After a couple test runs on the plasma table and a little modifying of the design we finally got the design cut dialed in. Here’s the center section fresh from the shop.
Unfortunately it jumped a little from getting too hot and warping some during the cut process and a few of the letters lost their center section so I had to make new ones. Here's a close up of part of it with the sections missing.
After getting all the letters except the e's (they weren't cooperating) fixed I then attached a piece round mesh like sheet metal to the back. This took a lot of tack welds to hold everything in place. Here it is after getting cleaned up and primed.
After the mesh like sheet metal was all tacked on I went after those damn e's that were being a pain. For them I used some putty type cold weld to fill in the area where the center of the e should be. I also pushed it through the holes and smashed into the back of the mesh to hold it. After it dried I used a dermal to shape them and then sanded them down smooth. Here's a close up of the same area as before.
This weekend I'll be painting the grille section and installing them. I will also be painting the lettering and flames on the grille, but that will be another weekend.
