timberwolfz28 wrote:I'm a little curious how much cutting and folding they did before they got to a workable design, and THEN traced it into a new flat pattern. Alternatively... (and how I would have - and have many times - done it) did they draw it in an as yet unseen actual CAD software, flatten the part and then print a pattern to trace? Would make them look like a genius on camera.
much doubt they're "secretly CAD-ing" anything.
Something like that looks
complex, but is actually quite easy- they just didn't show us all the steps.
It's essentially the same thing I would have done- take a single piece, cut a rough size, make a couple of fold, offer it up (as they say
)to the firewall and check for spacing and contour. Trim as necessary. Something doesn't fit quite right? Trim again and tape new paper to it.
Take that rough one, lay out a fresh one on new cardboard (technically card stock) taking more care to make lines straight and in hole locations. Cut that one out, fold, tape, try it out. Trim or tape pieces on to adjust.
Once you're happy with it, cut the tape at the folds, lay out, trace onto the flat steel, measure and mark the hole locations, cut out. Duplicate the folds in the brake, weld, etc.
That particular piece looked a little more complex than most, as they added... I guess you'd call it "more artistic lightness".
Most of these parts got "lightening holes", but this one, likely due to the fact it'll be a visible and somewhat prominent piece in the engine bay, they made the holes more contoured.