Emmick Express Build

[sam bennett]

Floor pan. 
I have to be honest here. The factory pan is pretty rough cut. Not only that. It also seems too small for the kart. Almost as if the real floor pan was left in the dryer too long and shrunk. But, it's definitely the original.
I had some extra 6061 .063" thickness to make a new one. For me the easiest way to do this is to divide the original pan in sections and take the measurements that way. 



The first step is to use an random orbital with 400 grit to level the surface. Then I place it under the chassis and transfer the holes with transfer punches. Then drill small holes. 

I layout the dimensions on the sanded pan and cut it with an angle grinder and thick steel straight edges clamped to the sheet. I don't have a fancy sheer--just a cutoff wheel and some kindergarten skills. 

Using the holes I fasten #8 screws to a sheet of plywood to serve as a support. Without the plywood the sheet becomes a very dull razor blade in close proximity to vital organs. Additionally, polishing builds a lot of heat and the plywood soaks some of that up.
Don't bend until you're done polishing.




Then I use the Emery/Sisal, Tripoli/denim, and White/flannel to get it polished. The final step is to bend the ears. Some alloys polish up better than others. I'm not certain why this is? I've had great luck with 3xxx and 5xxx alloys, sometimes 6xxx series gives me mixed results.






Oh yeah... What kind of fancy bender to I have for the Aluminum sheet? I think spent $20 for this thing from Harbor Freight?
It's o.k. for .063" aluminum up to 12" length (maybe). You have to use a lot of clamps--otherwise the bend wont be straight. I guess what I mean is the bend will have a slight arc from the lack of clamping. Your sheet metal friends will make you the butt of all their jokes.