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Recently, we decided to make a switch from the Audison LRx amplifiers we had been running to the new STEG K series amplifiers.
This meant that we had to redo the back end of the car since these amps were different dimensions.
We've had really good success running the tubular style am racks. It's kind of become our signature, so we decided to take it a step further.
Since these new STEG amplifiers are a bit beefier and more industrial looking than the Audisons, we wanted to do them justice.
2 1/4" 16 gauge steel pipe would do the trick!
One problem, how do you bend pipe like this? If we wanted precise bends, of a more extreme radius, we were fine. However, that's not what we wanted. What to do? How to get a very gradual bend in a 2 1/4" 16 gauge steel pipe?
We went to muffler shops, we went to a custom chopper shop, we went to metal fabricators, no dice anywhere.
We decided to notch the pipe every 3" or so at a 5 degree angle. Then we went back at each notch at a 0 degree angle and cut the notch out. We did this with a metal cutting blade on our table saw.
This made bending the pipe to a desired radius possible and extremely easy.
x2 for the two pipes that we needed.
Now came my favorite part! Welding it all back together. This should have really been done with a stick welder. However, those are fairly expensive. The welder we have cost us $350. It's a great little hobbyist welder, no doubt about it.
The welds were everything BUT pretty. Filling 1/4" gaps with 0.6mm filler wire on a pipe isn't an easy task. Some people say that welding plate steel to thing pipe is very hard. If that's the case, this is even harder. We have the capability to use 0.8mm filler wire, but the 6mm was already loaded and threaded.
Now came the time to grind down all of those hideous welds.
Thanks to our friend David for helping on this part. I think he just enjoyed hacking away at something for a while. You would be surprised how soothing it can be!
Trying to bend the 1/8" plate steel so it will fit under the trim panel isn't easy.
Spot welding the tubes in place and making sure everything will fit.
With the notches cut out for the amps to sit in.
With the braces for the amplifiers welded into place.
This is what a cooked drill looks like! This happened while trying to drill the holes in the end of the amp rack for the wires to pass through the end plates.
Bondoed to make the amp rack smooth.