As you can see here I now have what is the base of my pan. It fits the
bug body perfectly.
I now have to figure out how to get the rear torsion attached to the center
section of the pan.
I have seen in many publications to use cardboard to make a template.
Well that idea worked great here. I simply cut out a general shape and
transferred it to the metal. Then with the plasma cutter, a straight edge,
and a thin piece of tube (used as guides), I was able to cut out the pieces from
a single piece of 3/16", reducing the amount of scrap.
With the pieces set up on the pan/torsion bar, I simply clamped in place and
welded them in. To keep from causing thermal torsion or pulling on the
parts, I welded it in sections opposite sides of each other with ample cooling
time in between.
For the back of the horns, I had some scrap pieces of 1/4" thick
material that was already the shape I wanted. I just added a notch at the
ends, and a slight bend to them to follow the contour of the horns. I then
welded both sides from top to bottom, and completely to the torsion bar. I
was thinking that I might need to add more material to the horns, but after
placing the transaxle on the horns, and then actually sitting my 200+ lb butt on
the transaxle, with my feet off the floor, it made the center of the pan bow
about 1/4", and I have not even added anything to that yet. I will
also be adding bars from the roll cage down to the horns on both sides to help
support everything.
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