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 4/12/2018 10:39:43 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone planning to and/or actually building a Bat Vehicle.
DOJ/Justice League Donor tear down currently rocking along on schedule with my projection report goals for April-2018.
Could go a lot faster with a cutting torch but I am taking my time and using a reciprocating saw with Diablo 24 TPI blades. Using this method has allowed me to preserve wiring, tubing, systems, etc. intact.

The most dangerous risk to stripping down the donor is the gas tank.
Even after draining the 42 gallon capacity gas tank of it's remaining 25-gallons there was approximately a gallon of gas and copious amounts of gasoline/air vapor.
When I tried to remove the straps that secured the gas tank to the frame I found both securing bolts rusted solid. First thought, use the reciprocating saw to cut the straps.
Second thought, the reciprocating saw's motor produces sparks at the brushes. First thought unrestrained equals gas/air vapor explosion and bath in liquid fire. DON'T TAKE ANY CHANCES WITH YOUR LIFE.
I purged my gas tank with CO2 but decided to fill the tank with water and cover the exterior of the tank with wet blankets.

Spending a collective average of one hour per day on both my Tumbler and DOJ/Justice League Bat Vehicles.
Given my current production I believe I may soon have a rolling chassis for both Bat Vehicles. (Depends on how someone describes what makes up a rolling chassis.) vertigo


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Post #160506
Posted 4/19/2018 6:29:58 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Tried some of these Diablo carbide tipped hole saws. Bar none very best I have ever used.
Diablo introduces the first carbide-tipped hole saws on the market to cut both wood and metal (wood, nail-embedded wood, plastic, aluminum, metal, cast iron, stainless steel and metal). Delivering 50 times longer cutting life than bi-metal, these new carbide-tipped hole saws offer faster cutting performance and increased productivity.
60 mm (2-3/8 in.) cutting depth for 40% deeper holes in 1 pass and increased productivity
SnapLock Plus mandrel system includes: mandrel, pilot bit, 5/8 in. threaded adaptor (fits diameters 1-1/4 in. to 6 in.) and 1/2 in. threaded adaptor (fits diameters 9/16 in. to 3-1/16 in.)
1-size fits all mandrel fits all Diablo hole saws, from 5/8 in. to 6 in. Dia
Tool-free plug ejection for fast material removal
50x longer cutting life


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Post #160535
Posted 6/2/2018 8:37:21 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for the benefit of anyone planning to build and/or actually building a DOJ/Justice League Bat Vehicle.

Received an email asking what tools did I use to strip down my DOJ/Justice League Batmobile donor vehicle.

Heavy leather welding gloves. (razor sharp edges are everywhere when cutting donor sheet metal.)
Dewalt 20 volt battery tools.
Compact reciprocating saw and around 40 bi-metal blades
1/4 " drill driver with screwdriver set that includes torx tips
3/8 " Impact driver (out standing tool - removing bolts nuts fasteners took about 1% of conventional hand wrench and ratchet time.)
A good size mirror attached to a length of plastic pipe.
English and Metric sockets with conventional and deep-well sockets
Crowbar and a small pry bar
Utility blade knife (lots of insulation and plastic sheeting)
NOTE: My Dodge 3500 was built in a Mexico plant and most every fastener, bolt, and nut is metric.


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Post #160638
Posted 6/8/2018 8:12:07 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone that might be planning to and/or actually building a bat vehicle.

DEWALT DCS373P2 20V MAX Lithium Ion Metal Cutting Circular Saw Kit
Powerful 460 MWO, 3700 rpm motor
Bright LED Light with 20 second delay after trigger release
20V MAX Lithium Ion 5.0 AH battery
SIGHT-LINE Window provides for a clear view of the material
$339.95 & FREE Shipping at Amazon

If you already have a 20 volt tool with charger and battery you can get the bare tool
metal cutting circular saw for 191.00

Metal cutting circular saws cost 1-2.00 per foot to cut 1/8" - 1/4" thick plate.

Very efficient tool for cutting plates and flats vertigo



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Post #160664
Posted 6/30/2018 12:50:28 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone that might be planning and/or building a Bat Vehicle.

Received an email today asking,
"I bought one of the metal cutting circular saws and I only get a few feet of good cutting before the blade is too dull to cut. What is wrong and is there anyway to get more cutting from a blade?"

The usual reason for your cutting problems is not following a straight line. When you deviate from a straight line you are pushing the teeth sideways against metal on both sides of the kerf, generating extreme heat, and chipping the carbide sharp edges. You may even not be drawing a line at all. (freehand cutting)

Straight line alignment cutting: To get the most cutting out of a blade always use a straight piece of metal that is securely clamped to your work as a rip fence. I can cut 100-200 feet in 1/4 inch steel plate depending on other conditions.

Feed rate: Slow and steady generates the least blade tip heat and carbide sharp edge chipping.

Saw duty cycle rating: My Milwalkee 8 inch metal cutting circular saw on 1/4 inch plate is 1-minute at max feed rate. I usually use a slow feed rate to cut. Slow enough to make my cut before having to shut down the saw. Then turn it off an set it aside to cool. You can burn the motor out in a metal cutting circular saw is only a few minutes if you fail to adhere to the saws duty cycle. vertigo

Post #160716
Posted 7/3/2018 9:19:46 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Found this engine hoist on eBay for 150.00 with free shipping.
Missing a few bolts but other wise complete and new. vertigo


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Post #160727
Posted 7/19/2018 11:54:54 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone planning to and/or actually building a Bat Vehicle.
Here is my personal favorite.
Big, comfortable, light weight, and easily hangs on wall when not needed.
Bought this creeper off Amazon.
From my experience with creepers I have learned to buy with at least a 400 LB rating.
It is not so much the weight factor as the width factor.
Creepers with less than 400 LB ratings are usually around 16 inches wide.
Creepers with 400 LB ratings are approximately 24 inches wide.

Pro Lift Mechanic Plastic Creeper 48 Inch - Blow Molded Ergonomic HDPE Body with Padded Headrest & Dual Tool Trays - 440 Lbs Capacity Red
Price:$79.52 & FREE Shipping.

LIGHWEIGHT - Pro Lift Plastic Creeper is one piece blow moded creeper that made out of HDPE plastic. It is light weight (approximately 16 lbs), but strong. With its impact resistant, it gives an users extra comfort while laying on it. The carry handle makes it easy to pick up, position, or transport.
440 LBS CAPACITY - C-6048 Creeper features 440 Lbs capacity with the length of 48 inches and the width of 23 inches. It fits confortably for most users.
SWIVEL CASTERS - This plastic creeper features 6 multi-terrain swivel casters, which are industrial strength with oil, chemical, and grease resistant. With the caster size of 3 inches, it provides not only the maneuverability but also the extra durability
ERGONOMICS DESIGN - Rugged ergonomics design with the impact resistant to provide extra comfort for users. Sit slowly on the end of the creeper, and lay back to rest your head on the padded headrest to give you the extra relief. In addition, two molded-in tool trays offer ease of working while laying down.
WARRANTY - Pro Lift Plastic Creeper is covered one year limited warranty from the date of purchase. Due to a defect in material or workmanship under normal usage, we will repair or replace at its option.


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Post #160802
Posted 9/2/2018 7:39:29 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone planning to and/or actually building a Bat Vehicle.
Received an email asking,
"I bought a welder, so now I am saving my money, so I can buy a welding table, and start welding. I am new to welding a I was wondering what is your recommendation for what brand I should buy and how much I should expect to pay."

I never have bought a factory made welding table. My first welding table was a 4 x 4 foot 1/4" steel plate on top of an old oil drum. Bought it for 10.00 at a yard sale. Welding tables are all around us. As an example while visiting a scrap yard I bought two old steel ramps and two stands for 30.00. The two ramps and two stands make for an excellent break down 4' X 6' welding table that can be easily stored in a small space. I might weld a few braces to the stands for more rigidity.

NOTE: Hidden potentials exist in almost every assembly made up of multiple pieces and also in the individual pieces as well.

Anyone out there have a welding table they made or assembled from scrap metal etc.?
Any advice for new welders that have acquired a welder and imposed a delay in welding until they can afford to buy a factory made welding table? vertigo


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Post #160896
Posted 9/4/2018 8:15:50 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone planning to and/or actually building a Bat Vehicle.
Here is a technique for making perfect radius cuts in metal, wood, fiberglass, etc.
Cutting the radius and straight lines on my Tumbler side windows is a good example of this technique.
First, draw out the dimensions life size.
Measure the radius where the straight lines intersect,
Select the proper size hole saw to match the radius and cut the holes.
Cut the straight lines with a suitable cutting tool.
Use clamps and a straight piece of 3/16" thick metal as an adjustable rip fence guide when cutting the straight lines. vertigo


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Post #160906
Posted 9/7/2018 6:50:49 PM
Has NO LIFE!!

Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!Has NO LIFE!!


Last Login: Today @ 7:52:33 PM
Posts: 2,059, Visits: 2,952
Placed a copy of this post here for anyone planning to and/or actually building a Bat Vehicle.
A few of my observations from using portable metal cutting circular saws.
Blade Life: Approximate lineal feet of cutting expected.
1/4" steel plate using clamped on guide fence: 30-40 feet.
1/4" steel plate cut freehand: 4-20 feet depending on operators ability to guide saw straight with even feed.
3/16" steel plate using clamped on guide fence: 35-50 feet.
3/16" steel plate cut freehand: 8-25 feet depending on operators ability to guide saw straight with even feed.
1/8" steel plate using clamped on guide fence: 70-100 feet.
1/8" steel plate cut freehand: 10-30 feet depending on operators ability to guide aw straight with even feed.

Trying to cut through welds will destroy the blade in a few seconds.

Using too fast and too much feeding force will destroy 75-90% of the blade life.

Starting to cut before saw blade reaches full speed will result in chipped and broken off teeth significantly reducing the blade life. vertigo



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Post #160910
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