nstevic01
Well-Known Member
It was actually quite the process:
Tried bending the curve by hand using a PVC coupler I had that was the correct diameter, I could only get so far with the bend before it became difficult to close it. So I went out and picked up a ring roller from Harbor Freight. This made it easier, however, it "cupped" the metal as it formed the ring. So once I welded it closed, I had to sit there and grind the surface of the ring flat. This probably took the better part of 2 hours.
In order to shape the perforated metal, I had to build a die to press the sheet through the rings in order to get a perfect fit and the curved edges. The first time pressing it through, the weld on the ring failed and I had to fix that. At that point, I created a block of wood that the ring would sit inside and would not allow it to expand while pressing in the die and sheet of metal. This seemed to work the best. All in all, the exhaust caps took the better part of 6 hours to make.
Tried bending the curve by hand using a PVC coupler I had that was the correct diameter, I could only get so far with the bend before it became difficult to close it. So I went out and picked up a ring roller from Harbor Freight. This made it easier, however, it "cupped" the metal as it formed the ring. So once I welded it closed, I had to sit there and grind the surface of the ring flat. This probably took the better part of 2 hours.
In order to shape the perforated metal, I had to build a die to press the sheet through the rings in order to get a perfect fit and the curved edges. The first time pressing it through, the weld on the ring failed and I had to fix that. At that point, I created a block of wood that the ring would sit inside and would not allow it to expand while pressing in the die and sheet of metal. This seemed to work the best. All in all, the exhaust caps took the better part of 6 hours to make.