1 - Hammer forming is definitely the way to go. Thanks for the great suggestion!1- hammer forming longer sections is more accurate and simple
2- now that you have the MDF/HDF buck you can do this coupon fab repeatedly
2 - I've got to do the driver's side. After that, I hope I don't have to do any more of them! 🍻
Tacked into place:
Welding complete - lots of tack welds! And all the extra holes were filled too.
Welds ground flush, and looks pretty good.
I still need to re-tack some pin holes:
Red circles are small pinholes that need to be tack welded shut.
re-tack weld the pinholes
mark and drill the flare mounting holes
test fit of the flare