Ducati Laser Cut and Etched Mirror, Ideal Gift

We can take any image and produce a file from it to cut and etch in detail on a sheet of mirror stainless steel thus producing an individual Mirror.

Ideal as a gift or present for a loved one, size and dimension are only limited by sheet size typically up to 2m x 1m

Alternatively if you require an individually crafted kitchen or bathroom splash back we can offer this as well – either with an etched design or a shaped panel – e.g. Love heart, Kettle, Apple, let your imagination run wild.

Ducati Mirror

Ducati Mirror

I have a couple of these spare if anyone is interested @ £40 plus £7 p&p please message me or call me on 07866911093

Also – Stainless steel Splash backs, door kick / bash panels / stainless tabletops / work surfaces also supplied to order.

We look forward to keeping you up to date.

For all your Custom Car & Motorcycle Parts, Manufacture and Welding / Repairs

Alloy welding / repairs, custom parts, Welding Instruction.

 

Seat Aftermarket Intercooler Repair

Alloy Intercooler Repair

This is what happens when you mount an oversize intercooler, and then drop the car on the floor as low as possible; speed humps and rough local roads all add to the damage.

Many things can affect the performance of your car – a holed, leaking intercooler can play havoc with boost levels and drastically reduce overall power. So not an ideal scenario. The key to modifying cars (and bikes) is if you are going to, is to make the changes safely and well engineered. If this intercooler had managed to pick up dust and or stones when scrapping the tarmac this could have led to a catastrophic failure of the engine. Luckily this wasn’t the case this time.

Looking at the above Intercooler repair you can see that the bottom corners had been worn through and needed cleaning and repairing, I used the alloy chequer plate corner patch plates to give a bit more thickness and strength to the bottom corners.

My customer used the slots in the mounting brackets to lift the intercooler about 10mm higher to try and reduce the chance of further damage. My advice was if there was still a problem with it bottoming out in future, modifications to the end cans could be made to shorten the overall height by some 20mm, this would have been ideal but would have taken a little more work.

We look forward to keeping you up to date.

For all your Custom Car & Motorcycle Parts, Manufacture and Welding / Repairs

Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Throttle Body Intake Plenum for Cambridge University Students Project

I had been approached by a student in his final year at Cambridge University. He had modeled up exactly what was required, I had all the drawings and even flat layout patterns for the cones and wraps. So a bit spoilt on this one really but, apparently no one else would take this on in 1mm aluminium. I relished the challenge.

Duly parts were laser cut where possible and I started some real sheet metal work shaping with rolls, planishing hammers and stakes to form up the panel work to suit.

A lot of work went into this as all the joints had to match up spot on as I was going to need to purge the welds to leave a nice smooth bead of penetration on the inside.

As the material was only 1mm thick heat input was difficult to control as with aluminium heat is sucked away from the weld pool area. However, with the material being so thin once a weld pool was formed if I didn`t feed filler wire in immediately them it would drop through and leave a hole in the joint. Careful control with a foot pedal was needed to keep the welded joint from “blowing away”.

 

Fabrication of the main plenum had been analysed by the final year students to allow good airflow in conjunction with the rules and regulations under which they was going to be racing this single seater car. All parts had to be fabricated and welded together by the TIG welding process, other parts included cnc machined bell mouths and laser cut panels and flange. I also had to machine up a couple of bosses to incorporate sensors into the plenum.

The most difficult thing about this job was the simple fact that the drawings allowed little or no material from the bell mouths to the edge of the back plate, When welding such thick cnc machined parts to such thin sheet material the difficulty is always getting enough heat in the thicker part without melting away the thinner part. This was accomplished in a couple of ways. Firstly the back plate was sat on an aluminium heat sink block which helped drag some of the heat away from the thin material whilst directing the arc at the thicker bell mouth part. In future it would be advisable to leave a “land” if possible in order to reduce the chance of blowing away the thin sheet before sufficient heat build up was gained in the machined bell mouths.

Purging the inside of the plenum during welding with argon reduces the chance of atmospheric attack on the inside as weld penetration comes through the joint. This also helps in maintaining a nice smooth bead around the inside which will not disturb the airflow as much as if we hadn’t purged the joints. If I didn’t bother purging when welding the inside penetration bead would have been rough and inconsistent and possibly even hang through like “grapes” as we in the know call it. This would have been unacceptable for the job in hand.

 

We look forward to keeping you up to date.

For all your Custom Car & Motorcycle Parts, Manufacture and Welding / Repairs
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Brake and Clutch Fluid Tank, Polished Stainless

Brake and Clutch Fluid Tank, Polished Stainless

I started this small project with a letter and some fittings from my customer. He had seen my previous work on our website www.flashcustoms.co.uk and wanted an integrated fluid tank for brake system and hydraulic clutch system. It was to be bulkhead mounted with 3 off 4an fittings, lower to be brake system, upper to be clutch system.

It had to be mirror stainless steel as it was being fitted to a top end Dax Cobra Replica.

I pride myself on completing 1 off custom made parts such as this and to ensure that everything is millimeter perfect I used solid works 3 d  modeling package to draw up the item and produce a dxf (drawing exchange file) to send to our laser cutting system.

The material itself is 304 BA (bright annealed) stainless steel in 1.5mm thick. Bright annealed is a chemical etch finish on the surface of the stainless which is almost like a dull polish. This eliminates some of the time involved in bringing the parts up to a “mirror” finish prior to assembly and welding.

Please see below photos of parts and assembly process


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Tomorrow I will Post up pictures and details of the finishing processes I use to ensure the whole tank is mirror polished and pressure tested for leaks.

We look forward to keeping you up to date.

For all your Custom Car & Motorcycle Parts, Manufacture and Welding / Repairs
SEE –
www.flashcustoms.co.uk
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Thanks for reading our blog – we hope this has been of use to you.
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For all your Custom Car & Motorcycle Parts, Manufacture and Welding / Repairs
SEE –
www.flashcustoms.co.uk
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Thanks for reading our blog – we hope this has been of use to you.