disabled modeler Posted February 13, 2015 Share Posted February 13, 2015 That is AWESOME...! You have out skilled me by a long shot. Quote Link to comment Share on other sites More sharing options...
futurattraction Posted February 13, 2015 Share Posted February 13, 2015 The work you're doing the and step-by-step process you're taking to move from Point A to B to C is mesmerizing, Ray. Will you have this, in some fashion at KC this year? I'd love to see it in person. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 13, 2015 Author Share Posted February 13, 2015 (edited) Thanks, guys. Scott, I've been thinking I'd like to show this year, as a work in progress, if they have a class for such. Is the show going to be in June, this year? Edited February 13, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 13, 2015 Author Share Posted February 13, 2015 The shape is beginning to reveal itself...knew it was in there. Slow going here, working by hand with files & sanding sticks loaded with 80 grit. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 14, 2015 Author Share Posted February 14, 2015 (edited) This project is a worthy challenge & that's what attracts me to it....to take on a difficult task & see if I can figure out how to do it well. As such, at times, it consumes my mind with thoughts of, "what's the best way to do this?". Found myself thinking about the frame this morning. Got my jigs & pieces down for the first time in over a year. The rails are long pieces & I'm thinking about what's the best way to join the sides with the tops & bottoms. I'm thinking about the heat required to join & wondering about controlling distortion & whether or not I'm going to ignite my forms in the process. It occurred to me that perhaps it would be easier to build a male forming die & bend/shape the rails over it with a hammer & caulking tools. It's the weekend & I'm off for a couple of days, so going to spend some time checking this idea out, since it's on my mind. I Need to have a frame on which to assemble the body pieces as they are completed. Edited February 14, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 14, 2015 Author Share Posted February 14, 2015 Lovely dense, hard mahogany for the frame rail forming die. Excellent guitar neck wood & had been set back for that purpose, but this is important here, now today, so it's being used for this worthy project instead. It occurred to me that my aluminum side pieces are the same width as the overall width of the kit pieces & when I bend material down the sides of the die, I'd end up with an oversized frame rail, on the outside dimensions. My plan has been to do the frame with 1/16" thick material for strength, even though that scales up to 1/2". I'm willing to make that concession, because I don't know how much this thing is going to weigh when it's all said & done. I'm not, however, willing to have visual dimensions that far oversized, when viewing the car from the side. So I still have to shave it down 1/16 on each side. Quote Link to comment Share on other sites More sharing options...
Ace-Garageguy Posted February 15, 2015 Share Posted February 15, 2015 It occurred to me that my aluminum side pieces are the same width as the overall width of the kit pieces & when I bend material down the sides of the die, I'd end up with an oversized frame rail, on the outside dimensions. Material thickness is always a consideration whenever any tooling is made for working in any material. A way to make press dies that you may not be familiar with involves sculpting your master to the exact finished dimensions you want, making a reinforced mold from a specialty toughened-epoxy tooling material, lining the inside of the mold with sheet-wax of the thickness of the sheet metal you wish to form, and making a matching mold, again with the specialty resin. This method produces a press-die in which you can accurately form metal parts, repeatedly. There's rather more to it than that (you also have to design for material "springback") but it's an interesting process. The specialty resin I've used for this purpose was manufactured by Magnolia Plastics, and was proven to be able to press 1/8 inch thick steel wheel centers for a military vehicle. We also used it to successfully reproduce an experimental copy of a Beechcraft (airplane) landing gear inner door skin, a very complex shape, in aluminum sheet, using only hand-operated presses. Here's a patent document that discusses the process in more depth, if you're interested. http://www.google.com/patents/US4601867 Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 15, 2015 Author Share Posted February 15, 2015 Most interesting Bill, thanks. I've been aware of much of what you said, in theory. Had never heard of the sheet wax procedure, though. Have done some reading on the epoxy molds. Have thought of cutting one of the 2 bodies that I have into individual panels & pouring the epoxy over them to create the dies. That would be a no-go if the epoxy cure generated enough heat to melt the body pieces. Thought provoking about being able to press aluminum skins with a hand press....humm. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 16, 2015 Author Share Posted February 16, 2015 I have the frame die figured out. All that's left is some shaping. I'm hot to see some progress down on to the side of the body. To help my visualization process, I pulled a pattern of the kit body & drew it up on the buck. Still way too fat on the side, back half of the wheel opening. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 17, 2015 Author Share Posted February 17, 2015 The tip of the lower body panel template locates the back point of the wheel arch feature line. Cut the excess material from the rear of the quarter panel. That's more like it. Re-drew the feature lines. Still quite a bit to do, but the basic shape is getting closer. Quote Link to comment Share on other sites More sharing options...
futurattraction Posted February 17, 2015 Share Posted February 17, 2015 Impressive work, Ray! I love your updates. And to answer your question from a few days ago, to the best of my knowledge, KC should be in early June. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 19, 2015 Author Share Posted February 19, 2015 Thanks, Scott. Did some refinement around the corner. Still some waver in the lines in a couple of spots. All in all, happy with it at this point. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 19, 2015 Author Share Posted February 19, 2015 Been studying these. First vids will link to a series of related vids. https://www.youtube.com/watch?v=Ktj5DWaKXYI https://www.youtube.com/watch?v=eMk-uJ35T0c This one especially is relevant to my project, in that I don't have all of the power equip as used in the above Covell vids....in miniature. This guy does it all with hammers & wood stumps. Rough it in on a stump & use the buck I'm carving for planishing & smoothing.& detail. https://www.youtube.com/watch?v=q6DfdOFRPFA Quote Link to comment Share on other sites More sharing options...
Alfalfa Posted February 20, 2015 Share Posted February 20, 2015 Very nice car, awesome build. Respect! Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 20, 2015 Author Share Posted February 20, 2015 Thank you, Alex, I truly appreciate that! Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 22, 2015 Author Share Posted February 22, 2015 Want to start practicing hammer work on sheet material while the buck is still in development. So I hollowed out some bowls for shrinking. Heading to the ace hdwre store now to see if they have anything there that I can use. . Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 22, 2015 Author Share Posted February 22, 2015 (edited) Got some .008", .016" & .032" aluminum. Domed the plastic face on a small hammer & just started emulating the techniques demonstrated in the vids I've been watching on stump shrinking. The .008 is too light....moved too easily & was not controllable. The .016 worked nicely, as did the .032 with heavier hammer blows & both pieces took a lot shape in a short amount of time. About 20 min to form both. Initial impression is that the .032 may be too thick for this project, as I'm going to have to be able to crisply define my raised feature lines in the panels, working directly on the buck with hammer & caulking tools. The .016 has surprisingly good strength in the piece I formed with it. This will be necessary so I can handle the model without damaging the body, later on. The .016 piece is the one with the most shape, laying in the smallest bowl. Time will work it all out. Edited February 22, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 22, 2015 Author Share Posted February 22, 2015 (edited) I gotta have something like this for planishing out hammer work. This thing is just way too cool! Flat roller bearing for the top wheel & the ball out of a small rod end on the other side. Edited February 22, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 23, 2015 Author Share Posted February 23, 2015 (edited) Spent some more time on the first piece of .016 from earlier. After the hardwood bucks are complete, I will be able to work a roughed in piece like this on to the buck for final accurate shape. Edited February 23, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
Twokidsnosleep Posted February 23, 2015 Share Posted February 23, 2015 Taking notes on the techniques you are using This is authentic hand hammered vehicle production I think your wood bucks will make into nice models as well! That is the woodworker in me coming out Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 24, 2015 Author Share Posted February 24, 2015 I am in a learning curve on this as well, as this is my first attempt at hammer forming. Technique is slowly developing with practice & research. Here's another very good video on hammer forming panels without the use of industrial power equipment. https://www.youtube.com/watch?v=KIpOhz0uGRM Quote Link to comment Share on other sites More sharing options...
bobthehobbyguy Posted February 24, 2015 Share Posted February 24, 2015 Great tutorial on the process. Just curious on how you are going to join the pieces. I've seen Wingroves work and he uses copper or brass so it can be soldered. Quote Link to comment Share on other sites More sharing options...
Ognib Posted February 24, 2015 Author Share Posted February 24, 2015 (edited) Thanks, Bob. My plan is to tig it together. This is a 1:4 Ferrari body in aluminum. They tigged it together...you can still see traces of the weld lines on the quarter panel top, where they're in the process of metal finishing it. More pics of this body in the early part of this thread. Here's a vid of a guy tigging on a .003" soda can. https://www.youtube.com/watch?v=eX_sepp9T_M I've considered going to brass on this & read a lot of what Wingrove has written about his work. He has had to invest in good resistance soldering equipment in order to add pieces to a project, without previously soldered pieces coming loose from the heat. I welded on steel bodies, daily, with mig & torch for over 30 yrs before retiring, so actually feel most comfortable with that approach to this project. Edited February 24, 2015 by Ognib Quote Link to comment Share on other sites More sharing options...
vintagercr Posted February 25, 2015 Share Posted February 25, 2015 Ray, you are doing a very nice job Quote Link to comment Share on other sites More sharing options...
Guest Posted February 25, 2015 Share Posted February 25, 2015 Do you hace an AC, high frequency TIG welder? Quote Link to comment Share on other sites More sharing options...
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