So, any chance someone on this board will start making these like F250 makes the covers for us?

 

I can take what we all have and put it into acad, maybe change out some bits and get it run in aluminum of some other non ferrous metal on my cnc?

For templates I can send the file to any Kinkos and have them print it there for whoever for 2.00 or so per 24 x 36 page.

This is a mod I also plan on doing, but will relocate both batteries inside, possible under the bench seat, recessed through the floor board. This way we , might be able to change the design up a little? Won;t start on it for at least a2 weeks though.

 

I have the template in DWG format if you would like it.

 

yeah that would be a great start. Send me a pm and I'll send you my e-mail address and get this posted somewhere for future downloads, maybe as a pdf for others.

Mike

 

I think someone did that. You could print it on a plotter or you could print off a bunch of .pdf's and tape them together. Did you read the whole thread? I thought it was in here.

 

Ya, that is what I have. DWG large format or PDF to print out in 8.5 x 11 sheets and tape them together. Send me a pm if you want either one.

 

Sent you a pm

With the dwg file, I can then convert it to cut the pcs on our cnc in aluminum, and actually create a fold up pattern from what I have seen. We run a 45 degree bit over the pattern leaving just enough material on the bottom side to allow us to fold the parts together. At the other corners we go through to allow the parts to fit as a mitre fold. I'll know more when I see the dwg file, but we do this with complicated wooden boxes all day. I'm thinking of running it it aluminum, with the cnc mitering the sides etc, and making score lines so I have to fold the pcs in or up and then weld en up from the inside. Make a lip for the bottom ,and drop on a pcs and rivet it in for future access? We will see.

 

I sent you the files. I dont think you need to score it,. IMHO if you score the aluminum it could lead to cracking in the future. Just calculate the bend allowance and bend it if you are trying to get it perfect.

Funny thing is I have made the drawings, but have yet to make one myself. I want to use aluminum as well and just rivet it together. It will be a reminder of structures class in college trying not to put smiley faces on rivets. LOL!

 

I did my cold air box today per your design...

I called my HVAC Tech and he had all the tools and scrap pieces to get the 3 different pieces made. His tools were too cool. perfect bends and flat clean angles.

Sorry i didnt take any photos... but I do have some info.

I used rivets to pull the 3 pieces together and it worked well.

I would recommend some kind of gray tape / duct tape to line the sharp edges of the sheet metal.

I was also able to use the stock battery mount by cutting down the stock battery/intake to fit in the designed cold air box... The trick to getting it to fit for me was cutting down the 2 fins on the bottom side of the battery box. basically you have to cut off the "ridges" on the bottom side. These ridges will prevent the stock screws from reaching the bolts they attach to. Once I "Shaved" them down by using my air tools (cutting disc) the stock bolts worked perfect, and the stock battery box was perfect.

Just to clarify... I cut off the furtherest side of the box to the passenger side of the truck. Basically I cut off the air intake all the way down that side of the intake box. This is a "go, no go" commitment. Once you go down this path there is no turning back.

Please feel free to pm me if you have any questions.

Thanks,
Andy

 

You should know better by now Andy. We want to see some pics.

Have you test driven it yet? Notice any difference in sound?

A door edge guard works sell for the exposed edges of the metal and gives it a nice finished look.

 

I have to take it back out to make some adjustments.... when I do, I will take some photos and upload.

 

I got all the pdf templates a while ago. For a rainy day. I saw your post Andy and thought. Dang no pictures.. Jee wiz.. lol..

 

I will not be lashed with wet noodles

My only thing with pics is that I use photobucket and they only allow your photo to be viewed so many times and then it is no longer viewable. I cant stand it when I take the time to upload a picture only for it to rendered inaccessable. (unless you pay for their premium service with unlimited access to your picture files) ... are there any better sites for picture hosting?


Oh yeah... I forgot to mention... on the shaving off of or cutting off of the ridges on the bottom of the battery tray... you dont need to do this if you get longer bolts. IMHO, I would have rather had longer bolts.

 

I just upload photos to my gallery here at FTE. Seems to be easier for the internet challenged like myself.

 

I haven't seen that with my freebee photobucket yet and i have boat loads of pics in there. I know Geocities(yahoo) does it like you described.