How to - Metal shaping ?
Tue, 31 Aug 2021 16:45:26 GMT
I have it in my mind to make a letterbox for the front of our property that the kids will enjoy.My idea is to make one look like a pink Hippo.I was thinking of making it out of sheet metal possibly about 1mm thick ?? I need a fat round body and big head with an open mouth. The legs and tail I have no problems with, but how do I begin to form that sheet metal into a round shape ? My guess is I may have to do it in two halves or even possibly 4 or more ? I don't have an oxy set, so it will all have to be done with brute force and no heat.Any suggestions ??I was going to use the gaping mouth for the postman to put the mail in but thought I might be a bit cheeky and put a large vertical bum crack on the hippo and the mail can be deposited there (pun intended ).
Reply:Sand bag and hammer?Lincoln Promig 180
Reply:Whats the sandbag for ?
Reply:I don't know if anyone enforces these rules, but:2.0 Curbside Mailboxes2.1 Manufacturer SpecificationsManufacturers of all mailboxes designed and made to be erected at the edge of a roadway or curbside of a street and to be served by a carrier from a vehicle on any city route, rural route, or highway contract route must obtain approval of their products under USPS Standard 7, Mailboxes, City and Rural Curbside. To receive these construction standards and drawings or other information about the manufacture of curbside mailboxes, write to USPS Engineering (see G043 for address).2.2 Custom-Built MailboxThe local postmaster may approve a curbside mailbox constructed by a customer who, for aesthetic or other reasons, does not want to use an approved manufactured box. The custom-built box must generally meet the same standards as approved manufactured boxes for flag, size, strength, and quality of construction.
Reply:Jack: He's in Australia. Maybe rules are similar, maybe not.eyspy: Might try to find a tank of roughly the correct size to start with. Some of the tanks used by HVAC and automotive shops (the smaller refrigerant tanks in the US) are about right for a large mailbox, though the standard 20 pounders are a bit big. Sandbag is used as a soft backer. solid enough to back a hammer blow, gives enough for the metal to change shape. You can both stretch and shrink metal with practice. Key things are to keep the material soft and not to thin too much in one area. Frequent annealing may be needed. Worst case, you can cut sections out and weld in new.I am not very good at forming sheet, but have done a little and watched some true masters at work, including watching an old union tin knocker make a fool out of an 'expert' and 'experienced' professional blacksmith. (The blacksmith in question is pretty much a fool, but is actually fairly capable in some aspects of his trade... just doesn't know his limits. A mans got to know his limits)You might try a variety of hammers. Pick up as many as you can find and dress the faces to different curvatures. Smooth the faces (mine are polished to a mirror shine for copper). You can use blocks of steel or bronze as dollys, as well. Harder surface then sand, and gives more control over a smaller area. Check out a decent auto body shop-- traditional resto, not panel swappers- and watch them work.
Reply:You may want to start with some simpler metalshaping projects to begin with- making a hippo from sheet steel is going to be exercise in frustration if your a shotbag virgin. You can stretch low carbon sheet steel a LOT without need to anneal but if you can get your mits on DQ (drawing quality) sheet it'll be easier- well to stretch/shrink anyway, getting the shape you're after and a smooth finish is another thing altogether...I'd suggest a night on youtube to begin with, lots of videos showing different techniques with basic (and specialised) tools. These should get you started...[ame="http://www.youtube.com/watch?v=IGElSHzm0q8"]http://www.youtube.com/watch?v=IGElSHzm0q8[/ame][ame="http://www.youtube.com/watch?v=7-cIDfe0FfE"]http://www.youtube.com/watch?v=7-cIDfe0FfE[/ame]Prettymuch everything looks easier than it is, metalshaping more so than most. Search youtube for 'aluminium shapes John Glover' for a couple of vids about the English wheel- some good examples of bucks (a template to check the parts progress). Lots more hits from 'tuck shrinking' too
Reply:Originally Posted by enlpckJack: He's in Australia. Maybe rules are similar, maybe not.
Reply:you may want to at lea invest in a MAPP gas torch to help form the metal. MAPP gas burns hotter than propane so it heats faster.
Reply:Join metalmeet.comBest sheet metal shaping site on the netMiller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Thanks for the tips ppl, very helpful. Cheers ..
Reply:Yep Sand bag with an old blanket on top, neoprene or brass /copper faced hammers maybe a couple of bodymans dollies and be imaginative probably like you figure 3 or 4 piece construction for the main body. With that thin of steel you should be able to coldwork every thing except minor details
Reply:Originally Posted by jamlitjoin metalmeet.combest sheet metal shaping site on the net
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