Hey Ben, I did spend some time pondering the trim on my Clipper. I've pretty much come to the conclusion that to accurately duplicate the original trim would require either a very long custom punch, a press brake and an accurate back stop to do one flute at a time, or as Joe suggested, a roll forming machine. A bead roller or a Pullmax and a very skilled operator might be able to pull it off but It would be difficult to make the pieces as straight by the latter methods. I read a bit about roll forming and spent a little time drawing the final station dies. I think it would require a minimum of 3 roll forming stations. The first set of rolls would coin, or tip the top of the flutes slightly. The second set would begin to form the flutes and the third set would set the final shape. Before the roll forming operation the edges would be joggled in a brake. I forgot to measure the length of the individual pieces but I'm sure the trim is fitted together in sections not over 8' long. The ends could be hammer formed over a metal form with heat or they could be welded on then metal finished. There are also risers at the ends of the trim to adapt it to the curved sides of the bus at the front and rear. These are about an inch high at the thickest section.
I'm not in a position to do this any time soon. I do have most of the hardware to build the rolling machine and I have access to a CNC lathe to turn the rollers. I can imagine that before the end of the year I might have something at least started. There are many talented folks around here. Terry Stolarski and others can do some amazing things with a Pullmax. Maybe someone will be willing to try it that way.
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