Exhaust tunnel second attempt
I got to try out a second attempt at making the exhaust tunnel today. I tried a similar approach, but with some new tactics. This time, I made both of the bends needed to form the main flange and the secondary 'wings' to cover the gap with the side panels first. I didn't make any cuts this time other than the outline of the part. The main flanges were bent first on the brake. Then I fit the part with the side panels installed to mark the bend line for the overlap with the sides.
The secondary bend was made by clamping two lengths of one inch square tubing on each side and leaning into it. This was tricky, since the the two bends meet before the end of the part. I had to muscle it around a bit, but it came out as planned. With some additional work with a pair of seamers and a rubber mallet, it all came together pretty well.
I still have some smoothing to do on and near the wings, but the fit is nice and tight. The pictures make the ripples stand out more than they appear in person. With just a little more work, it should look pretty good with primer and paint. I got about half of the holes drilled and installed sheet metal screws to hold everything for now. I will replace them with nut plates and machine screws.
More pictures here.
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