Editing How to make "speed holes" using dimple dies
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== PREAMBLE == Have you ever made a panel or a bracket for your hot rod, only to find out that it was flimsy and flapped in the wind? Here is a way to firm up those flimsy panels and brackets so that they hold solid and release the air that flows over them. '''How to make 'em''' Start off by drilling a hole or series of holes in the panel or bracket that you want to make using a drill bit that fits the pilot hole of the dimpling die. [[File:1_sheet_metal.jpg]] After the hole is drilled, insert the pilot bolt along with the male and female dies. Center out the die in the hole. [[File:2_centered.jpg]] Using a breaker bar, start tightening down on the pilot bolt until it comes in contact with the panel (sheet metal). Spray some WD40 on the dies and threads of the bolt to ease the strain it causes on the metal. [[File:3_tighten_down.jpg]] After tightening down to an appropriate level, this is how it should turn out. [[File:4_bottomed_out.jpg]] Nice line of holes. [[File:5_end_result.jpg]] If you were making a bracket that required stiffing to make it ridged, this is what you would end up with after making a series of holes and using the dimpling dies. A ridged panel that would flow air through it, not hold air back. [[File:Pickup_panel.jpg]] [[File:Rad_cradle.JPG]] [[File:Brackets.JPG]] == WHERE TO GET THE DIMPLING DIES == Check these guys out: http://www.kartek.com/Product/Tools/DippleDie.html Flared hole dies: http://www.lightracing.com/lightracingFlaredHoleDies.html Sets of dies: http://www.vansantent.com/sheet_metal_machines/dimple_dies.htm Or, make your own. A special thanks to Drewfus from the HAMB site for offering up the pictures for the homemade dies that are shown here. [[File:Homemade_dies.jpg]] We’ve all seen fancy dies, toss them a elaborate press, and off you go………..unfortunately I don’t have that luxury. So, I had to create a cheap and easy method to get the flair, without breaking the bank. Using a 4” long piece of 2” solid bar, the following details will explain the basic process I used to create the dies. The female die Firstly, I drilled a 10.8mm hole through the centre. In an effort to make 2 dies from the one bit of bar, I machined a female taper to both ends, the angle was approx. 30 degrees(from square to the centre line), with the O.D. of each taper being 46mm(for the 1 ¼” hole), and 33mm (for the ¾” hole). I then tapped a ½” UNC thread through the centre (because that’s what I had closest to hand, a UNF thread, or a larger bolt size would be better if handy). The male die From an off cut of the 2” bar, I machined a ½” hole through the centre (to match the bolt), and machined a large chamfer at approximately 15 degrees (any bigger of an angle and you will have difficulty in ‘nicely’ flaring the hole, at least by hand anyway…..
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