I had some extra aluminum lying around so I decided to design and fabricate a strut tower brace, mostly for show purposes. Here are some photos from the process. I didn't record the amount of hours put in, but let's just say it was 'a lot'. I should have some pics of it mounted in the next few days.

1. Design part in 3D using Solidworks


2. Design render. Wasn't sure of the colors or materials just yet.


3. Using MasterCam, the model is imported. Using feature-based-machining and specifying which tools I have available, the code is written. In this case, the code was 15,000 lines. Imagine what it took to machine this part manually 10 years ago. In this case with a CNC Mill, it's about 15 minutes, once it's set up.


4. Cut the rough block out of the plate.


5. Outline is cut out on a water-jet, leaving some clearance for machining.


6. Part loaded in fixture and machining begins.


7. First machining operation completed


8. Secondary machining complete


9. Strut mount is anodized to protect the finish and for aesthetics.


10. Cross bar is machined, formed, and anodized.


11. Overall shot.

 

Man I wish I had a CNC mill.
Yuor brace looks great, I want to see it installed.

 

Man, I've always hated SolidWorks but this post may have changed my mind. Your brace looks awesome, I hope you put up some pics of it installed!

 

pretty sweet

 

Man, that's frakkin awesome! You should laser etch something on the top of the bar.

 

Nice, real nice.

Great job.

 

That is fantastic!

I'll take it

 

Wow, looks great! The only thing I would wish for would be flush mount hardware.

Solidworks is actually pretty nice to work with IMO, once you get the hang of it.

Just finished modeling this today:




Sorry didn't mean to thread jack

 

^ Wow, looks really good! I've always liked Inventor better, but that might just be because I use it more. Hopefully I'll be doing nifty stuff like making my own strut braces if I ever get out of school

 

That looks beautiful. Very nice work.

Mio

 

work of art! well done for sure

 

That's funny, a few people have told me that. I'm into simple, minimalist design, so it's not for me, but I can see how others would like it. I actually don't have the engraving tool either. Thanks for the kind words though.

Creeve - that's a good suggestion. It didn't even occur to me, but I could have done it fairly easily.

 

Inventor is a little more solid, in terms of parametric modeling. Things don't 'blow up' if you change dimensions, etc. Solidworks is just way faster and more practical. The sheet metal commands are reason enough to switch, IMO. Anyway, good luck in school. We need more good engineers in this country. It's sad the amount of things I outsource these days.

 

Wow, that's really nice. Have you played with the Photoview 360 at all? It comes with 2009-10 version of SW. Very simple to use. Has a cool new feature too with depth of field and the ability to illuminate parts.

 

Here are a few of it mounted. The quality isn't the greatest because I was running out of light. And yes, the engine bay is filthy, I know.

 

Man, that's awesome. I forgot I read about your custom CAI too, I'm jealous.

Great work

 

Looks really nice.You should produce a few more,I'm sure you'd sell a few here.