[RHClarke]

The diamond/dot plate steel running boards off the Pilot Model were in fair shape - except for the lower reinforcing edging or railings. As mentioned, these were removed to make way for new replacements.

The biggest challenge was to make sure that the outside radius of the bends matched the outside radius of the boards. To do this, I used a fine blade on a grinder and cut some slots. The first slot was where the bend began and other slots were cut into the steel until the bend was completed. To do this, some of the slots had to be widened with the grinder. Once the slots were completed, the rail was bent to match the radius.

Once both rails were "slotted" and properly bent, the rails were clamped to the running boards making sure that the edges were flush. A few zaps with the welder held the long length of the rail in place. The ends of the rail were pulled in, clamped and then welded into position. After a few "insurance" welds, the slots were welded close. Next step is to cut off the excess railing and then drill the attachment holes.

Photos
1- The start point - new steel
2- Slotting the inside radius
3- Note that the short arm does not match the outside edge - it gets pulled in once the inside radius is welded
4- Welding completed
5- Final product - looks the part