headlight project

[burninbriar]

I started my headlight project but didn't get as many pics as I intended to. Takeing pictures always seemed to slip my mind whenever I got a chance to work on it. I was wondering if any one can tell me about how much it should cost to have the retainer cut out of 1/2" alluminum with a CNC router, or if there is a better way ?? I have the alluminum plate and was thinking of doing it myself but I know it would be very difficult with my primative tools.
The first pics are the shell and the inside retainer that I will weld in when I get my foot control back. The last pic is a drawing of the outside retainer whitch measures 5"x7 3/8". The outside border will be routed 1/16" deep to plug into the shell and the inside border will be routed to 1/8" deep to hold the lamp.

[Richs]

Without access to a milling machine, that's gonna be tough. Do you think you can get a retainer from the aftermarket? Are the headlight buckets aftermarket?

[burninbriar]

I made the bucket myself to my own dementions. I was originally going to make the retainer out of sheet metal too but since I have the 1/2" alluminum plate I figured it might be easyer to have it cut.

[Richs]

And it may be crazy or even dangerous but if a mill of any sort is out of the question, you might try a router with rounding, ball, etc... bits. You'll need to make some plywood templates. And I never tried this so I don't know how a router would react to cutting metal. You may need a Variac speed control?
I might add that little bites with the router would be best.

[Richs]

The buckets are awesome! Mind if I ask how you molded the corners?

[burninbriar]

I have routed thinner guage aluminum, about .090" but I was going to try to find someone with a computer operated router or simular equipment to do the job. I just don't have any idea of how much money it would take to get it cut by those means.

[Richard]

Hey Pete,

those look great so far .....good job
I hope you get it all worked out.

good luck.

........Richard

I work with a guy that has a cnc machine at his house and is allways looking for some side work. maybe you could go to some machine shops and ask around and see if some one would be willing to help you out.
also the guy at the local steel suplier knows guys that do that kinda stuff,
you may be suprised the people he knows.....I guess just try asking around

[burninbriar]

The buckets are awesome! Mind if I ask how you molded the corners?

I had a freind, who owns a lath, cut cut a punch and die for me. I put it in a wood vice to press it. I'll get some pics of it to post.

[Richs]

Yes, I suppose that would be best. Hopefully you'll get an idea of the kind of money involved from one of the other members...

[burninbriar]

The buckets are awesome! Mind if I ask how you molded the corners?

Here is some pics of the punch & die set I had made and my woodvice/metal press.
In an earlyer thread I showed the radius corner jig I made for my brake. I'll look that up and post a link to it. I cant remember what I titled the thread.
Heres the thread on the radius corner attachment I made for the brake.
http://www.millermotorsports.com/mbo...ead.php?t=4993