Flying Bulls P-38 at Ezell

[Michel Lemieux]

Flying Bulls P-38 at Ezell

What is that material they are using for stamping ?

Seems strong enough for small runs & easier to machine also.

Just curious....as always.

http://www.ezellaviation.com/Past%20Pages/P38/header.html

[Ztex]

Looks like it might be UHMW (ultra high molecular weight polyethylene)
Just a guess

[RMAllnutt]

What I am trying to understand is how they got the wrinkles out in this piece. If you look at the complete set of photos, it is an amazing bit of labor. I am simply stunned at the craftsmanship of these guys. I don't think I have seen its equal, other than perhaps the guys at Precision in Australia.

Cheers,
Richard

[MX304]

That could also be Delron (sp?) they are using to make the dies.

[daveymac82c]

Quite awesome stuff! I can't wait to see it back in the air.

-David

[Paul Draper]

It looks like it could be "Renboard". I've had dies made from renboard in the past to make dies for short run stampings. Works pretty good if you're stamping aluminum or other soft metals.

[Bill Greenwood]

Some of those old country boys do know a new trick or two! I was there this summer and saw how much work was going into the P-38, because it was complex and a lot had to be made from scratch.

[bdk]

What I am trying to understand is how they got the wrinkles out in this piece.

I think they are hydro-forming the basic (rough) shape and then knocking the wrinkles down/out with a wooden block and a hammer as shown in this photo:



As they knock down the wrinkles they can hydro-form more. They just go little by little.

Regarding the header tank molds, the material is a high density, machinable plastic. This was the first time we have used it for this application.

Thank you for the kind words!

Ashley

[Lynn Allen]

Regarding the header tank molds, the material is a high density, machinable plastic. This was the first time we have used it for this application.

Thank you for the kind words!

Ashley

Ashley,

Hello and welcome to the board. Keep up updates coming....

Lynn

[6trn4brn]

Sure hope the hand in the first photo is not going after the chip wrapped around that drill! Made that mistake ONCE myself

I think Delron might be a bit too soft for molding metal aroud.

[Michel Lemieux]

On the subject of......

Is the original part scanned in 3D as a base or does someone goes through the necessary pains of manual mesurements to CAD drawing from scratch

Outstanding work in any case.

Michel.

On the subject of......

Is the original part scanned in 3D as a base or does someone goes through the necessary pains of manual mesurements to CAD drawing from scratch

Outstanding work in any case.

Michel.

We have the tanks that came off the project, but there was too much corrosion. No new ones were available (with no dents anyway) so we decided to fab some new ones.

The bungs were all manually machined on a Lathe using the originals for dimensions. The end caps were spun using a machined male mold.

Using the original tanks and original blueprints, I made a solid of the tank using Autodesk Inventor. I split the model into two halves and formed a base under each half making two male molds. From there, it goes to Gibbs Cam to program the tool paths for machining the part.

Ashley

BTW: Thanks Lynn- we are getting closer!

[Michel Lemieux]

Tks for the info...and a late welcome

The cad part is also a lot of work.

Congrads one the amazing craftmanship displayed.

Michel.