I posted that on forums to solicit a response from some of forums members. Apparently it was thought of as sexually suggestive to some of the readers. Sorry. I was more making fun of the one in my head where all the aluminum goes. Any way, I have this hole. It has bothered me tremendously since I pulled the huge blob of silicon off it.
It is a result of, what I am sure was, a classic case of lost keys. Instead of using the proper dead bolt, one was adapted. It was Jerry rigged and I fucking hate to do that.(Sorry, it is my blog and that is how I feel about fucking assholes that do things half ass. Sorry, it is my blog and sometimes I speak my mind)
As you can see the back side has the same gap. So I asked folks on the forums as to what they would do. I got some good feed back. I was surprised that the high acclaimed California professional Airstream restorer, parts mogul and axle emperor told me to put a bead of vulkem over it. Now that is exactly the non professional look I was trying to get away from. So a plan was hatched and SoldierMedic thought it was a good one. That was the one vote I needed, thank you Steve,
So I got out a piece of 2024 T3 .032 and contact cemented a star photo copy to it. I punched a center to give my dividers somewhere to seat and drew out the out limit of the beauty ring I was going to make. Next I drew the center line of each point of the star. Drew out the star to the full diameter of the ring. I then created a inner ring 1/8" larger than the diameter of the dead bolt. The hole in the back of the dead bolt was 1 3/8" so I drilled out the center with a sharp Forstner bit.
I next went at it with my super fancy hand shears. Wish I had some cool tool, but sharp shears and patients cuts it out real well. My hand break came in handy for flattening the edges and points out. A heavy hammer on the cast iron table saw top took out every ripple. Next I used a combination of bench top grinding wheel and fine files to smooth and straighten (or curve) all that cuts.
The other half of my bench grinder has a doubled cotton wheel on it. A little brown rouge, and a few minutes... BAMMMM!
Even thought it is raining, I just had to dry fit it into place. Vulkem and five Olympics will hold this new beauty ring in place. I just need to wait for it to stop raining and it will be installed.
For the inside hole, I will be making an even more funky shape, stay tuned for that...