UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING, AND SPECIAL TECHNIQUES
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UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING,... Expand / Collapse
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Posted 3/18/2017 6:50:29 PM
Supreme Being

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Placed a copy of this post here because someone may be able to benefit from the demonstrated proxy tire technique used to figure tire clearances, tire backsets, turning ranges, and overall fit.

Used proxy tire method to determine my Tumbler's tire clearances, tire backsets, turning ranges, and overall fit.  vertigo

Post #153468
Posted 3/19/2017 8:43:21 AM


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Thanks vert. I will probably be using your proxy tire technique on my mock-up.
Post #153475
Posted 3/23/2017 7:50:36 PM
Supreme Being

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I placed a copy of this post here because it may be of some use to
someone doing a Bat Vehicle build or planning to do a Bat Vehicle
build.

Based on my collective research and study, so far, of the Batman v
Superman Batmobile it appears the easiest way to build this Bat
Vehicle with the least amounts of man hours and expense is to build
the body first completely in wood.

An alternative to building the body in wood is to use one of the 3D
available programs to have the vehicle routed life-size in foam. This
would be a great way to go but the lowest price I found to have this
done is 12,500.00 delivered to my door.

The next step is to find a donor vehicle, with the title, could be a
car but most likely a truck, conforming closely to logical body
attachment points.

After acquiring a suitable donor vehicle, one would probably fabricate
a frame around the donor vehicle that matches the bottom edges of the
wood body and weld in additional braces as needed.

Once the wood body fits on the donor vehicle frame then the builder
will have two choices. Remove the wood body, build a frame on the
lower frame, attach the body panels that have been translated into
steel or other materials, and join together. The second choice is to
remove the wood body and translate it into steel or other materials
with the end result being a bolt on body, probably with a few modules,
that can be taken, on or off, at will.

Completing these steps should get you to approximately 80% completion.
   vertigo
Post #153517
Posted 3/24/2017 7:54:37 PM
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Placed a copy of this post here because axle, wheel, tire, and suspension fitting with a proxy tire may be relevant to another Bat Vehicle builder.
Spent a couple of hours today working with proxy tire to calculate the exact axle length needed.
Re-adjusted the proxy tire's wheel mounting center to be the exact same dimensions as the custom wheel rims I have on order. After remounting the re-adjusted proxy tire I discovered that I need to shorten the Tumbler arm axle length by 2-inches, maybe a little more. Will cut 2-inches off the axle, set everything up again, and check the fit again. One good thing about fitting the Tumbler arm axles is their symmetrical aspects. Get one side right and the other side just needs a transfer of measurements.


  Post Attachments 
PROXY TIRE FIT-AA-1.jpg (1 view, 375.48 KB)
PROXY TIRE FIT-AA-2.jpg (1 view, 242.96 KB)
PROXY TIRE FIT-AA-3.jpg (1 view, 238.06 KB)
PROXY TIRE FIT-AA-4.jpg (0 views, 170.00 KB)
PROXY TIRE FIT-AA-5.jpg (4 views, 275.41 KB)
PROXY TIRE FIT-AA-6.jpg (1 view, 257.02 KB)
Post #153531
Posted 3/25/2017 8:19:19 PM
Supreme Being

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I put a copy of this post here because it may prove useful to a Bat Vehicle planner or builder.
One method used by a friend of mine who has worked in metal sculpture for 40 years might prove viable in building the Batman v Superman DOJ Batmobile body.
SKIN and BURN is his name for the method but the method has been documented to have been used for more than two-thousand years in art and construction, etc,....
I am currently thinking about using it in my DOJ Batmobile build.
Here is how SKIN and BURN would work on the DOJ body.
Build the body and other pieces in wood, cardboard, or foam.
Cut steel pieces, fit to wood body, and secure with adhesive. Repeat procedure until all translated metal pieces are attached. Then use a MIG welder with a dwell timer set to 1/4 to 1/2 second on high heat. Same welding method is sometimes used by custom exhaust welders. Tactical welding techniques must be used to avoid distortion effects. The wood is then burned out slowly or cut away inside in pieces. I probably would cut away the wood so I could weld inside as I cut away the wood pieces.
Cut steel pieces, fit to foam body, and secure with adhesive. Repeat procedure until all translated metal pieces are attached. Then use a MIG welder with a dwell timer set to 1/4 to 1/2 second on high heat. Same welding method is sometimes used by custom exhaust welders. Tactical welding techniques must be used to avoid distortion effects. The foam is then dissolved with solvent, but could be burned out slowly or cut away inside in pieces. I probably would use solvent.
If a 3D routed 1:1 foam Batmobile didn't cost 12,500.00 I could embrace the foam method. vertigo
Post #153539
Posted 4/11/2017 6:30:19 PM
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This is an old post reposted that is still relevant to the design,
planning, and building of Bat Vehicles.

The best book I have found on automotive performance welding.

Welding is an essential skill for the avid car enthusiast, car
builder, and fabricator. Engines, exhaust, intake, suspensions,
frames, all can be welded for repair and fabrication purposes. While
many introductory or entry-level welding books are available on the
market, this is the first book to comprehensively cover advanced
techniques, complex joints, advanced processes, and working with a
variety of materials, including aluminum, Chrome-moly, stainless
steel, carbon steel, titanium, and magnesium. Using the techniques
revealed in this book, you can fabricate body panels, frames, and any
number of structural and functional automotive components, and perform
structural repair. Welding projects found in this book include welding
the tubes of roll cage for strength and safety, welding sub frame
connectors for improved chassis rigidity, repairing an aluminum frame,
creating a seat support on a rod, welding in a floor pan, fabricate
body panels, frames, and any number of structural and functional
automotive components, and perform structural repair. Welding projects
found in this book include welding the tubes of roll cage for strength
and safety, welding sub-frame connectors for improved chassis
rigidity, repairing an aluminum frame. With this book, beginner to
intermediate skill-level welders will be able to improve and complete
more advanced projects.

ADVANCED AUTOMOTIVE WELDING by Gerald Uttrachi
ISBN-10: 1934709964
ISBN-13 978-1934709962
vertigo
Post #154621
Posted 4/12/2017 5:49:03 PM
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A couple of years back I studied Big Wave Dave’s travels, adventures,
problem solving, and construction issues in setting up his Rumbler
rear axle and tires. And in a moment of later arrogance and deficiency
of perceived necessary knowledge, I still made the blunder of buying
my rear axle before solving the dually spacing and adapter problems,
having failed to sufficiently grasp all the important details within
his posts on this matter. I have since re-studied his tire and rear
axle posts in great detail with the result that I found most
everything needed to do this part of the build correctly. For this
knowledge, I am very grateful to Big Wave Dave.

Lessons learned from all this:

Number One: The Tumbler is a Bat Vehicle that one needs to buy the
rear tires for first and then solve the dually spacing and adapting
issues before buying the rear axle.

Number Two: Buy a cheap 16.5” diameter X 12” wide steel wheel, install
it in one of the tires, and inflate to the proper pressures. I have
ordered one and will do after I receive it and my tires.

Note: You will not be able to get accurate measurements without
following this step. It is the only way to accurately measure for
changes in tire expansion characteristics due to inflation.

Note: In this case a proxy tire is not the preferred method for dually
tires because of the unpredictable expansion characteristics due to
inflation.

Number Three: Use these carefully recorded measurements to draw two
detailed tires/wheels in profile and scale of your choice.

I plan to draw two in 1:1 scale on cardboard and cut them out.

This way I can move them around to get the spacing I want on the real
tires to be and once in position they will make it a lot easier to
design and measure for my wheel adaptors or other methods of spacing
and axle mounting.
Post #154629
Posted 4/14/2017 7:59:22 PM
Supreme Being

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Something to seriously consider when designing, planning, and building
a Bat Vehicle.
Been spending a lot of my time looking for the right rear axle and
wheels. The most important thing that I have learned from searching
for the right wheels and axles is that the most common heavy duty axle
and wheel bolt pattern is 8 on a 6.5" bolt circle. Almost every
factory steel wheel is available in this bolt pattern and it is the
most common bolt pattern found on axles from 250, 2500, 350, 3500,
etc., etc., pickup trucks. vertigo
Post #156634
Posted 4/26/2017 6:31:24 PM
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Placed a copy of this post here because it may be of use to others planning or building a Bat Vehicle.
Here is a diagram of the 4-link suspension and truss setup I will be using to set up my GM 14 bolt rear axle.


  Post Attachments 
4-link.jpg (0 views, 72.48 KB)
Post #156682
Posted 4/29/2017 6:44:15 PM
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Placed a copy of this post here because it may be of use to others planning or building a Bat Vehicle.
My GM 14 bolt axle weighs 550 pounds. Was looking at my axle and thinking about how I was going to position it for mounting and happen to glance to my Auto-Twirler. So, took one of the end rotation units and I am now using it for axle positioner. Quite effective really, up, down, side to side, and can move forward and backwards.


  Post Attachments 
AUTO TWIRLER-1.jpg (0 views, 320.40 KB)
AUTO TWIRLER-2.jpg (0 views, 285.53 KB)
AUTO TWIRLER-3.jpg (0 views, 304.75 KB)
AUTO TWIRLER-4.jpg (0 views, 305.41 KB)
Post #156711
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