Reference: Ford CMP Truck- Battery Holder plans

[Jacques Reed]

Well, after a false start I am ready to finally get the holder folded up for me.
Learnt a few things along the way about sheetmetal work too.
I had the fabricator fold up the front retainer bar first to check bend deductions before I cut out the main sheetmetal for the holder. Glad I did, as the deduction worked out to a generous 3/16" (5 mm) using his equipment. I was therefore able to adjust the pattern before cutting.

As shown in the photo of the front bar the bottom leg "grew" by 3/16" by keeping the front leg exactly 1" high. The original piece of steel was 1-5/8" wide (moulded width) before folding.
When I got back to the fabricator he suggested I use galvanized steel which was 0.049" thick, only 0.002" less than the original. Wish he had suggested it to me before I got the black steel front piece from him.

Also experimented with sheet metal drilling before I drill the holes in the holder. As you all may know, when drilling sheetmetal it notoriously creates triangular holes even when done on a drill press with a sharp jobbers bit and clamped tightly as I confirmed. So a bit more reading and off to the local industrial supply house for a 17/64" stub drill, not the kind of item you get at the local Bunnings Warehouse (Home Depot for our North American friends).
So a bit more practice on steel offcuts with the new drill bit and maybe a pilot hole before I commit to the important holes. Stay tuned.

Brgds