| |
|
HOME |
|
|
|
The Bull |
The Growing Bull |
The Bull Tail |
The BullPen |
Bull-O-Knee |
| |
|
THE BUILD -
part 1 |
|
The BTF Chassis comes to life |
|
|
|
Well, this will definitely be the shortest section of this
entire build. As BTF has some unique ways to "jig" their
chassis, they did not let anyone take pictures as they want to
protect these techniques. Their method is so fast to build
an entire chassis, that Bender was able to knock out the entire
exterior portion of the cage in a few hours. Each tube is in
perfect position, so this technique is not only fast, it is very
accurate. Clearly, they have created something worth protecting
so you won't see that portion of the build on these
pages...however, if you decide to buy one of these production
chassis, you will save money simply due to their big savings on
time to assemble.
Since I cannot show you pictures, I'll give you the basics as
best I can without revealing any secrets they want kept.
After the
"MockUp",
the chassis information was loaded into SolidWorks and a
computer generated version of the chassis was created.
This gave Blue Torch many details, including how much tube to
buy, how much the finished chassis would weigh, how long to cut
each tube, where to place the bends and at what angles...even
the angles of the "cope" cuts on the end of each tube. It
also told them exactly where to place each tube to weld in
place. |
|
 |
|
Once they had the 1.5" diameter x .120 wall chromoly tube in the
shop as well as a selection of different thicknesses of flat
plat for the many custom tabs and accents they'll build, they
went to work using Matt's blueprints as a guide. Matt
would print out a cut list as well as a bend sheet and both of
those included all of the info needed to do the tube work.
Any plate work was sent from the SolidWorks program straight to
the CNC Plasma cutter which we'll expand on later in the
"engine" section. From those plans, Bender and Dan would
double check the math on the blue-prints. |
|
 |
|
Cut the tube according to the cut sheet and then mark the tube
with a Sharpie at the point where the bend should begin. |
|
 |
|
Load the tube into the bender with the Sharpie mark lined up
with a small arrow on the die that tells them the tube is
properly lined up. Enter the bend information taken from
the blueprint. Then hit go and the machine bends the tube
automatically to the angle entered on its keypad. This is
similar to the way Bender used to do things in his
"Bendin' Tube 101" days, only taking out a little time and
effort with automation. |
  |
  |
|
Remember, this is being done this way simply because this
chassis is a full-production version. The MockUp chassis
was done by hand, Sharpie, tape measure, angle finder, and
experience...no computer...using the
"Bendin' Tube 101" method that Bender wrote about so many
years ago. After the tube is bent, it is either hand coped
with a hole saw or cope cut in the plasma table (yes, their
plasma cuts copes too!), and then the pieces are ready for
assembly.
The next steps are the one's I cannot show but basically, the
tubes are placed into a special jig and then tacked into place.
Once that part is finished, Dan and Bender came into the shop
late at night (when it was cooler) and pulled endless straight
hours TIG welding the entire mainframe. |
|
 |
|
 |
|
 |
|
 |
|
Of course, BTF has a reputation for custom work that stands
apart so they added in a few special treats to go with Becca's
Red Bull relationship! |
|
 |
|
Then, as the build continues, you constantly
go back and double-check that the chassis does not un-planned
interferences, especially with the suspension. |
|
  |
|
Speaking of suspension...the chassis end of the links are TRICK!
Check out the chassis link mounts! BTF sure knows how to
make something practical combined with having a STYLE that sets
their product apart. |
|
  |
|
Other things that are part of the chassis are the simple yet
strong motor-mounts and the seat supports that will delineate
the interior. |
|
  |
|
There is obviously more to this chassis and we'll add to this
story as we get more pics and info ready. Keep in mind again
that this chassis is the Red Bull RockHer II, designed specially
for Becca, but you'll see soon that it is far more than a pure
competition rockcrawler. It will have a full pickup bed
without a ton of tube or accessories taking up the cargo area,
it will have a better look compared to the endless line of tube
chassis on the market, and it will be available at a price that
will surprise you considering what it really is. If you
are considering a new chassis or a turnkey rockcrawler /
trailrig, you'd better give
Blue Torch Fabworks a
call as soon, the waiting list will be LONG! Their phone
number in Dothan, AL (central time zone): 334-673-2755. |
|
|
|
Back to "the GROWING BULL" menu |
|
Forward to the next story - "THE BUILD part 2 (front end)" |
|
Back to "HOME" |
|
|
|
All images and text Copy Right 2006
Blue Torch FabWorks, Inc
Red Bull
RockCrawling Team
Pirate4x4.com
Disclaimer |
