liam.mccaffrey
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| posted on 16/3/11 at 04:29 PM |
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Metal Shaping Question
I want to make this following dome shape. I have a couple of options for materials and I would like some opinions/advice for how best to do it
Option 1
Form it out of 1/8 Ali sheet, by far the preferred method, already have materials though my ambition may outweigh my metal shaping skill. Though
could make in sections
Option 2
Form it out of 0.9mm steel sheet, already have materials though again my ambition may outweigh my metal shaping skill. Again could make it in
sections.
Option 3
Make it out of fibre glass, easily within my capabilities but would have to purchase the material and I don't really want to make it out of
GRP
Any advice?
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designer
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| posted on 16/3/11 at 04:35 PM |
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Personally, fibreglass then foam filled for strength.
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Fred W B
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| posted on 16/3/11 at 06:02 PM |
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More or less as above, but I would make the shape first out of polyurethane foam, and then lay glass matt / resin straight over it - moldless
construction. You could get to that stage in a weekend.
Applying filler and sanding to get the finish would take a bit longer though.
If you want to make more than one, then glass for sure, make a mold from the first one and you are in business
Cheers
Fred W B
[Edited on 16/3/11 by Fred W B]
You can do it quickly. You can do it cheap. You can do it right. – Pick any two.
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Hammerhead
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| posted on 16/3/11 at 08:36 PM |
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That's made from upholstery grade pu foam, high density, with leather or vinyl upholstered to a 6mm mdf base by the look of it
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2cv
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| posted on 17/3/11 at 05:28 PM |
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Hi Liam
Nice little project. I think I'd go for your option 2 and use 0.9mm mild steel. 1/8th aluminium would be terribly difficult to form.
The steel will shape quite easily and welding should be straightforward. I'd make a station buck along the lines of the one I made for the
Clamshell Wings in the Tools and Techniques section and then decide how many pieces to make the piece in. It is best to have the joins on the curve to
avoid distortion when welding. Cut paper patterns and then mark onto the steel allowing 10 to 15mm oversize. You can put the shape in using a bossing
hammer and sandbag and then planish with a hammer and dolly. Each piece should fit nicely on the buck. Once you are satisfied, trim so that one part
buts up to the next with no gap and then tack every 25mm to prevent distortion when fully welding. Prior to fully welding, using a hammer and dolly
make sure the edges of the steel are still flush with each other and that any distortion is removed. Once welded the weld can be filed and planished
ready for finishing.
Do hope you taske the metal route and look forward to seeing your progress. Best of luck.
[Edited on 17/3/11 by 2cv]
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