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 06-05-2018, 07:41 PM
BTromblay BTromblay is offline
ADMINISTRATOR MetalShaper of the Month August 2018
 
Join Date: Oct 2015
Location: Mukwonago, Wi
Posts: 567
Default Beech Debonair access panels.

Hi,

A sheet metal project for a 1960 Beechcraft Debonair. The panels are spar inspection plates that mount under the pilot and co-pilot seats. The originals were bent up, cracked and damaged from years of abuse. Not a structural component, but critical as they keep debris out of the retractable landing gear system.
20160708_155012.jpg

Both panels made out of .040" 5052-H32 aluminum.
20160709_115847.jpg
20160709_120737.jpg

It's a deep draw, about 3 inches in the deep end of the pool.

I wish I had taken more photos of the form process, but I do have a couple. I had pre-stretched the area with the Pullmax, using a urethane dock bumper and a delrin lower doming die.
20170201_192513.jpg

Once I had the general shape, I wheeled out the dish area with the E-wheel. To finish the corners, I made a 3"dia ball roller for the English wheel. I have one of Peter Tommasini english wheels and I love it. One great feature is, I can adapt the machine for many different ideas. The ball bearing allows you to roll in any direction and great for finish work.
20170201_192617.jpg
20170201_192939.jpg

The ball bearing idea is from Cass Nawrocki Book "Any impossibility in shaping metal". If you don't have the book, get one, it's a great reference to have in your shop. I have a nice planishing hammer now, which I didn't have when I formed these panels. A P hammer, would have made the corners easier, but the ball and wheel worked fine as well.

To finish the panels, once the dish area was formed and wheeled out, I tipped the edge in a bead roller and trimmed to size. I don't have any photos of that process. I can post more pictures of the urethane die in the pullmax and the 3" dia ball for the e-wheel if anyone is interested.

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 06-05-2018, 08:49 PM
Onemorehammer Onemorehammer is offline
Member
 
Join Date: Nov 2009
Location: Huntsville, Al.
Posts: 170
Default

Nice work Bill, Thanks for sharing your process, Dan
__________________
Dan Shady
Reply With Quote
  #3  
Old 06-06-2018, 01:02 AM
longyard longyard is offline
MetalShaper of the Month September 2013
 
Join Date: May 2012
Location: Winston-Salem, NC
Posts: 1,083
Default

Really nice photos and explanation. Thanks Bill
__________________
Bill Longyard
Winston-Salem, NC
Reply With Quote
  #4  
Old 06-06-2018, 06:05 AM
skintkarter skintkarter is offline
MetalShaper of the Month Nov. 2018, Jan. 2021
 
Join Date: Feb 2013
Location: Auckland New Zealand
Posts: 877
Default

Wow! Thanks for posting Bill. Really like the ball bearing idea. Does this just sit in a cup somehow?
__________________
Richard
"I know nothing. I from Barcelona" (Manuel - Fawlty Towers)
Link to our racecar project https://www.facebook.com/pages/Elan-...ab=public&view
Reply With Quote
  #5  
Old 06-06-2018, 07:08 AM
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

Hi Bill

Clean results, thanks for sharing the process

Steve
__________________
Steve Hamilton
Hamilton Classics
Auto Restoration & Metalshaping
Reply With Quote
  #6  
Old 06-06-2018, 08:40 AM
Marc Bourget Marc Bourget is offline
Member
 
Join Date: May 2013
Location: North Ca
Posts: 716
Default

More pictures, please?


What, you couldn't find replacements at your corner Beechcraft Store? hahahaha!
__________________
Marc
Reply With Quote
  #7  
Old 06-06-2018, 10:38 AM
Kevinb71 Kevinb71 is offline
Member
 
Join Date: Oct 2014
Location: South Dakota
Posts: 56
Default

Nice work Bill!
It would be great to see more pics on the Urethane die and ball bearing. Thanks for the post!
__________________
Kevin B
Reply With Quote
  #8  
Old 06-06-2018, 11:40 AM
MP&C's Avatar
MP&C MP&C is offline
MetalShaper of the month Feb.-11, July - 2018, Sept. 2020
 
Join Date: Mar 2010
Location: Leonardtown, MD
Posts: 1,707
Default

Beautiful results Bill!
__________________
Robert

Instagram @ mccartney_paint_and_custom

McCartney Paint and Custom YouTube channel
Reply With Quote
  #9  
Old 06-06-2018, 05:14 PM
Charlie Myres Charlie Myres is offline
Member
 
Join Date: Jun 2013
Location: Narrogin, Western Australia
Posts: 579
Default

Nice work Bill!

I would love to see some detail of the ball and mount please,

Cheers Charlie
__________________
Why does dust stick to everything, but nothing sticks to dust?
Reply With Quote
  #10  
Old 06-07-2018, 09:20 PM
BTromblay BTromblay is offline
ADMINISTRATOR MetalShaper of the Month August 2018
 
Join Date: Oct 2015
Location: Mukwonago, Wi
Posts: 567
Default

Hi,

The ball roller for the E-wheel is using a 3" dia ball bearing from Mc Master Carr. The holder I designed and machined, the ID matchs the ball radius for only 1/8" contact area. The ball rolls on another conventional ball bearing so only the two tangent points are touching, to reduce friction. The ball works great for finish planish work, but it is easy to put furrows in the material if you have the pressure to high.
20180607_202151.jpg

The loading dock bumper is from McMaster Carr as well, part number 9546K53. I machined an adapter to mount in my Pullmax (SMV Presses Nibbler Medium). My tooling uses a 25mm dia round shank, instead of the Pullmax square. I prefer the round as it is a fast way to make tooling. I did machine a set of square hole collets for my machine so I can run purchased Pullmax tooling in my machine as well.
20180607_202851.jpg
20180607_202903.jpg

Dan Pate gave me the idea of building a lower die holder that will accept my lower CP planish hammer dies.
20180607_202713.jpg
20180607_202729.jpg

The urethane die is a stretching Mad Man. What I like is, it is fast, but very controllable. All of the stretch is only happening in the work area, look how flat the rest of the material stays. For the spar covers, the stretched area tapers down to 3" deep. As it gets deeper, you stretch more and more, layering one stretch pass onto the next stretch pass.
20180607_203131.jpg
20180607_203138.jpg
20180607_203146.jpg
20180607_203152.jpg

It works well, and as Dan Pate says, "we have electricity, so let the machine do the work"

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
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 11:55 AM.

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