Thread: Convertable / Removable Flounder Lite System / Rod Holder Set

Very cool!

Looks like an awesome start.. I need to find one of those white gas Coleman lanterns
That has been converted to a flounder light . Believe a company out of Texas used to do them. May have to convert an old one myself.

I don't know if I should lead with a picture or not? Let me try.



Pipe Bending 101 - You always, always have to know a repeatable mark location. Here I use the leading edge of the clamping shoe. If you look close you will see a sharpie mark right against the shoe. Not a 1/4in either way but right in a repeatable spot.



I'm bending 1-1/4in Sch 80 Aluminum pipe with a 7in Radius Bending Shoe so at 90 degrees my bend will grow 10-3/4in. This 10-3/4in figure never changes as long as you are using the die you used in the first place. Without out knowing the growth of the outside edge of the bend repeatable bends are impossible. When fabricating Roll Cages from scratch your "Offset figure" gets welded into the brain, pun intended. This is a "One-Shot" Bender. I made a pile of money bending T-Tops with this bender. Being Air over Hydraulics I don't have a ratchet handle to pull on.



Mine did not come with a gauge so I made this one and it works great. If you need to repeat a bend just stop in the same place each bend.



To prevent axial alignment issues or twists not intended to be in the pipe I use a digital angle finder. Here it is zero degrees but when I put full bend torque the dies allow a .02 degrees down so when a start my second bend I will make sure I get the pipe in the exact (within .05 degrees) before starting the bend.



This is a target of 63 inches outside to outside on this pipe. The reference mark shown is written on the table 32-1/4in but since I have been bending pipe for a long time I realized the finished pipe was going to be too short so since my bud is deer hunting in Illinois I just added 20 inches. 63 inches minus the offset of 10-3/4in is 52-3/4in. This reference mark is 52-3/4in from the starting mark.



Here is a picture of the pipe after bending still in the bender. Please don't judge all the debris on my table. This poor table has to carry and support a lot of projects.



To drop in the Rocket Launcher Liner without damaging it I sand a radius to 320 grit in the ends of the 1-1/4in pipe.



Here I'm preparing to weld the Rocket Launcher to it's Pad. All 6 get welded the same. I will only weld one side so the Rocket Launcher can be bend into alignment with the 1-1/4in pipe. After getting a perfect alignment so the pipe slides in and out with ease I will weld out.



These are done for now but 2 get welded out now they will have individual light fixtures up on the Bow shining forward.



TIG Welded anodized aluminum in one pass with a Miller Dynasty.



A match set of pipes. If you know the offset and put the initial clamping shoe mark you can calculate the rest of the bends.



In a holding pattern now till I talk to my bud. I think the light mounts need to be under the pipe with the fixtures mounted under that to reduce the glare on the water.

Fine work you are doing

Beautiful AND professional!

Very clean and nice. Quality craftsmanship.

Got up this morning and got back on the Flounder Lite System. I had to crank up my big welder Mr Miller 350P. This thing is a beast. You must open the big door and personnel doors to let the smoke out when using this MIG Welder.



Welding such contrasting thicknesses I chose to weld the perpendicular edges and seal the parallel edges from saltwater intrusion. I welded all six pads after prepping the gunnels. The smoke stains was all wiped down with water then the opposite edges were sealed. I will paint these tomorrow.



next was test fitting the Rocket Launchers to the Rack Pipes. Bending the Rocket Launcher welds to align everything as best as it could be then welding the Rocket Launchers out to the pads.



Now I can weld on the Light Mounting Pads to the Light Racks.



After everything is totally cool I put the Light Racks into their corresponding Rocket Launchers for another test fit.



Still need to mount the new custom windshield and built a grab bar around it after.

Definitely a big Mig welder. Most shops run 250's