Post #313
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Wednesday, 07-Oct 2020 @ 6:33am
Edited by
beetwenty
Wednesday, 07-Oct 2020 @ 7:29am
Chopped up an old stereo amplifier on the radial arm saw at work. (using a blade we have that is specifically for aluminium as it has a different rake on the tooth profile to that of a timber blade).
This was just to get some finned stock as I had an old broken amp kicking about.
Otherwise I would have been just as happy to use a panel saw on thicker stock to create the fins.
Marked my shape on the flat backside of my finned stock.
Cut the basic outer shape with a 100mm skinny wheel on the grinder and then sanded to my scribe lines.
Cut off the unused fins where the bolts go with a hacksaw, and then filed that surface flat.
Slightly beveled the outer edges and also the ends of the fins as I thought this looked far nicer than it all ending at a hard 90 deg edge..
Peened the surface with a needle scaler as an attempt to create a cast alloy look.
Flattened the mounting face on my disc sander and then figure 8 paterns on a sheet of sand paper on a flat surface because the peening process had added a small ammount of warp to the mounting face.
Drilled holes for mounting.
And finally put it on the engine with a new gasket and some rtv silicone.
It was kind of hard to know where I was in relation to the fins on the opposite side to my scribe marks, but it all worked out for me in the end.