HOW TO: Making a DIMPLE DIE Gusset - WRX Wagon - Custom Roll Cage - TMR Customs
HTML-код
- Опубликовано: 3 июн 2013
- Here is a video on how I make a gusset from the Main-Hoop to the B-Pillar of the Subaru. This cage is 1-3/4" .120 wall DOM Tubing w/18 gauge gussets & MIG welded. Thanks for watching!
WARNING: I'm not trying to be reckless, I ALWAYS wear at least safety glasses when using cut-off wheels but often wear my welding helmet (on grind mode) or a face shield. NEVER STAND directly inline with the cut-off wheel, stand offset from the "line of fire" if it were to break/explode and come loose it'll be less likely to fly at your face, neck or body. I wear leather gloves too but wasn't during this demonstration due to handling a camera. I'm not trying to promote bad safety behavior, I said this is not for "newbies" but should have also mentioned NEVER buy China/Taiwan cheap brand cut-off wheels from places like Harbor Freight. Those are not nearly as quality and come apart (explode). I always buy quality Made in USA or alike brands that I know to be legitimate quality. 
Авто/Мото
that’s one of the tidiest gussets Ive seen in a while. Seriously though, you’ve done a smart job. ‘shame some folks have nothing better to add than preaching health & safety. Mr Smith is a grown man who can make his own decisions re PPE. Nice video.
Thanks! and ya... the safety Nazi's are annoying. lol
been a year since I made my gussets this way from watching your video and racing with them. still holding strong. Thanks for the good video brotha.
logan scoyne Thats awesome man. Thanks!
Really well-made video,thanks. Very informative and helpful. Much appreciate you posting this.
I love all the comments about how there is a better way, and they are right. But even more fun to see a video of getting it done anyway. Any way you can. I was wondering how you were going to do the dimples - a die set of course - that's one thing you need a tool for (it is possible to make them...) And you are right, anybody who makes a sheet metal part should ALWAYS clean up the edges, because people are going to run their fingers over the edges, that's what people do.
Nice work man!
I use them quite a bit as a industrial mechanic. Its one of the most dagerous tools I use on a regualar basis. Some places require safty glasses plus goggles plus face shield to opperate one plus regular ppe. The guards move so you can rotate them they also have a screw in them to tighten the guard. I do some crazy shit on my own even sometimes at work but I dont mess around with an angle grinder.
Ya, they are definatly sketchy! It takes a lot of hand control for sure. For what I do the guards just get in the way and they inhibit me from using anything larger than a standard 4.5" wheel. I like using bigger cut-off wheels! But you are right about eye protection, always wear safety glasses or a face shield and gloves are good too!
Really cool video. I like the commentary as well.
Sunning work! Handcraft at it's best. Keep up the great work!
KALARADO Thank you!
very cool. good to see the dimpling done without an expensive, specialized tool.
Great job and loved the detailed explanation. Thank you for taking the time! :)
Hey thank you! I appreciate the kind words and taking your time to watch my video.
Dude love your work !! Awesome keep the vids comming..
Thanks man! Comments like yours keep me motivated to make more! :D
Amazing work!
Use the death well all you want you have mastered it as it would seem but for sheet metal i like a jig saw with a goid metal blade i can get it nice and clean to jyst my 2 cents but your doing good on your own
Hi
yes, your video is watched even in Iran and we thank you for sharing,it was helpful.
Greetings from Iran to you
Wow that is awesome! Thanks for the comment. :)
Good job on the video, I like your attitude!
1bbpracing haha Thanks man. I try and keep it a little entertaining!
Pretty epic garage workshop you have bro.
Thanks! :)
Very cool video I like seeing how people make stuff. I am a computer guy this world fascinates me. Can that round saw rashly drill steel? Seems like it'd wear out fast.
Informative for the DIY guy. Thanks.
Well explained, Nice job.
Thank you! :)
i loved you vid man im taking metal fab & welding right now, so this was kool, I think you should invest in a tripod though lol.
Nice...I dig your work.
Would love to have some of your stuff on the forum.
-Kyle
Right on, Thank you. And I'll have to check it out. :)
Maybe would could do a collaborate on something sometime.
WOW. I never thought this video would have 100,000 views! Thanks for watching and sharing. Hopefully it helped someone! haha
You helped me! You make it look so easy, makes me want to try and tha's half the battle!
Dang... 200k one year later. I can't believe it. Thanks for all the views! :D
I can never get why Americans never use the guards on their grinders, they just take them off... only reason I think of is that they haven't got the mental capacity too look around the guard and tell where they are cutting???
stupid
+Michael Fletcher Because a 7" Metabo cut-off wheel will not fit with the guard on, its a 4 1/2" grinder Einstein!!!
+Michael Fletcher haha Thanks for viewing my video and for your concern.
This is how people get cool nicknames……… like…… “nubs” “stumps” “uno cashew” “exploded eye socket” “taser face”
Before you use a grinder like this guy without the guard search and watch the video on youtube called "Angle Grinders (2 of 4) - Graphic Content! " Other than that amzing work this guy is a pro
I appreciate the concern and safety video. I'm not trying to be reckless, I ALWAYS wear at least safety glasses when using cut-off wheels but often wear my welding helmet (on grind mode) or a face shield. NEVER STAND directly inline with the cut-off wheel, stand offset from the "line of fire" if it were to break/explode and come loose it'll be less likely to fly at your face, neck or body. I wear leather gloves too but wasn't during this demonstration due to handling a camera. I'm not trying to promote bad safety behavior, I said this is not for "newbies" but should have also mentioned NEVER buy China/Taiwan cheap brand cut-off wheels from places like Harbor Freight. Those are not nearly as quality and come apart (explode) much more often. I always buy quality Made in USA or alike brands that I know to be legitimate quality.
R Smith are you going to post more of your car and cage and fabrication stuff or what, I loved the video so good job....and you did most of it 1 handed lol.
crxtech1 Yes, I need to go through my videos I took of this cage. I'm currently working on another Half-Cage video I'm doing right now in a Mark3 Supra!
krusher74 I do not recommend removing the guard but I don't like them because they get in the way when making cuts in tight spots or the guard constantly needs to be adjusted for different angles. Also my larger cut-off wheels don't fit with the guard. I buy larger wheels so I can get deeper/reach further into tighter spots. They are also more cost effective for me. I DO however use a guard on my big Metabo grinder, it's a must to keep the massive amount of sparks pointed away from me when doing lots of grinding.
You'll have that on those big jobs.
When I saw the thumbnail, I thought for sure this was a machine cut and formed part. Watching you do it all pretty much by hand is really impressive. I like to do work like this, but I lack your precision. Good stuff!
Thanks for the kind words! You can do it tho! It's why I made this video. So people can see the process. It's a long video, maybe even boring but I tried to explain the whole thing, start to finish. It's really not bad if you have the proper tools, it just takes time! Glad you enjoyed it. :)
Right on man! I got them at King of the Hammers for a discounted price... I forget exactly but well worth it! I LOVE DIMPLING EVERYTHING! haha
Nice work
Very good you do nice work
Thanks! :D
Dude that gusset looks great! I'm gettin' a set of dimple dies from TMR!!! How much did they cost? I'm gonna' custom build an off road Light Bar for my 96 Bronco! I'll post vid when done. Thanks for takin' the time to make & post this vid! I subbed ya!
Crack 👍 saludos desde.Buenos Aires Argentina
Came out looking decent
very good bro
Can’t beat Cardboard Aided Design (the real CAD).
Johnathan Doe You know it!!! Love me some cardboard templates. Cereal boxes work great!
the pins in the hole saw are to stop it stripping the thread. put the guard back on your grinder n buy 4 1/2 discs before you've 4 1/2 fingers!!!!!!
Good video
hey nice build man! im wondering if theres a reson why you have the roll cage sitting against the the middle pillar? is it to strengthen the car even more ?
We need to see the Toyota more :D
Oh for sure!!! Hopefully I’ll have some stuff soon!
good stuff fellow angle grinder professional haha.
Thanks! haha
it is a tru skill man great work again!
This is fresh! Ive been wondering how the hell to do this. what about the other side? Wouldn't it be better to make 2 of them and weld them together so that you don't have a front and back? Idk, don't listen to me.. I'm just thinking out loud. Haha.. What gauge are you using? Looks about 20? I definitely need to get a press now, and a set of dimple dyes! Keep the vids coming, the WRX is Guna be Pimp when ur done! Oh yeah, one more thing, what Cage are you using? Custom Fab'd or bought?
En español es conocido como rechazado y da rigidez sobre todo es liviano.
if you don't use the set pins on the hole say it will eventually strip the threads in the hole say. did it yesterday lol. just an fyi.nice job.
Damn put a guard on that angle grinder.
pussy
@@thegazillionmask say that when the grinder wheel shatters and explodes on you. You'll get a nice amount of metal fragments in your arm and body.
@@acoustic6865
Friend of mine lost an eye all for not using a guard. Good luck to him
@@chloe19815 Idk why people have to risk their damn livelihoods just to "be badass" or whatever. Its plain stupid and if they die doing it, thats natural selection at its finest.
Obs: nunca use o disco de corte sem a proteção da máquina, acidentes com esse tipo de disco são terríveis.
Thumbs up for knipex pliars!!!!
haha good eye! I love my MANY pairs of Knipex! :D
4:14 I put a large washer behind mine. with slits in to suit the arms from the arbour
Just where do you buy your cutoff wheels??? That are for sure made in USA???
It was 16 or 18g material. I built the cage from scratch. It's Road-Course/Time Attack style. The owner just wanted something badass haha. It's 1-3/4" .120 wall DOM on the main cage and 1-1/2" .095w DOM on the extra diagonal tubing in the back for extra rigidity. The car is finally up and running with it's new FULLY BUILT engine. Currently being broken in, running a conservative tune/boost, but already putting down over 400 WHP. :D
Coulda just bought the punch and die sets but those look like harbor freight which are muh less expensive. Nice cage on a nice car!
yeah i wouldn't recommend using 6 inch 10,200 rpm rated cut off wheels on a 4 1/2 inch grinder that spins 11k+ rpms... nice build looking great :D
you sound just like my dope ass stoner friend. also killer video. liked and scribed
+Jesse Link haha right on and thanks!
Lmao I thought the exact same thing! great vid by the way!! Subbed.
Lol... Harbor Freight doesn't make dimple dies. These are TMR Customs dies. I'm using a H.F. 20 ton press tho! And thanks, it turned out pretty good!
Ya, those are GREAT but a little out of my price range at the time. Hole sawing em isn't too bad! :)
What Ga. Sheet metal did you use? Im wanting to do this to my 70 Chevelle A-Pillar. Unfortunately don't have a shop/garage, or all the fancy equipment right now. But where there's a will there's a way.
I used 18g. :)
Thanks man.... happen to know a good place to get a somewhat cheaper dimple die, with the bolt style clamp?
Grim Reaper No problem! TMR Customs sells the dies individually... I dunno about any bolt-style ones available...
Grim Reaper SPC makes some with a hole all the way through, with some fine thread grade 8 bolts and a few of the right size washers/bushings you should be good to go www.summitracing.com/parts/sps-15810
Ah, my mistake. But yeah if you ever get tired using a hole saw some places make punch and flare sets which lets you just drill your guide hole then the punch and flare takes care of the rest leaving you with not much of a sharp edge at all.
how mutch does the all rollcage weight ?
haha thanks man! :D
👍👍that’s true not for rookies
Great Job . What gauge are you using ?
Thanks. I use 18g, lightweight but very strong once dimpled.
Hi.. I am a new subie guy, so i dig ur build. I thought I saw something in your cage that concerned me... the horizontal door bar that is flattened at the main hoop. I think that is a big no-no ... round tubing shouldn't be flattened like that because it could potentially fold. Thats why you shouldn't use a pipe bender on tubing .. so you don't flatten out the heel of the bend. But anyway, I dig ur build and wish you good luck
I'm not sure what "flattened bar" you're talking about but theres no such bar on this cage, that sounds terrible! haha. My bender is full hydraulic mandrel style. It makes very nice professional bends. Thanks for your concern and for watching the video!
very beginning.. pause at 00:27 .. to the left of the b-piller .. that horizontal door bar going to the rear hoop looks awfully flattened out to me. But I still dig ur build and ur vid.
I cringe every time I see someone using a grinder without a blade guard. Sorry Mr Smith, They are not a joke.
I'm sorry you cringe and have less hand control than me. I've been using cut-off wheels like this for 15 years. I learned from a pro right away that the guards only inhibit you from making cuts. They get in the way period.
That's the stupidest thing I've heard today. You didn't learn from a "pro" If the blade ever shattered, I hope you at least have gloves on your " hand controlled" fingers.
i have a hydraulic knockout punch that's pretty cheap and can make those holes ways faster with no burs on the edges...
Ya, eventually I hope to buy a nice hydro punch set but for now, it's hole-saw time! haha
Bro your videos are dope as fuck
Appreciate that man. Thanks!
“Cuz people be fingerin your dimple dies on your nice cage gussets, cuz you know they look cool and they wanna touch em” 😅
Straight Chaos lol yup!
What gauge sheetmetal are you using? I apologize if yiu said it in video and i missed it. Good sh$#@t
This was 16g. I use a variety of gauges depending on location & size of gusset between 20-14 gauge. Thanks for watching! 😎👍🏻
skil-saw with abrasive blade or metal blade would have been faster, but yeah grinder cut off doesnt take long
Is that a 4 and 1/2 in angle grinder with a 6 in wheel and no guard?
Yep, it sure is! The guards are a joke and only get in your way...
R Smith noobie noob says not to be a noob.
Can you give me the name of the tool used in the garment to expand the sheet!!!
I got them from TMR CUSTOMS - Dimple Die Set.
Fuck all the "use a guard on your grinder" comments. If people don't want to use one they don't have to. It's not as though it will cut fingers off like a circular sawblade. Even if it did, there's still not going to be any come back on the safety conscious people that post their warnings..
MrFuriousG except a cutoff wheel is more susceptible to shattering, especially when used like a grinder(it isn't rated for top or bottom loading of the disk). there are well documented cases of people being impaled through the eyes, neck, jaw and forehead by misusing tools. People are allowed to voice concern, videos like this are partly instructional and he assumes liability when he or someone else gets hurt. We are allowed to care about other people's well-being.
hell yee
Hello! Please tell me what is the name of the device than you ring squeeze? and where can you buy? if you could link
It's called a Dimple Die. You can look them up by searching that. I got my set from TMR Customs.
R Smith thanks
What die set did you use.
TMR Customs. I got their - 5 Piece "Fabricator" Set. It's $379. Very quality product with lifetime warrenty, great company.
what brand is the dimple die and the tube notcher?
TMR Customs Dimple Dies and it's a Pro-Tools notcher with a Swag Off-road "Super Shaft."
How thick is the sheet metal?
18 gauge. Once you dimple the material it increases the strength by A LOT. :)
Where did you get the dimple dies from?
TMR Customs. I got their - 5 Piece "Fabricator" Set. It's $379. Very quality product with lifetime warrenty, great company.
You are not thinking right with the hole saw mandrel , you are driving it through the thread which can strip out, the pins cause the drive to go into the top face of the holesaw and make it easy to get off.
which dimple die kit is that?
Final Drive Racing TMR Customs. They’re out of Canada but have killer sales on them a couple times per year! Check em out. Lifetime warranty. Great guys too, I’ve met them several times at Offroad races.
why dont you just use a punch flair tool?
Rotary Addiction Punch flares don’t make as nice of holes and they don’t flare/dimple the metal nearly as much. They are rad but not for me... at least all the ones I’ve seen for sale.
It's under 180 lbs. I'd have to check the hard number but it's around 160 lbs.
you have a few nice ways to potentially damage both your tools and yourself. other than that your project is nice. gl:)
what is the purpose of those holes?
Maks - The reason is to strengthen the metal by adding a dimple hole. It allows you to use thin material but making it sad strong as thicker metal so you can save weight. I use 18 gauge sheet metal on my gussets and by adding the flared hole it greatly strengthens it, making it as strong as 10 gauge (1/8th inch). You'll see dimples on high end racing applications where weight saving is a huge factor. Some companies specifically build chassis with as thin of metal as possible with hundreds of dimpled holes to save lots and lots of weight. I can take a piece of 18 gauge sheet metal and bent it in half by hand but if the same piece has a dimple hole, I can't even begin to bend it. It's very cool. Hope that makes sense. Thanks for watching!
that actualy makes alot of sense. Thanks for the reply. Great video
Ok , I just found the gusset gauge .
where are you from? I'm in Santa Cruz, CA. there's no one who talks like you that's not from or in CA
haha never heard that. I'm from Washington, 20 minutes North of Seattle.
just look up Santa Cruz lingo or something.
just look up Santa Cruz lingo or something.
damn where are you located
morpheus I’m located in Snohomish, Wa.
Green corps
And whatever you do NEVER WEAR SAFETY GLOVES to protect your fingers!!!!!!
lol i have been using an angle grinder since i was 10
Wow that's the craziest thing I've ever heard.
WOW... so far.... WE GOT 74 HATERS....
you wouldn't need gussets if the cage wasn't 7 inches from the a pillar.
Oh... I've never heard that before... If you knew anything about cage building you would know that 90% of the time the main hoop needs to be positioned behind the b-pillar to conform to the drivers seating position. If the main hoop were built tight inline with the pillar, the drivers head would be right below the rollbar which wouldn't give enough helmet clearance for safety/tech inspection. Now, as for the gusset, the main hoop should have a gusset no matter how close it's located to the b-pillar. It adds chassis rigidity and overall structural integrity of the cage. Thanks for viewing my video.
Is this fucking Danny McBride were watching, seriously you have his voice.
Put that guard back on man. And get rid of that ring.
wildgoobsid5 I only run a guard on my big boy Metabo grinder but not always. For my small Dewalts, the guards get tossed in the scrap bin day of purchase. As for the ring, I haven’t worn the gold band for several years now. I had a custom carbon fiber one made. It’s ultra lightweight but very strong. Super badass. I don’t wear that either tho cuz I’m getting divorced. LOL :(
RIP earphone users HAHAHAHA
1. Not a good idea to film and use a cut off wheel
2. Use the proper size cutting disc
3. Use a guard
4. Don’t use the cutting wheel for grinding that curved cut, that’s how they explode
thebaggins321 1. Meh, I'm fine.
2. No, I need larger disks for certain jobs.
3. Guards are a joke!
4. I didn't side load the disk, I stay perpendicular to the cutting surface. Thanks for your concern and watching!
A cut off wheel for sheet metsl?...really?
How hokey pokey,janky as hell,not the right way..
Thanks for watching and for your constructive? criticism...
DONT use the grinder like this guy did! Major hazard!!
I agree it's sketchy & not for everyone but I'm VERY careful. I posted a Warning comment in the "About" section above.
totilsom the grinder guard serves its purpose.... but the reason some fabricators including my self take off the guard to get in tight spots and cut odd spaces.. and also a 360° view of the cut.
fortune favors the bold
Good video
Thanks! :)
Ya, those are GREAT but a little out of my price range at the time. Hole sawing em isn't too bad! :)