[ModCrate DIY] Project #2 Pinch Weld Covers

Russ.Cere · Oct 25, 2023

For the second project in the ModCrate DIY series I am going to make some Pinch Weld Covers.

If you run an Active Bronco Club on B6G or Facebook, I would love to help you develop club merchandise or set up club discounts!

If you like this type of content, please consider visiting my store, ModCrate.com. Your support means a lot and helps fund future projects and products.

This Project

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers 20231025_125452

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers 20231025_125447

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers 20231025_143646

You can follow along and make your own from scratch. Alternatively, you can reference the method outline in the first post, located HERE.

If you're going to follow along you will need access to a suitable 2d drawing program or a modeling suite capable of 2d sketching. I recommend Fusion 360 It's an intuitive platform, has a free version and if you run into issues, I'll be able to walk you through the process.

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers How To background

Step 1: Take a few measurements and jot them down. Pay special attention to critical constraints like the overall length, spacing of screws and, body curves. Failure to account for constraints can make your final part unusable.

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers Measure

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers Hole Constraints

Step 1.1: My measurements ended up looking like this. I have a 2023 WildTrak there may be variations out in the wild so make sure you check your Bronco and make adjustments as needed.
*NOTE: all units are inches, all rounded edges are diameters

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers Measurements

I covered general sketching in this guide as well as how to use Send Cut Send for fabrication, so I won't be covering it on new projects. There is a huge knowledge base on YouTube if this kind of thing interests you head there for drawing tutorials.

Step 2: With your measurements and constraints in mind sketch it up in Fusion 360 or a program of your choice. I went with a smple square with some chamfers at the ends and a nested feature in the middle. *Turns out I don't like the nested feature post install.

Ford Bronco [ModCrate DIY] Project #2 Pinch Weld Covers Fusion Header

Step 3: Export your sketches to Send Cut Send or search for a local fabrication shop. Wait for your parts.

Step 4: Install I went with 5/16-18 stainless steel socket cap hardware. It was the largest diameter bolt I could fit through both the slots and holes, and I like the look of protruding hardware. You can experiment with different styles.