All MetalShaping

Go Back   All MetalShaping > General Metal Shaping Discussion > General Discussion
  Today's Posts Posts for Last 7 Days Posts for Last 14 Days  

Reply
 
Thread Tools Search this Thread Display Modes
  #1  
Old 05-12-2018, 11:54 AM
BTromblay BTromblay is offline
ADMINISTRATOR MetalShaper of the Month August 2018
 
Join Date: Oct 2015
Location: Mukwonago, Wi
Posts: 567
Default 1941 Waco UPF-7 battery box. "Its just a box"

This is battery box we had made for a customer in California. It is for a 1941 Waco UPF-7 biplane.
DSC_0961%20Waco%20UPF-7%20N32135%20cn5767%20right%20front%20taxiing%20l.jpg

This is a Waco similar to the customers airplane.

The box is mounted aft of the firewall, below the floor boards. It was designed inverted and accessible from the outside of the airplane for maintenance and battery replacement. The customer brought a old corroded box, plus I have the factory drawings for the Waco. Parts that I had formed up.
20170921_171903.jpg

The box and lid are made from .040" 5052-H32 and the structural mounts are .080" 2024-T351 aluminum. The lid and box is TIG welded together.
20170921_171925.jpg
20170921_171934.jpg

The cross "X" in the lid was done with a MDF form and Delrin tool in the Pullmax. Most of the tooling I make is out of Delrin, it is hard, easy machining, holds up well, easy to get and the most important for aircraft work, tool mark free.
20180512_111516.jpg

The lid is double seamed. It was made easy with the Baileigh magnetic brake. I was skeptical at first, about an magnetic brake, but I'm a firm believer now.
20170921_171946.jpg

Once the sub-assembly's were built, I had all the parts chromate dipped, for corrosion resistance due to possible acid from the battery. Most aircraft battery's now a days are "RG" Recumbent Gas or sealed battery's. They last longer and for the most part, don't leak.
20171005_151041.jpg
20171005_151034.jpg

The lid hold down studs are built from 4130 chrome moly and AN aircraft bolts, per the drawing. Once welded and fitted, they were Cadmium plated to a Boeing aircraft plating spec.
20171031_114326.jpg
20171031_114340.jpg

All sub-assembly's riveted together with aircraft -4 (1/8") AD rivets.
20171031_121604.jpg
20171031_121653.jpg

For the battery electrical connection. Waco designed there own connectors, which we re-produced in our CNC turning center. We had one sample connector and the drawings. The way it works, a post is threaded onto the battery terminals. The tulip shaped female piece is mounted to the box, insulated with phenolic washers. You set the battery on the lib and push it up into place. Easy.
20180509_174023.jpg
20180509_173955.jpg

It's just a box Don't you love it when someone tells you this

Thanks for looking, Bill
__________________
Bill Tromblay

"A sign of a good machinist, is one who can fix his F$@& Ups" My mentor and friend, Gil Zietz Micro Metric Machine.
Reply With Quote
  #2  
Old 05-12-2018, 12:42 PM
cliffrod cliffrod is offline
MetalShaper of the Month January 2020, March 2022
 
Join Date: Dec 2014
Location: Spartanburg, SC
Posts: 2,845
Default

Very nice box, Bill. Thanks for posting.

fwiw, I hear the "it's just a ....." quite often in my work.
__________________
AC Button II
http://CarolinaSculptureStudio.com
https://www.youtube.com/channel/UCzSYaYdis55gE-vqifzjA6A Carolina Sculpture Studio Channel
Reply With Quote
  #3  
Old 05-12-2018, 03:24 PM
dwmh dwmh is offline
MetalShaper of the Month May 2018, July 2022
 
Join Date: Aug 2015
Location: Nr Oxford UK
Posts: 659
Default

Beautiful work Bill. Time well spent.
__________________
David Hamer
Reply With Quote
  #4  
Old 05-12-2018, 04:18 PM
Gareth Davies Gareth Davies is offline
Member
 
Join Date: Aug 2012
Location: Staffordshire, England
Posts: 665
Default

Yes, nice job, and those words “it’s just a......” are very familiar. They are normally followed with “I’d do it myself if I’d got the tools”
__________________
Gareth Davies
Reply With Quote
  #5  
Old 05-12-2018, 04:35 PM
RockHillWill RockHillWill is offline
MetalShaper of the Month Jan 2019
 
Join Date: Oct 2009
Posts: 3,089
Default

I like the rivets!
__________________
Will
Reply With Quote
  #6  
Old 05-12-2018, 07:57 PM
Steve Hamilton's Avatar
Steve Hamilton Steve Hamilton is offline
ADMINISTRATOR MetalShaper of the Month Dec. '09 & May '11
 
Join Date: May 2009
Location: Fond du Lac WI.
Posts: 2,405
Default

Bill very nice quality!
I enjoy seeing all the details

Thanks for posting

Steve
__________________
Steve Hamilton
Hamilton Classics
Auto Restoration & Metalshaping
Reply With Quote
  #7  
Old 05-12-2018, 08:26 PM
MP&C's Avatar
MP&C MP&C is online now
MetalShaper of the month Feb.-11, July - 2018, Sept. 2020
 
Join Date: Mar 2010
Location: Leonardtown, MD
Posts: 1,707
Default

Beautiful work Bill!
__________________
Robert

Instagram @ mccartney_paint_and_custom

McCartney Paint and Custom YouTube channel
Reply With Quote
  #8  
Old 05-14-2018, 04:44 PM
Kevinb71 Kevinb71 is offline
Member
 
Join Date: Oct 2014
Location: South Dakota
Posts: 56
Default

Interesting method of connection. Looks like fuseholder terminals that we use. Nice work!
__________________
Kevin B
Reply With Quote
  #9  
Old 05-15-2018, 02:52 PM
bimmer1980 bimmer1980 is offline
Member
 
Join Date: Feb 2011
Location: York, PA
Posts: 38
Default

It's just a box..... yup, the words of the ignorant!

Nice work! Lot's of little details to make this box and the associated parts.

Do you have a pic of the old box?
__________________
Brad

Currently working on a new garage for the tools...
Also a member on garagejournal.com
Reply With Quote
  #10  
Old 05-15-2018, 09:31 PM
BTromblay BTromblay is offline
ADMINISTRATOR MetalShaper of the Month August 2018
 
Join Date: Oct 2015
Location: Mukwonago, Wi
Posts: 567
Default

Thanks, I will look for pictures of the old box.
__________________
Bill Tromblay

"A sign of a good machinist, is one who can fix his F$@& Ups" My mentor and friend, Gil Zietz Micro Metric Machine.
Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

All times are GMT -5. The time now is 07:01 PM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.