PHASE 3: Tunnel
It was time to lay out the tunnel. I wanted to make the side pieces as one unit with the divide down the middle. This would give more strength to the entire structure.
I will admit, it was the first time making a tunnel from 5051 .080" aluminum. I did not get the first attempt correct. I was off by less than an 1/8" inch, but the bottom rivets would not have seated properly. So I did use 2 sheets of 4' X 8' aluminum. At $76 a sheet, it was still a LOT less than buying one already made.
Here you can see the layout. My next door neighbor builds custom lighting and neon business signs. I help him out from time to time, so I do have some experience bending aluminum. He has a press-break, so I can say that I did actually make it myself. I cut it out with a jig saw and a metal blade on the rounded corners, and cut the long straight lines on my neighbors 12" Niagra sheer.
There is also a picture of the formed tunnel after I got it home.
CLICK PHASE 4 TO CONTINUE.
Copyright©: Racine Extreme
Web designs & updates provided by firstname.lastname@example.org