It definitely shows, as was said before those cuts look waterjetted. Is it easy to turn the aluminum as you are cutting with the bandsaw, or is it like a hacksaw where you can pretty much only make straight cuts?

For this purpose, does a band saw work better than a mill?

I cut the tvp out in about 2 mins with the bandsaw. Only areas I filed were the rounded corners and the small slots that line up with the skidplates. With the correct tension I can cut circles with the bandsaw, maybe as small as 6". So most curves and odd shapes can be cut with ease. The bandsaw is not as versatile as a mill, but for quickly cutting flat stuff it is very useful. I also cut plastic on it, and have modded parts and cut trays out of chassis with it. It is very controllable as you can use both hands to move and hold the material.

Great info, thanks. Last question -- How will you go about cutting the holes out for the tranny? Ive always wondered, do you maybe drill a couple holes and then fit the saw blade through the holes and tension it up and then proceed to cut? Or is there a much easier way?

There is no way to cut an inside hole with the bandsaw as the blad is just a big circle, no ends to speak off.

I have a really nice dewalt jigsaw, and I use that with a metal blade to cut the inside holes. It has a foward/backward oscillating action that helps the blade cut smoothly and quickly. I start buy drilling a hole large enough to get the jigsaw bade thru, and then go to town. I finish it up with a round bastard file for the corners and a flat file for the sides. If I have some notches to cut I usually use the file to do that. A good bench vise is your friend during the filing process, and some decent gloves while you cut is a good idea to hold the parts steady on the bench.

I maybe have $250 invested in cutting/filing tools to do this, but I can make just about anything, and they are also good for wood and plastic projects too. Recently used the badsaw to cut up pvc couples to make my new bathtub fit. Tools that will last a long time with proper care and use.

Is that what you want the street tires for? Or for that big Baja body?

Shhh, its a surprise! Not for this or the 5t baja!

O, that other big ole body!!!!

You have too many projects for me to keep track of....

Yeah, definitely going to be something different. I have a feeling that everyone will like it!

Oops yah I was thinking of a jogsaw when I wrote that last comment. Thanks again, looking forward to the finished product!

More progress...
 

Ok, had to work a bit late, so I only got a chance to cut the tranny/motor holes on one plate. But being the nice guy that I am I decided to mock it up so that you all can have some pics.

Getting the rear mount on the flux motor was a real PITA. I had to bend the mount open and riddle with it till I got it on, then I had to clamp it closed with the bench vise... Crappy design IMO.

Any who, here is the closed to finished product. I put the driveshafts in to check fit, and all seems good. Using 20/47 gearing, and it may fit a 21t pinion, but that will be about it. Unless I go to a smaller spur, like the 44t stock flux spur.

http://i206.photobucket.com/albums/b...p/DSCF3390.jpg
http://i206.photobucket.com/albums/b...p/DSCF3391.jpg
http://i206.photobucket.com/albums/b...p/DSCF3392.jpg
http://i206.photobucket.com/albums/b...p/DSCF3393.jpg

Looks good...making progress!

Sometimes making these custom pieces can be more trouble than it is worth at times, but that is the fun of customizing

Yeah, but the finished product will be unique! And that is what I am looking for!

Thats sweet! I want that savvy!

Batt up front to cut down wheelies, should be a nice setup when its done!

Thanks, I may sell it...

The forward placement of the batt makes wheelies more controllable, found that with the last savvy I did and the lst. I plan to run a wheely bar (the single wheel setup from hpi). The main difference I find is jumping benefits most from forward battery placement. You can jump at close to full throttle without having to back off much or brake to keep the nose down. The added weight up front helps to counteract the bigger truck wheels/tires spinning unloaded.