Thread: I couldn't build it for $3 K either!

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I cleaned up the pieces and beveled the edges where they fit together.

After centering the 3/8 filler pieces on the 1/4 outside pieces I tacked them together and added the pockets to the one end.

I used a MIG welder to weld the plates together. Not only are the MIGs good for welding thin sheet metal, but they will also lay down a lot of metal in a hurry if you need to. I ran those passes pretty hot. The object here was to make sure the bevels were filled and the weld was burnt in well.

I switched to TIG to weld the tubing pieces on, but in hindsight, I should have stuck with the MIG. I had to go back and add metal in few places while I was grinding them, especially in the areas around the pockets. I had to add enough to fill in the radius. I colored this area with a marker in the pics.

I used a 4 1/2" grinder to do the rough finishing and then switched to the belt sander.

The final finishing was done with a DA sander. I locked the spindle so that the disc would just spin like a grinder. The DA sanding discs don't last long, but they give a nice finish. I used the DA to round the edges and give a softer "organic" look to the piece.

I went back to the "holes" theme to add a little more hotrod look to the post. My son thought I was crazy for doing that, but I thought it fit with the overall look of the car.

If I was doing this over I would probably taper the posts slightly from the bottom to the top. Maybe just a 1/4" narrower at the top.

I'm leaning toward the high luster silver powder coat for the frame and posts so I didn't sand past 120 grit. I may go a little finer when I get to the detailing stage at the end of the build.

Well that's all I have right now and I won't get to do any more until Monday of next week. I plan to finish the other upright and cut the windshield frame down then. I also still have to weld and finish the corner posts.