TIG welding the aluminum Exoskeleton - How to build an Overlander.
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- เผยแพร่เมื่อ 14 เม.ย. 2016
- In my last video I concluded that it would be simpler and less risky to glue and rivet the panels to the exoskeleton prior to welding. But without any panels and hand, curiosity got the best of me and I started tacking some parts together. Everything progressing smoothly and after a few nights of welding and grinding everything was done.
Such a beautiful structure!
Very cool build.
Watching you using the circular saw on a panel reminds me of the bear from Revenant "playing" with Leonardo di Caprio.
Great job. 👍👍👍👍👍👍
That's what I was going for...
Looking good.
Mike Patey level work
Thank you for "Welcome, everyone" (previously "Welcome, gentlemen") in your intro. And so, I welcome you to the 21st Century.
Thanks happy to be here, sadly, still only 0.2% of our viewers are female...
This is so cool, I love the aluminum exoskeleton design! Lightweight but rigid and won't rust, and can be done in the garage. I want to build a custom composite setup of some sort. I've thought about panels like this or insulated "sandwich" panels, as well as building something from fiberglass/carbon fiber. I wonder if any of the custom boat companies would consider fabricating a fiberglass/carbon fiber shell? I'm thinking one of the biggest hurdles/costs would be having the moulds made to fabricate the shell around. Ok, gotta get back to watching all your videos! Inspiring work!!! I have the Solidworks student edition too but haven't installed it on my computer. Guess that will be my first step so I can teach myself how to use it :-)
Whichever panels you go with, get samples and test for delamination. I ruled out foam cored panels because they easily pealed away when any bracket was riveted.
Please do a Solid-works design Video. What CAD techniques you used to design your rig. Nice joints by the way. Thanks
I was also looking forward to this. I really could learn so much from a SolidWorks video from him
Great build - love watching your series. How did you decide on your chinesium light?
We tried to find one that still had (or claimed to have) high-quality Cree LED modules. Once we received them we tested the current draw against the claimed wattage and then sent them back... We actually ended up going through 3 bars before finding one that was half decent. We also bought a common width so that we could upgrade to a Ridged or other High End Light if we found the need.
Los acabo de ver aca en la ciudad de Lorica, Córdoba, Colombia 😍😍😍 la camioneta es más impresionante en persona 😎
Gracias, nos han dicho esto muchas veces ...
I've been pouring over and over your videos for days. A very amazing build thank you for sharing. Did you outsource the plasma cutting of the exoskeleton?
Thanks for watching, sometimes I wonder if anyone other than my mom actually watches, so it's nice to get comments like this! I have a friend who has a big plasma cutter and break at his workplace, he was able to get it done there during a slow time. Although not strictly required for most of these pieces, a table saw does a great job of cutting straight lines too! However the CNC brake was priceless, required to achieve all the exact angles.
Haha! Just discovered you a week or so ago. And making my way back through your process when I ran across this comment. A lot's changed in 5 years! X-D @@Everlanders
Very cool ☺...like like
What cad package is used to build this model? Very informative videos, thanks for making these and showing the whole process.
AutoCAD and Solidworks
Your old video popped up so I watched it again! Oh yes I remember, the “Magic trick”. When the whole thing comes together. I would have loved to see how you get it on the truck! After that video, do you carry a extra SD card in your pocket ?
It wasn't that I didn't have SD cards, it's that I was juggling too many things at once and didn't notice the camera on the tripod just stopped mid event. But as I recall, it wasn't super eventful, it just tipped on and we pulled it forward till the bolt points lined up and then we bolted it up.
Everlanders / With that bit of insight I’m looking forward for more behind the scenes adventure videos. As a DIY electronices enthusiasts and retired bench tech anything you design and manufacturer has me watching with interest.
Raspberry Pi projects can be your best friend when it comes to making custom equipment for your rig. Right now I’m working on designing a security system for my 79 GMC suburban. Your Android audio upgrade was a good learning tool.
Thank you for posting these videos. If you don't mind me asking, where did you get the cad drawing of the truck?
... I drew it. It is my own design.
Everlanders will dm you regarding the design if your open to a conversation about it!
Very nice build I wish you can share where you can get those panels and how much is a cost per sheet thank you and very interesting
Me too.
Such an awesome build! Were you able to give the drawing to a local machine shop for the cutting of the exoskeleton?
Sure did!
Wow, awesome work here. May I ask what alloy you use for the aluminum sheet and rod?
The sheet is 6061 and the TIG rods were mostly 4043
Everlanders Cool thanks for letting me know. I’d like to do a fifth wheel out of box extrusion aluminum and the fact that you could do this in your garage is very encouraging to me. Would you recommend any resources which helped you design your structure to be strong enough? I want to make sure I don’t “final destination” whatever poor motorist is behind me on the freeway
In our case the strength comes from the honeycomb composite panels, not the aluminum... I have friends in the mechanical engineering world who reviewed my CAD design, and gave me the nod of overbuilt!
Everlanders Overbuilt is a good way to be. Keep up the great work and thanks for putting the effort in to show your process 👍
Did you ordered custom size for composite panels? I'm trying to order from a company making only 4'x8' but i need lager than couple of panels.
The full panels are 13x40... We had them rough cut to size.
@@Everlanders I see. I can't not find any company take custom order. Than you. i love your camper.
"Chinesium" Light Bar......... Too funny!
Nice work approx weight of aluminum frame?
Fantastic Question! I get asked that a lot in person too, So I've opened up the CAD model and got you some numbers.
The CAD of the frame can be seen here: th-cam.com/video/vLkxmSkcLvQ/w-d-xo.html
Top 3/16" Plate - Custom Angles and Framework - 6061
235.17 lbs or 106.67 kg
Bottom 2x2" 3/16" Wall Tube - Frame - 6061
47.58 lbs or 21.58 kg
Total Aluminum not Including Welds
282.75 lbs or 128.25 kg
What CAD program did you use?
SolidWorks
What design program did u use to mock it up?
Solidworks
what software did you use to make the prototype design
SolidWorks
How thick is square tubing of the platform?
3/16" wall, 2" square
That what I thought you said. People don't borrow you something, they lend you. It's your grammer.
*Grammar
How much did the material cost?
Hello if you calculate a 2 x 2 x 4m box with Alu angle, this is approx 12lengths of 6metres giving a cost retail of approx $500. There is also sheeting and I dont know how much the honeycomb/foam is.
Did you ever experience any issues with panels bowing, detaching or dis-bonding from expansion/contraction of the aluminum exoskeleton? I would think there would be issues from solidly joining two unlike materials together that don't expand and contract anywhere near the same rate. But proof is in the pudding, as they say. So how has your build lived for these years? If you report back good news, I will also consider employing this method of construction, as I can see where it would be incredibly strong for off-road use.
We used the proven method of adhesion, Sikaflex 252 and 107 primer, make sure to use a 3mm rubber spacer near the rivets, this ensures the Sikaflex has a 3mm cross section to allow for thermal expansion and contraction...
7 years, 10 Countries, 2 Continents, 100,000Km and it's still as good as the day (after) I built it.
th-cam.com/video/EPgfyJ9bou0/w-d-xo.html
@@Everlanders Outstanding. Thank you for the quick reply! I'll be watching all your videos. It's gonna take a minute. You've got so many!
What CAD design software did you use to draw this up?
Solidworks, Autocad, Fusion, Sketchup...
@@Everlanders I'd like to see a video on your design/rendering/CAD workflow for these sorts of projects -the more detailed, the better.
Nope, project is done and were half way through Mexico at the moment and not stopping any time soon...
@@Everlanders This comment did not age well!
How does he get it out of the garage
James Keetch like this: th-cam.com/video/2MlN0xplkJQ/w-d-xo.html
Great,Can I buy one from you? Thanks
Nope...
Do you offer to take Matt camping? Maybe Mexico?
We did!
I'm a welder when I do large frames I clamp it to a table
I built this in my Garage and had no such table.
Did you say " borrow me "? What is borrow me?
I said, thanks to Regan for borrowing me his Milwaukee caulking gun...