In the last several issues of CCT, you've seen No Limit Engineering making progress on the construction of the F-100 SuperNationals giveaway truck. Have you ever wondered whether No Limit would leave even one tiny element of the '56 Ford F-100 stock?
If you've learned one thing from the past tech stories, No Limit is not a pro shop that likes to leave well enough alone. When there's a piece of raw metal in front of any of the talented No Limit technicians, they're apt to run to the FlowJet and program a means to carve up the metal. Or they might fire up the plasma cutter and start sculpting. It's always a dead giveaway when we see founder Rob MacGregor scratching his chin and reaching for a pad of paper and a pen. Half the time he won't even bother with paper; he'll do his engineering with a Sharpie, a tape measure, and a virgin body panel. What we're getting at is, these dudes are quite the craftsmen. It's a pleasure to watch them fabricate and create. If we didn't think we'd get in trouble with our superiors, we'd eBay off No Limit Shop Tour tickets to hot rod hauler hobbyists so they could watch Rob, Tim, Carlos, and Mike crafting automotive/truck/motorcycle finery.
Within the No Limit Engineering shop there is an abundance of automated machines, plasma cutters, die grinders, TIG and MIG welders, specialized tools, and hand tools at the ready for the Four Musketeers of Fabrication. We've watched them creating motorcycle frames, aluminum radiators, custom vintage truck chassis, headers, and engine mounts, not to mention an entire truck.
The F-100 giveaway truck the crew is building has a Ford Racing theme. Before construction commenced on the pickup, some sweet-looking renderings were created. Rob and crew are following the renderings to a degree, but like we said, led by Rob, they're following their own race car building and engineering roots to create cool components from raw metal, aluminum, stainless steel, reproduction fiberglass, and steel parts. In this installment of metal mastery, follow the leading Musketeer, Mr. MacGregor, as he fabricates some Ford Racing-themed running boards. By the way, he did get a running start, thanks to the assistance of Avenger Fab & Supply (AF&S). The running board sheetmetal blanks Rob worked with were initially cut and formed by AF&S. For now, you don't have to be the winning bid to learn some fabrication fine points. Simply read your copy of CCT.
Also in San Bernardino, AF&S...
Also in San Bernardino, AF&S collaborated on the F-100 giveaway truck by fabricating the sheetmetal panels--trim pieces and running boards--to No Limit's specifications. AF&S also incorporated the rolled edge on the running boards, as required.
One of the trim pieces AF&S...
One of the trim pieces AF&S created will become the back of the running board. No Limit will need to form the straight piece around the curve of the rear fender.
To form an outside radius...
To form an outside radius in the rear trim piece, Rob used the stretcher tool. The rule of thumb for the stretcher is: "Easy does it." Go slowly and methodically to stretch the metal and form a smooth outside radius...
...If you go too far, you...
...If you go too far, you have to use the other part of the stretcher tool, which is the shrinker tool (for flattening the outside radius).
The driver-side running board...
The driver-side running board now has a rear trim piece that is the correct shape.
Using the shop's metal snips,...
Using the shop's metal snips, Rob cut off the end to the correct length. He also rounded the top outer edge.
With the piece held in position,...
With the piece held in position, you can see why Rob rounded its outside edge. The piece will be welded to the running board, which also has a rounded outer lip.
There was one sheetmetal panel...
There was one sheetmetal panel that AF&S didn't provide--the piece that fits beneath the bedside. Rob went to work creating the panel, which would cover the No Limit tubular chassis. He determined the panel would be 19 x 4 3/8 inches long.
Since the panel bends in at...
Since the panel bends in at the bottom of the bedside and bends out underneath the running board, Rob put the two bends in the panel.
By holding the panel in position,...
By holding the panel in position, one can appreciate how the custom running boards are created.
To clear the chassis tubing...
To clear the chassis tubing at the corner and under the driver-side door, Rob wielded the metal snips to remove a bit of excess sheetmetal.
With the excess metal removed,...
With the excess metal removed, the trim piece fits much better.
Starting with the AF&S front...
Starting with the AF&S front running board trim piece, Rob used the stretcher to give a gradual outside radius to the metal. See how well the panel fits against the Mid Fifty F-100 Parts reproduction F-100 front fender?
Rob marked the running board...
Rob marked the running board where it needed to be trimmed to clear the rear fender and the chassis tube under the driver- side door.
After putting on his safety...
After putting on his safety glasses and gloves...
...he cut the driver-side...
...he cut the driver-side running board with a plasma cutter.
The die grinder is a handy...
The die grinder is a handy air tool to have in any shop. Rob smoothed the edges that had been cut with the plasma cutter.