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Old 30-08-2015, 10:04 PM   #1
moonhugger
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Default Brass Work

A start with the brass work.

Hoping to get the fish mouthing done so I can solder in the colder months.

I have bought thicker walled stuff for the structural parts. I CNC machine the fish mouths using a 4mm cutter and circular interpolate with a helical path. The sizing is good and the burrs minimal.

The photos here are the just the 1/4" length to make the 4 cage halves that fit over the walkways (sawn, before and after CNC fish mouthing - about 15mins cutting for the each set up). I have made the flat faced tubes; turned on the lathe.

Quite unbelievable; about 6 meters of brass here!
Attached Images
File Type: jpg IMG_2771.jpg (94.4 KB, 100 views)
File Type: jpg IMG_2772.JPG (131.8 KB, 98 views)
File Type: jpg IMG_2773.jpg (75.0 KB, 60 views)
File Type: jpg IMG_2774.JPG (140.7 KB, 60 views)
File Type: jpg IMG_2775.jpg (166.9 KB, 94 views)
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Old 03-09-2015, 08:03 PM   #2
Eaglelover
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Nice start, seems like you have it planned out well. I will be interested in watching and learning, best of luck with your build!
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Old 03-09-2015, 09:16 PM   #3
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Thanks EL. we will see how well it is planned, I think OK. I have sketched the brass out in CAD and hope the tube lengths are good. I need to get the 3/16th tube cut, buy some brass angle and a piece (or 2) of 5/8th brass tube. Just about set then for the soldering (not too sure how that will go).

The CNC router did a good job of cutting the brass; for those that might fancy a go at cutting brass tube the program I used is attached. It is fairly self explanatory but any Q's just ask.
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File Type: zip 1-4inch tubes Milling 4MM Cutter.zip (1.4 KB, 50 views)
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Old 22-12-2015, 03:52 PM   #4
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Default Merry Xmas

A little gift to myself!
Might get to use them during the break; I will let you know.
Happy Holidays!
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File Type: jpg Plates.jpg (204.7 KB, 58 views)
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Old 22-12-2015, 08:32 PM   #5
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Default Test Assembly

is looking ok!
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File Type: jpg IMG_3075.JPG (188.1 KB, 80 views)
File Type: jpg IMG_3076.JPG (111.8 KB, 57 views)
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Old 22-12-2015, 09:07 PM   #6
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very nice.when your done you could hire them out
cheers Paul
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Old 22-12-2015, 10:18 PM   #7
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Thanks Paul.
I will take the compliment!
I am sure someone with your capability and contacts could do the same and better.

There has been concern, the aluminium plate will be too much of a heat sink. A fine balance between that and keeping its shape / preventing distortion.
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Old 05-01-2016, 07:44 AM   #8
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Default Soldering

Made a start on the soldering.
Jigs work ok for me; the thermal problems (aluminium heat sink) discussed elsewhere did not materialise although the joints next to the plates did take noticeably longer to get up to temp.
Have never soldered anything like this before but confess to having some training with silver soldering (nearly 30 years ago as an apprentice).
The frame is straight and square - that is the important thing for me.
Some of the work is not great but ok (I am happy). When I come to do the cleaning up and if I need extra heat I can slip the jigs back in to place.

I need to fish mouth more brass and make the odd angles where tubes meet 3 into 1.

The soldering torch only came in the post yesterday, it is nice - Portasol, more expensive than some but quality I think.
Attached Images
File Type: jpg IMG_3095.jpg (116.6 KB, 55 views)
File Type: jpg IMG_3096.jpg (86.7 KB, 44 views)
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File Type: jpg IMG_3102.jpg (158.1 KB, 63 views)
File Type: jpg IMG_3103.jpg (123.9 KB, 62 views)
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Old 05-01-2016, 02:48 PM   #9
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To my untrained eye, that cage looks very nice! Job well done.
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Old 05-01-2016, 07:33 PM   #10
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Default Soldering on....

I agree entirely - what a good job you're making of this. A couple of coats of undercoat and a good top coat and you'll have an Eagle frame you can trust. Keep up the good work and let's see more of your progress when you have time.

Kindest regards

Patrick
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Old 05-01-2016, 08:19 PM   #11
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Default Much Thanks

Thanks Chaps.
Didn't want to keep photo bombing....but
very happy with the way things are going, the vertical tubes went in well and managed to make a start on the cross bracing.
I was quite nervous about the soldering, it is alright.
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Old 06-01-2016, 03:41 PM   #12
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Just ordered my next round of brass from Noggin End
Mike there is very helpful, I recommend.
http://www.nogginend.com/

Julian
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Old 06-01-2016, 07:09 PM   #13
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Default Well this is an effort.................

The cross bracing is going to take some time!
Only 14 more short lengths to fish mouth!

The plans say 3/16 brass tube; anyone use resin or plastic for this?

Sorry for "over posting"; I don't mean to annoy, I am really enjoying this. I have gone from being quite nervous and wondering whether to even start this myself to being really happy working away each night and getting to play with fire. You can tell I have some time on my hands again!

When people talk about the effort when contemplating starting a 44 - it is all true but well worth it!

Thanks for looking in.

Julian
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File Type: jpg IMG_3110.JPG (164.2 KB, 38 views)
File Type: jpg IMG_3111.JPG (168.2 KB, 47 views)
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Old 07-01-2016, 09:29 PM   #14
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Default Bit the bullet.....

...and just got them done. Still an effort but Ok.

My walkways fit nicely, that is a bonus!
Walkway build....
http://www.eagletransporter.com/foru...d.php?t=160322

Still a bit to do, central 5/8's tube; some angles and a couple of tubes in the sides (and then a second assembly to make!)
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File Type: jpg IMG_3112.jpg (64.6 KB, 23 views)
File Type: jpg IMG_3114.JPG (139.1 KB, 27 views)
File Type: jpg IMG_3115.jpg (55.4 KB, 57 views)
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Old 08-01-2016, 03:01 PM   #15
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True pro....looking great..
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Old 08-01-2016, 03:14 PM   #16
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Default Don't feel bad.....

....overpost all you want J, as people will never tire of seeing lovely handiwork like this. You're putting in the hours and producing top quality cages, so you deserve a few plaudits here and there.

Happy Walkways,

Kindest regards

Patrick
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Old 13-01-2016, 08:50 PM   #17
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Default Mid-Week Update

Thanks for the kind words chaps (Pro?...not sure about that but thanks)

I have set about with the fish mouthing of another batch of brass.

Have a near full set of brass prep'd for the other frame.

Managed to get a start with the soldering CM frame and Engine Frame.
Lots of jiggery pokery with the joints of the engine frame - looks good but I might adjust one of the long inner tubes; it is less than 1mm out of square but looks wrong. It might disappear when the other angles / 3d shape comes together.

The alignment of tubes is great, tech jig works a treat. These frames obviously made on the same jigs.

Thanks for looking in.
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File Type: jpg IMG_3136.JPG (129.9 KB, 18 views)
File Type: jpg IMG_3137.JPG (114.7 KB, 12 views)
File Type: jpg IMG_3138.JPG (136.9 KB, 26 views)
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Old 17-01-2016, 03:45 PM   #18
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Default And it continues........

Todays efforts,
and along side last weeks efforts.
Another good session.
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File Type: jpg IMG_3141.JPG (102.8 KB, 26 views)
File Type: jpg IMG_3142.jpg (89.1 KB, 55 views)
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Old 17-01-2016, 11:36 PM   #19
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That's a particular skill you have there Moonhugger, a lot harder than it looks on the images I bet.
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Old 18-01-2016, 07:57 AM   #20
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Thanks Slate.
I don't know about the harder than it looks; I always thought that.........but don't think I have found that. I am lucky; I did have some training with the silver soldering of copper induction coils during my apprenticeship but that was just 1 week about 30 years ago.
It was certainly very daunting to get started, but it is a skill and already I think I am doing better now than when I started. That is what skill is, practice on top of knowledge (there is some good advice around this great site!).
I know I am really enjoying the work; it is great seeing it come together, but it is a lot of work; that last cage is about 5 hours work (fish mouthing and soldering) so far.
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