Alternator rubber splash shield clip.

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Karl
Posts: 782
Joined: Sat Oct 05, 2013 6:03 pm
Location: Brisbane, Australia

Alternator rubber splash shield clip.

Post by Karl » Sun Nov 10, 2019 8:06 am

I thought I would start another thread for the clips that I needed for the rubber splash shield that goes onto the side rail in the right hand wheel well. I made them out of 2.43mm spring wire.

If anybody is interested here are the steps that I took to make the clip.
Cut the wire into 160mm lengths.
Straight wire.jpg
Place the wire into a jig and measure 50 from the end to the 1/4" mandrel.
1st bend A.jpg
First bend B.jpg
Measure the same distance and bend the other end.
2nd bend.jpg
Place the loop end in a vice about 8mm and bend one of the legs at about 30 deg
3rd bend.jpg
Repeat for the other leg.
4th bend.jpg
Place the wire back into the jig and measure from the end of the loop to the mandrel 7/8" and bend 90 deg.
5th bend A.jpg
5th bend B.jpg
Move the wire along and finish the rectangle.
6th bend.jpg
Place the wire back into the vice and straighten up the loops.
Straighten up clip A.jpg
Straighten up clip B.jpg
Place the clip into a jig and do the final bends for the legs.
Fit to jig.jpg
7th bend.jpg
8th bend.jpg
Try the clip on a sample rubber and steel.
Check fitment.jpg
The jig for bending the final steps for the legs is made out of an old axle. Mild steel is not strong enough and starts to deform on the sharp edge from the spring steel. The axle steel hasn't a dent in it and I have made about a dozen of the clips.
Now you may think that it was a simple process to get to the final product, not so, I purchased about 5 meters of steel and I only have about 1 meter left, the rest is in the bin. Small pieces of bent and twisted wire.

Karl.
P.S. you may be wondering why I use metric and imperial - that's what happens when you country changes to metric and you still use the imperial measurement system.
1963 Thunderbird Hardtop

Ian M Greer
Posts: 486
Joined: Thu May 12, 2011 9:22 pm
Location: North Bay On. Canada

Re: Alternator rubber splash shield clip.

Post by Ian M Greer » Sun Nov 10, 2019 5:42 pm

Amazing work Carl!!!!
1963 M Landau Caspian Blue (Remember Not All Birds Fly South)
Member #-12090

Ian M Greer
Posts: 486
Joined: Thu May 12, 2011 9:22 pm
Location: North Bay On. Canada

Re: Alternator rubber splash shield clip.

Post by Ian M Greer » Sun Nov 10, 2019 5:43 pm

Sorry Karl !!
1963 M Landau Caspian Blue (Remember Not All Birds Fly South)
Member #-12090

ICON 1956
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Location: Mokena, Illinois
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Re: Alternator rubber splash shield clip.

Post by ICON 1956 » Sun Nov 10, 2019 11:00 pm

Nicely done Karl, You are the MAN !
1956 Thunderbird Sage Green
1997 Heritage Springer with Motorvation matching side Car Red/Birch White
VTCI Member # 12309

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