Making a part for a B-17 turbocharger.
Zeuz-cat, you possess skills that are steadily disappearing from the American workforce. We need guys like you to train as many folks as possible. I'm in kind of the same situation. I have trouble finding anyone willing to listen.
Stainless steel sheet cut to shape and clamped to a jig. Pounding the exposed side to bend it 90 degrees. We use nylon, rubber coated or leather hammers to avoid seriously denting the steel and damaging it. The steel needs to shrink at the top of the curve and stretch at the bottom.
A dent that will need to be worked out.
Working the dents out with the English Wheel.
About an hour of pounding and it is starting to take shape.
We actually tried that method the last time we attempted to make these parts. We drilled strain relief holes near the bend and then cut out sections. However, we had to abandon that attempt when we realized that the mold someone else had given us was made from a part that was out of spec. My coworker kept insisting that we could make it work, but I thought it would faster to make a new mold from an original that was the right shape (photo 1). We used the part shown and made a wooden box it could sit in. We filled all the holes and corroded areas with Bondo and then greased it up. We cut Styrofoam insulation to hold it in place and then poured Quickrete vinyl patching cement into the mold. A few days later it was ready. Unfortunately, trying to form steel over concrete results in a lot of rebound when you hit it with a hammer. I then made a two dimensional form from oak which can be seen in photo 2. A plywood piece on top sandwiches the steel so you can hit it and it stays on the mold.Geometrically, it would help to remove wedges of material from the areas that need to shrink. Bend until the edges meet, weld, and then continue the shaping. Structurally and otherwise, I don't know if that's acceptable.
I assume they were stamped, but we have no capability to do stamping. We have a hydraulic press, but no forms. Besides, I doubt our press could form steel as it can only generate about 5,000 PSI, if that much. It can form aluminum, but it struggles on big pieces.Were the original parts stamped? I can't imagine that those were all hand-made for all those B-17s.....
Congratulations! Only once did I even win the collegiate teaching award. No way would I ever have gotten the university one! Well done!I won the University teaching award today. It was a total surprise.
Tonight I was telling my wife that the award comes with cash, and the first words out of her mouth were “That’ll build a big rocket.”
It doesn't sit flush against the fireplace. I am thinking magnets on the steel fireplace frame and some chains to hook onto the back of the wood frame. I just need to find some black magnets so I can move the screen and just leave the magnets on when we use the fireplace.Awesome! That looks fantastic.
How about velcro?