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Aluminum Ductwork Fabrication and Installation

28:18
38:06
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At 28:18 in

Vintage NASCAR Monte Carlo Build: Dodge R5P7 Engine Install with Doug Richert! (Part 1)

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What happens here

After creating cardboard mock-ups, the presenter transfers the designs onto aluminum sheets. He uses a straight edge and his hands to bend the aluminum into the required curves, creating a top piece and bottom piece for the ductwork. He uses clekos (sheet metal screws) to temporarily hold the pieces in place inside the car's nose, ensuring proper fitment and airflow direction to the radiator. He demonstrates the finished top piece, which includes a mesh grill covering the radiator opening, emphasizing the custom fit and aesthetics.

Goal: Fabricate aluminum ductwork based on cardboard mock-ups and install it in the car's nose to direct airflow.

Tools and materials

  • Aluminum Sheets N/A — Final ductwork construction
  • Clekos — Temporarily holding aluminum pieces in place
  • Mesh Grill — Covering radiator opening
  • Rivet Gun N/A — Permanently securing aluminum panels
  • Sheet Metal Shears N/A — Cutting aluminum sheets
  • Straight Edge — Guiding cuts and bends on aluminum

What they say

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here I've made a couple versions of cardboard mockups I make a rough one just kind of by taping crap together this was all one piece I built that with it being inside the bumper taped to the face then I made this bottom piece taped it to that and it was all put together like this it would not fold down because this was curved up here then I just split it laid it flat transferred that to one piece of cardboard this time to test it again and tape some tape sticks to it to keep it from flopping around locked it up in here best I can show you with not having enough hands I promise you it fits perfectly when it's flat to verify that then trace it out on some aluminum here and instead of using a finger breake cuz that would be a lot of messing around I can just put this on here this is thin enough to bend with my hands I'll just take you know like like this hold it with two hands hold this down push this up do the same thing following the plane of each one then I

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