# Xeon sheet-metal Jeep — process notes

Documented September 13, 2026.

## Primary documents

- [Original steel Jeep](https://cad.onshape.com/documents/9db16ab34fb9c7ae29115658/w/d649b0915ab929c0f8bf464a/e/6c92ee3ea151c5ca1f15ab62)
- [Aluminum bending revision](https://cad.onshape.com/documents/6f3b89577399aa4bcde4e3f1/w/9f603a954e09cd64ffa4222c/e/8c109636ae0409f9b2019eb7)

## Observed aluminum configuration

- One modeled part, nominal length input 8 in.
- 5052 H32 material; thickness 0.080 in (2.032 mm).
- Inside radius 0.126 in (3.2004 mm); K factor 0.48.
- Nine native bends: eight at 90 degrees and one at 70 degrees.
- Four rip joints in the native table.
- Hood logo height 40 mm; displayed etch-depth input 0.001 in.
- Source names EV006 and a 1 mm punch as the tooling reference. This is a design assumption, not a verified physical setup.

## Saved construction

1. Draw panel surfaces with integral wheel, grille, window, and deck openings.
2. Join the surfaces; thicken them through the native sheet-metal operation with selected bend edges.
3. Inspect the formed body and native flat together.
4. Finish the sheet-metal model.
5. Add the shallow hood-mark feature to the resulting solid. It does not update the flat pattern.

## Revision story

The original document shows a 6-inch, nominal 16-gauge mild-steel model. Its displayed thickness/radius inputs are 0.060/0.063 in and K is 0.42. The 8-inch aluminum revision changes stock and bend inputs, shortens the grille openings, raises the solid lower windshield rail, pulls in the deck opening, and increases bumper depth.

## Release checks

Verify the actual stock and tooling data, bend sequence and tool access, narrow-profile integrity, developed dimensions, export units and revision, and a separate marking definition. The saved STEP/DXF filenames identify intended configurations; filenames alone do not validate geometry.

## Capture method

Direct Onshape views and visible feature source were inspected without rewriting model geometry. The article explains the saved construction; it is not a time-stamped record of the original session. No physical manufacturing result is claimed.