Drip Rail Fabrication

[MP&C]

Spent last week in Rock Hill SC for a metalshaping workshop. My project was going to be making a section of drip rail to match a section cut from a vehicle.. I was going to use the bead roller but any attempt showed distortion was difficult to control. Just to clarify where this is situated, this is welded along the outside of the A-pillar with the tail comprising part of the windshield opening.





After looking at some of the home made Pullmax dies others had brought, I think eliminating the deformity can be best addressed by making dies for the Lennox (Pullmax). Here's what we started with, a section of 18 gauge (to match OEM) and folded the lip that will form the outside face of the drip rail..



Next, a die is used to add the joggle seen at the bottom, and a clamped-on guide prevents the flange from wanting to move skyward.





Next operation is to add the slight bit of radius to the front face of the drip rail. Here's our die configuration for this step..



Shown here with the original cross-section piece...

[MP&C]

Our first task tonight was to modify die set #2 from last night so it would also tighten up the reverse joggle.











Next, Die set #3 for adding the remaining folds. A partial bend is done in the magnetic brake, and then the die set forms them more accurately.

Before:



After....



Comparison:







I like this method much better, looks to be more easily repeatable with better consistency.

[Florida 57]

Excellent work as usual Robert.Do I see a new supplier for drip rails in the future?

[MP&C]

Thanks, These are for FSJ Wagoneer, not as bad as the trifives drip rail as they are hemmed at the top edge. Fabrications like these are more time consuming than the market would probably bear with all the off shore stuff available. I've got a car show I plan on attending (if the rain stays away) this weekend with a display of metal fabrications and most I've done is now in primer. This does a good job showing fabrication of something different.

[bigblock]

Robert I wish you were here in Ohio, you are amazing to watch. Everything you have ever shown is better then new. Thanks for always sharing.

[NickP]

Super!

[carls 56 (RIP 11/24/2021)]

thanks Robert.

[55chevysedanX4]

Amazing you are a master and i hope to learn more from you.

[567chevys]

Fantastic work Robert

You should Make a Video and sell them

Thanks for taking your time and posting on this site for all to see

Thanks Sid

[Rick_L]

Robert, that's awesome work.

Do you have to put a curve in the drip rail to fit it to the vehicle? How would you do that?

[NickP]

Robert, that's awesome work.

Do you have to put a curve in the drip rail to fit it to the vehicle? How would you do that?

Shrinker maybe.

[MP&C]

Robert, that's awesome work.

Do you have to put a curve in the drip rail to fit it to the vehicle? How would you do that?

If you let loose of it while pulling through the dies it flops around and does a nice vertical radius. Yes, experience. For where this is going I believe there is a miter cut at the top of the a pillar and then it has a straight run to the back. For horizontal curves I would imagine you might have to cut the blank with that radius already cut into it, and tip the flange. You can put a slight amount of radius in while pulling through the dies while forcing the direction desired. Not sure where the breaking point / kink point starts.


Thanks for the comments guys!