Friday, November 30, 2018

Cold Hammer Forming Of Sheet Metal

So when it comes to camping trailers, I have always found teardrop designs very appealing. I have one on my list, but when I get there I don't know. Over the years I have accumulated hundreds of pages of plans and pictures from around the web. A flared classic fender is a perfect match to compliment the teardrop shape, and would be my preferred design. Similar to this:

Or this.

An English Wheel or Planishing  Hammer will form these fenders, but if you don't do a lot of sheet metal forming, and would rather avoid the learning curve, and expense of one of these machines, cold hammer forming is a good option for the occasional project. I looked around the web and found a nice article on cold forming of a classic flared fender.

To download this step-by-step article click Forming Sheet Metal # 1, 256 KB - pdf.

 Above is a picture of the first page of the 12 page article. The article takes you step-by-step from a flat sheet below.

To this fully formed section of the fender.

This was all done cold working with hammers, sheet metal working chisels, and a wire form to guide the shape forming. My new 4' cold work RR anvil is perfect for this type of work. You may recall how I expanded the bottom of one of the doors on my band sawmill by cold hammering.  This gives me the idea of another improvement, round off one end for doing circular work.

Thursday, November 29, 2018

Avoiding Electrocution

No plans or books today, but browsing some of my Word docs. I figured some might find this article both enlightening and entertaining.

"Avoiding Electrocution" is a short article that I found many years ago. It was originally published in 2002 on the "Atomic" site, dealing with computer electronics. The author communicated the subject matter very well, while still being quite entertaining. Hopefully you will think so as well, I only wish I could write like that.

Early on I was taught that a live wire is much like a pipe line, Where the size of the pipe represents amperage and the pressure in the pipe represents volts. The analogy holds true here too. If you stand in front of a large pipe (high amperage) but there is low pressure in the pipe (low voltage), suddenly opening a valve will get you wet but that is about it. However if you increase the pipe press (voltage) to 120 or 240 psi, when you open that valve, they will be scraping you off the far wall, or in the case of voltage you will be lucky if you just look like the picture below.

Wednesday, November 28, 2018

"How To Make A Folding Machine For Sheet Metal Work" # 1

So here is the # 1 manual in the Workshop Equipment series " How To Make A Folding Machine For Sheet Metal Work" or in short a "brake".

When you look at it you will say "this has been uploaded before" and you would be right. The previous upload was the poor quality file I had downloaded, out of alignment, smugged, and a few pages missing.

I have cleaned it up and repackaged it. If you are collecting these, this is the preferred copy.

To download "How To Make A Folding Machine For Sheet Metal Work" # 1, go to my Books - Free Downloads page. # 69 - 4 MB - pdf.

"Jig And Fixture Design" 5th Edition

So I have uploaded a couple of books on jig and fixture design before, one older and a newer one from the 60's. Here is a recent publication more suited to todays machine set-ups and available hardware.

 "Jig And Fixture Design" 5th Edition, by Edward G. Hoffman was published in 2004, there is probably a 6th edition out now, but this edition is well into the computer age. I found this uploaded to the internet back in 2013, probably when the 6th edition came out, it is very well illustrated with many examples of modern jig and fixture designs. It was published by Delmar,Cengage Learning, a long time publisher of technical learning titles.

To download "Jigs And Fixture Design" 5th Edition go to my Books - Free Downloads page. # 68 - 8 MB - pdf, enjoy.

Tuesday, November 27, 2018

"Rust Never Stops" The Rust Belt Expands

By now most have already heard, GM is shutting down the big plant in Oshawa Ontario, and 4 plants in the US. The CEO made 29 Mil last year, the company had 3.3 Billion in profits, they blather on about how they have to switch to self driving and electric cars. Thats fine but the parts and cars have to be made and assembled somewhere and heres the catch, the insatiable greed of the top 1% has set their sights on 8 Billion in profits in the future, and to achieve that, manufacturing and assembly will have to be done off shore, where wages are still keeping people in poverty.

The Oshawa plant has existed since 1907, the original Buick was built there until GM bought it out in 1918. Over the years the Gov. has transfered billions of $'s from our pockets, through taxes, into the coffers of these companies, because they complained of going out of business, if they didn't get it. Meanwhile their top 1% kept raking in millions. Somebody came up with the bright idea that their profits would be much higher if they kept the design department and low paying call center jobs here, and moved the manufacturing and assembly jobs (the well paying working man jobs) off-shore. Greed has no loyalties.

What are they going to do when the wages start to rise and eat into their profits. They will complain to the government of these countries, whose human rights are questionable, and for a while anyway, they will keep wages down on threat of life and limb.

What happens when even these measures can't keep their greed satisfied. It's up in the air, I won't be here, but visions of a dystopian future run through my head. Something like what is represented in "The Hunger Games" or "The Handmaid's Tale".

Am I ranting more often? Forgive me. We need a solution for the ever consuming rust in this world.

Monday, November 26, 2018

"Ingenious Mechanisms" or "Mechanisms In Modern Engineering Design"?

I recently had an inquiry asking about good starting books for woodworking and metalworking, The "Sears/Craftsman" manuals and "Ingenious Mechanisms For Designers And Inventors" were referenced.

The Sears/Craftsman manuals are very good instruction on the operation of woodworking machines and power tools, but their is so much more to woodworking. "Ingenious Mechanisms" is a must for the bookshelves or digital files of inventors, designers, and machine builders, but it has nothing to do with metalworking methods. Possibly self serving (ha, ha), but I recommended reviewing the posts and downloads available on my blog, there is a wealth of information here for someone starting out.

In a reply I discovered that the greatest interest seemed to lie with machine mechanisms and design. I aim to please, so here is a write up on two sets of the best books on mechanisms out there.

"Ingenious Mechanisms For Designers And Inventors" is a classic in this field. It was first published in 1930, over the years multiple authors and volumes have been added. My set, pictured below, is a 4 volume set, published in 1967, and is the newest edition. They have always been printed by The Industrial Press Inc.

If you want to download this set here is the link to download from the Open Source Machine Tools site. I have not downloaded these so I can't vouch for quality. This link is for the first volume. Change the volume number in your address bar to download the rest.

Here is a typical page from this set.

The Russians, always competitive when it comes to the Americans, published there own classic on mechanisms. "Mechanisms In Modern Engineering Design" was published in 1970 by MIR Publishing, a Moscow publisher. It was translated into English in 1975. It would be difficult if I had to choose between the two. Ingenious Mechanisms has very complete write ups on the workings and development of the mechanisms illustrated. The Russian set has much less of a write-up on the mechanisms illustrated, but the shear number is overwhelming, close to 5000 entries.

What the heck, download both. Here is the link to the Internet Archive page, to download this set. Again I have not downloaded these (if I can get away with it, I prefer paper ha, ha) so I can't vouch for quality.

Most pages have two entries. Here is a page with a single entry.

Here is a little article I found the other day. miChelle the proprietor of this art studio got an order for a small cupola (looks like 10-12" bore). It was a rush order and they cut, shaped, welded-up and I assume lined the cupola in two days. Man this lady's got balls, and I aways thought I had balls (long time ago maybe LOL).

Sunday, November 25, 2018

Even More Gifts From Santa's Workshop

As far as giving enough time to build, we are starting to run out of time for this Xmas. Here are a couple of more children's projects, that might be just the thing for a child this Xmas.

Everyone is familiar with the "Sunset" DIY books. They published hundreds of titles over the last 40 years on every aspect of woodworking projects and home improvements. Here are a couple of projects from one of their volumes titled "Children's Furniture". It was published in 1985.

For the first project, I don't know a child that wouldn't be over the moon, to tuck in at night on this project. This race-car bed is styled after the famous Can-Am racers, and sports some authentic detailing. It's a long project with lots of cuts to complete, but it is not a difficult project to complete. I am sure the time taken will be rewarded with many woops of satisfaction.

The second set of projects today have been visited a number times before. Few children from toddler to the age of 4 or 5 can resist a ride on a rocking horse (or other favorite animal). I have posted a number of plans before, here are a couple more. The lion is a quick easy project, and brings back memories of last Sundays, rocking horse post. The horse is very detailed but surprisingly there is no carving involved, all the cuts can be made on your band saw, even the comfortable looking seat.

I included a page from "Wood" magazine on how to enlarge gridded patterns here. Instructions apply to all gridded patterns, and some may find this useful.

So the Patriots are putting up a good fight so far against the NY Jets today. The Gronk is back, if he manages to play out the rest of the season, the future might be looking up for Brady and the Patriots.

For Canadians they are playing for the Grey Cup later today in Edmonton, Go Ottawa Red-Blacks go.

More Gifts From Santa's Workshop

So today I will put up a couple of more posts on items you can make in your workshop as gifts for the young.

The first post today focuses on a couple of toboggans. If you live in Canada or any country with regular winter snow, their is no need to tell you how much fun these can be, on your favorite hill. If your not bored by my reminiscent visits to my past, I recall a past experience with a toboggan, when I was a kid, at the bottom of this post.

The two following plans come from a Patrick E. Spielman book titled "Make Your Own Sports Gear" and published in 1970 by The Bruce Publishing Company. This fine hardcover text is full of plans for sports gear. All the plans have good clear instructions and all are within the reach of most workshop enthusiasts.

Here is the cover and contents page. As always if you see something you like, and can't find the book, message me, and we will try to get it posted.

The first plan is a fast looking one person sled, quick and easy to pull back up the hill, and the shallower curve is easier to bend. 

The second plan is a full size classic style toboggan. You can get three or four people riding this sled for lots of spills and thrills. Getting that full classic bend is a little more involved, but the classic look is well worth it.

When I was 12 Santa got me a full sized toboggan for Xmas. Not far behind our house at the time, there was a small mountain of Can. Shield rock, very steep. There was a transmission tower at the top, and the maintenance company had a double track machine to pack a track up the side for access. It was a favorite sliding hill for the local kids.

The day after I got the toboggan my brother Vic and I decided to try out the hill. Now nobody ever started at the top, the last 100 yards or so was too steep for anyone but the very brave, and there were a couple of tight curves on the ride down.

We decided to start at the top, ha ha. By the time we passed the normal start point, we were flying. Half way down the hill, we come flying around the second curve and right in the middle of the track is a group of 4 kids coming up. We started yelling and waving our arms, "Get off the track", "Get off the track". Of course they froze, with there mouths agape. I managed to flip the toboggan on it's side, but the momentum still carried us into a spectacular crash. Lots of bruises, but nobody got severely hurt. One of their sleds got smashed and sadly, I looked down at our new sled, and one of the side slats was cracked and broken.

We walked home with our tail between our legs. Fortunately dad was working, so I picked the lock on his tool crib and set to repairing the toboggan. I was at the age when I was always building something, cabins, treehouses, soapbox racers, etc., which was why the lock on the tool crib, LOL.

So I removed the broken slat, trimmed the cross pieces to the new width and drilled them to accept the rope. Good as new, just skinnier. On a hard packed track we had the fastest toboggan for a long time, ha ha.

Its not broken till you can't fix it anymore LOL.

Friday, November 23, 2018

Odds And Ends 3

So I got a few minutes this morning, here are a few odds and ends pictures from some of my picture files, collected from around the web.

Here is a picture of a die to forge a mouse on the power hammer, to accompany the bear in this post Forged Bear For My Future Gates. You can go into production with this set-up, ha, ha.

Remember in the previous post I said a treadle lathe is not really an option in a small shop, well here is a picture I found that say's, "I am full of it" ha, ha. This compact treadle lathe is incorporated into a tough little bench. Not a great picture, but you get the idea.

Remember this post From Engine Block To Engine Mill. Here are a couple more pictures of the concrete lathe that I mentioned in that post.



Wednesday, November 21, 2018

Treadle Lathe Plans

So I realize there is limited interest in a item such as a treadle lathe in todays environment. My interest lies with Roy Underhill's colonial style reproduction. If you practice your hobby in a small space this is probably not an option, but if space is not a problem, one of these would be a great conversation piece, and if the power goes out, you can always spend your time turning up beautiful shapes, in the shop. No power, not a problem, ha, ha.

The first plan is a nice reproduction of Roy Underhill's lathe by Mike Adams. I found the plan of Mikes lathe on the web many years ago. Mike did a nice job of building Roy's lathe, and wrote and assembled an excellent 19 page pdf manual on the process.

To download the 590 KB pdf click  Treadle Lathe Plans

I found the second plan on the web, also many years ago. Nowhere in this 14 page pdf is the source identified. It is clearly from an older magazine, I suspect it was an older Popular Science plan. It looks like an efficient solid construction and the heavy cast concrete flywheel should do a nice job of storing energy, to even out the power output.

To download the 14 page 389 KB pdf plan click Treadle Lathe.

I have a number of other plans for treadle type lathes. The examples I have posted are a good start, I may revisit this at a later date.

So going to take a little break here, check back end of the week for more blood pumping, excitement inducing, project plans. Insert tongue-in-cheek imoji.