Todays Project - What did you do today?

[TomG]

I designed a fixture to emboss numbers into an a formed aluminum part and finally got around to making chips. It was all steel so the progress was slower than expected, but at least it's started. The fixture is a 1"x3"x8" base with a slot cut in it to hold three number dies and the part to be embossed. The three dies will be held together with a couple pieces of threaded rod and attached to the base using two thumb screws. Yet to be made are the brackets to hold and position the part and a block with a urethane insert to form the numbers. The whole fixture will be set in a hydraulic press (possibly dedicated) to form the numbers. This is a similar technique to the one I used to emboss the "Back in Black" logo in the trunk lid of my Chevelle.

Tom

[Bill Gruby]

If I have this correct Tom the metal sheet is set on that "Die" then a piece of rubber over that. Then a heavier piece of metal and the numbers are embossed when the rubber forces the thin sheet into the cavities. I think ??

"Billy G"

[Mayhem]

Greg - beautiful work on those cabinets.

Tom - interesting project. I'd like to see/hear more about the process...

[TomG]

Yes Bill, that';s how it works. Here's a pic of the trunk lid on my Chevelle that was done similarly. Hard urethane rubber and LOTS of pressure. The trunk lid took 40 tons to form and I could only do a couple letters at a time.

Tom

[TomG]

Finished the embossing fixture today and made a dry run. It did the job but as expected but left light marks between the dies. A sheet of paper placed between the dies and the aluminum sheet got rid of them so that will likely be part of the forming process. The final numbers will also be more fully formed. The sample in the pic was all my HF 12 ton press could muster, but a dedicated 40 ton press based on a couple of 20 ton bottle jacks is the next project in line. The urethane pad also expanded enough to start deforming the aluminum part so I will either need to use a harder grade or bury more of it in the steel block, or both.

Tom

[Mayhem]

That sample looks pretty good to me Tom

[TomG]

Thanks Darren. More pressure increases the size of the flat area on the letters and makes them stand out better.

Tom

[f350ca]

Started shingling the shop. Only bout 6 million more shingles to cut and nail on.

[EdK]

I see your faithful sidekick is there cracking the whip.

Ed

[TomG]

Greg,

Your shingles reminded me of a shingle sawing machine that I saw at a tractor show a couple years back and it was freaking scary. That's about a 30 inch unguarded circular saw. It worked great though. It was powered by one of the steam traction engines and they cranked out shingles by the bundle.

Tom