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Learning how to build Lotus Seven replicas...together!
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PostPosted: April 12, 2012, 2:14 am 
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Joined: September 30, 2005, 1:28 am
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Location: Sunny-Okanagan, Canada, eh?!
I really don't know what this is supposed to be called.

Image

I made a die to bend the 3/4" tubes for the back/boot of the S2/S3 chassis at the required bending radius.

The die was waste-cast from styrofoam (not my best pour, but it's solid enough), and I made this device to cut the correct shape out of it for the tube. Works slick.


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PostPosted: April 12, 2012, 7:51 am 
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Joined: December 22, 2006, 2:05 pm
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That looks like a modified drill key.

I'd like to see some of your casting photos.

Did you use an old wheel for the material?

I've been wanting to do some custom pieces but have not found the time.

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PostPosted: April 12, 2012, 8:04 am 
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Location: Sunny-Okanagan, Canada, eh?!
I teach highschool shop - we have a foundry in my Metalwork class. I use aluminum from whatever cars we've stripped in my Mechanics class (ie: wheels, pistons, cylinder heads, transmissions). The aluminum gets poured into ingots and stacked, so I don't really know what was used to make this.

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PostPosted: April 12, 2012, 11:33 am 
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Joined: December 29, 2007, 10:41 pm
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Location: Vancouver, BC
That looks slick! Can i send you up some tube and bend them for me?


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PostPosted: April 12, 2012, 4:19 pm 
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Location: Sunny-Okanagan, Canada, eh?!
You can. I ain't perfect, but you can. Give me GOOD drawings.

I may try making a 1" die (4" CLR) next. Beyond that, it's hard to bend by hand. I had bought a conduit bender from Home Depot so I could do 1" .090" DOM control arms. The aluminum bender went >>>SNAP<<< and the tube didn't even flinch.

My die to bend the wheel arches (14" Outside Radius) was just simple plywood.

I can also bend 1.5" roll bars for you too. Need any other size, buy me the die (Pro-Tools) and I'll bend them for free. :)

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PostPosted: April 12, 2012, 4:47 pm 
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Joined: November 14, 2010, 3:52 pm
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Location: Chattanooga, TN
I use a pro-tools bender with a 1.315" OD 5" CLR radius die for my buggy project. The pipe is 1" sched 40 pipe (1.315" OD, .133" wall, hot rolled). That stuff doesn't bend easy compared to 1.25" OD .095" wall tube. Your creation reminds me of something a machinist friend of mine would do. I show up at his house one day and he's turning cummins straight six cam blanks, and the next day he's milling excess case material off of tractor transmissions. He's not afraid to try anything. :cheers:


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