I have wondered how these were made for long long time. I have seen some made using a tube for the curved edge and sheet to fill in, but I'm wondering how you would go about making these with sheet only.

I'm almost sure I saw a post about it on a forum several years ago, and it looked like someone was working the sheet over a wooden template.

Is there any way to make these by hand? I'm thinking maybe making both halves seperately, and working the edge by hand, then welding them along the inside curve? It looks like there might be a cleaned-up weld along the inside seam, but I can't tell for sure with these pics.

Opinions?

 

theres dimple die sets to make those holes using a regular shop press, so you cut your sheet to shape, mark out the holes and go to town with your press.

 

Hey marrku, I'd suggest making as you where to make a taco gusset. But one that big, way need to be a 2 peace part as you mentioned. I've honestly never seen that style gusset before, or I have and didnt notice it wasnt part of the a pillar. To be honest, I'd build two halfs and connect them to the pillar its self. Unless you, or your customer want it done like in the pics you posted. I'd start with the section closest to the dash, then work back torwds the main hoop. I really dought I answered your question, but hope this helps buddy. Good luck.
Collin

 

The part I'm not sure about is the inner curved edge. Collin, not sure if you can see it, but in the last pic, it almost looks like the center of the two halves is bumpy along the inner edge. Almost like a weld that was cleaned up.

I think you're right, I bet even BMW Motorsport makes these by hand. I think it's damn near impossible to curve the folded edge of a taco gusset, even with the right machine.

I guess I could take a length of tubing, give it a long-radius curve, and use that as a die to curve the edge of a piece of sheet, and flip it over and to the other side. Then weld together.

Thanks guys!

 

See, these ones look more like curved tube and sheet :

(Opel DTM) :

 

yeah, in the grey car it looks like its two separate pieces welded on each side. My guess would be like everybody elses, hand formed, but two separate pieces for sure. Could you imagine trying to get both sides the form, after one is done, you'd have a bitch getting the other formed with only 2"s between both pieces of sheet. lol.

 

One way or another marrku its gona be a pain. Maybe a long radius bend, cut the bend in two peaces, use the inside radius for the bottom half, make two side plates and you have one peace. Not sure im much help on this subject as all gussets ive made are welded to the a piller. Never hurts to have another set of eyes helping though good luck brother

 

When fabing up some gussets what would you guys recommend for material ?

 

You could do that on a press brake with the right tooling (Read, not cheap)

 

whats the point of going to that extreme? Id really like to see some proof that the effort has a substantial impact.

edit -I understand if a customer wants this, just veering off topic for the sake of possibly furthering my education I guess :p

 

i think toxic is right. i think they used tubing, cut it in half & butt welded the sheet metal to it. it would be way too much time to form that out of sheet, & it is in a race car not a show car. with that being said they know that it is likely going to be wrecked, so they want things to look as nice as possible, but in the least amount of time to fab.

 

Found this one. This one is clearly made of two halves welded together.

 

Markku clear out your PM's!

 

Just did. I think I have room for like one more message.

 

Ah the mail order BMW race chassis, I was wondering the same thing when I found this on a DTM cage building website.

 

check this one out. He even shows how he made his gussets. http://www.vadriven.com/forums/showt...318492&page=14

 

solid attempt at helping, but thats not the style he was questioning, thats just metal between the cage and chassis.

 

http://forums.bimmerforums.com/forum...1157374&page=4

 

As has been said, I'd also be inclined to make them in 3 pieces - bend some tubing for the bottom curved edge and then split it in half, then weld sheetmetal for the sides to the tube.

 

bo2o, that is awesome! Thanks for the link! I don't think I'll need to make these any time soon, but I've always wanted to know how they were done.

If ever I had to make them, I'd probably use a wooden template and hammer-form the edges, and assembling the two halves into the car.

 

not a problem glad to be of help.

 

Unless you are going through the firewall and connecting the strut towers and front sub-frame pickup points to the cage I see little benefit in adding the massive gusset like that. Now maybe you were going to add those later, it would help tremendously.