to weld to.
I can certainly make the cut-outs for the flush mount LED's that I'm thinking about.....and I've got an idea to easily mount the back-up sensors cleanly....the factory sensor holders have ears in crazy places.
If I do the step part.....that's a fair bit of bending...or just weld individual sheets in there.
I have a super-crapilicious 240V Harbor Freight MIG welder with a gas bottle...the gun completely sucks though.....instant bird's nest when pulling the trigger. When I bought off of CL I figured the bottle and regulator were worth the $60 I paid for the whole thing.