Sat, stopped by a fellow member's business, where he has a fully stocked sheet metal shop! For me in the need for such a place, Disneyland would not have looked better!
I picked up some 12x18" 22 gauge sheet stock from Home Depot. Was cheaper than my local steel super store...by a great margin!
First thing I did was make more rectangles out of these large rectangles on the shear. This is a great tool for making straight cuts without distorting the edges like the hand aviation snips do...and you have to hammer them back flat...not with this guy!
Then I rolled two of them into the tubes that form the outer bits where the paper inlet tubes attach to the air cleaner. This roller is just too cool! I could have used this some more for making these parts!!!! (plus so many other things!!!)
(Tonight I found out that I made these just a tad to large in length, by about 1mm or 1/8", the thickness of a 3" cutoff wheel! When rolled they came out to 81-82mm, and I needed 80.)
When I got done I had a few scraps to practice welding with! I was gonna need more than this!
I made up a template for the top and bottom sections of the snorkles.....this too needed slight modification where the outer circle is formed for the round sections I rolled up....live and learn! I modified 3 out of the 4 that I cut out....I can patch the gaps easy enuf...I hope!
Using left and right aviation snips, I cut out my pieces, tapped them flat again, and deburred them.
After some right angle bending...
and some more round bending...
and some straightening and hammering and more bending, straightening, and hammering, I ended up with some pieces to tack together.
My stack of hand tools for this job.
After practicing my "22 gauge" welding, with ALL of the scraps I cut off of my patterned parts, and the left overs from the basic shearing, I felt I had enough time on the welder to give it a shot.
Here is where I left off tonight.
I have both round pieces seam welded, welds filed down and the outer edge rolled over a bit to allow you to get the paper tube on easily. One of the round extensions is fitted into the inner piece after working on it with a hammer and a heavy smooth piece of round stock and it's close to ready for tack welding together, then some more light hammer work to close up the gaps for final welding of the seams. I can see now where a TIG welder for this would be fantastic! The MIG, while good, just doesn't give me all that much control for this thin tin.
On the piece at the RH side of the above picture you can just make out where my pattern was off where the two halves form the round circle. I didn't compensate for the "pull" when forming the straight edge where the two pieces join together. Not a big deal...it will look like it came from Italy.... hand made and all! good news is that the pieces really do not need to be welded air tight....a teeny tiny hole here or there (just like the originals!) will not let that much warm air in to affect the operation of things....any dust would still be filtered out before the air got into the carb.
More next time!
Steve