Custom identical metal forming mandrels turned for a local performance engine header manufacturer.
The project: Design and fabricate display stands for some African Tribal Artifacts.
The customer called these “cotton needles”. The look similar however, the differences created a challenge. Since they would be displayed as a pair, the design had to accommodate the differences but the stands needed to look identical.
The solution was to incorporate the copper coated wire element to hold and support the darkened part of the needles so that it could be easily adjusted.
The round base made a statement almost like an exclamation point!
Cotton Needles ready for display.
Tribal mask ready for display.
This swimming pool filter clamp is no longer available. Instead of spending a small fortune and retrofitting a new filtration system the customer brought me the broken part to make one. With the cost of making the CAD model and the CNC programming was rolled into the first part the customer liked the reduced cost of a second part and elected to have us make him a spare.
Machined bosses and starting the through holes.
Quick blow off with compressed air to check progress.
Chamfering the bosses.
Hemstitching with .500 ball end mill.
Finishing the hemstitch.
Outer perimeter cut to leave a very thin attachment.
Finished part easily snaps out of the remaining material.
After some minimal deburr, another job is finished for a happy customer.
Simple modification to the alternator adjustment bracket.
Shortened the length and re-machined the end. Custom fit for a happy customer.
The challenging part is measuring all those stud locations accurately.
Machined torque plate.
Fits like a 36 finger glove!
Bolted to the head.
CAD model option 1 direct mount.
CAD model option 2. Customer chose this option.
CNC mill operation 1 completed.
Part completed in 2 operations.
Box of finished parts ready for the customer.
Finished part with mating part attached.
An o-ring holds the parts together.
A tab on the o-ring allows for ease of installation and removal.
This was an incredibly difficult project to fixture. The goal was to shorten the king pin bosses while maintaining perpendicularly to the pin centerline. By holding the king pin a 3-jaw lathe chuck clamped to the table the pin was perpendicular to the mill table. The king pin boss fit tightly and was clamped down with a bridge clamp on a bolt tightened in the set screw hole. The axle was supported with a screw jack and captured to prevent rotation. Once held properly, all that was required was simple CNC program to circumscribe the king pin. It worked fabulously!