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  #46  
Old 09-14-2007, 12:10 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

I like it!

I just came in from working on my hinges. I had a revelation yesterday.
Wow ...... so obvious I don't know why I didn't think of it before. Aluminum is relatively painless to cast. You make your part out of styrofoam, take it down to the local foundry. They pack it in sand, pour in the molten aluminum and voila ..... instant part! The molten aluminum vaporizes the foam when you pour it in.

I made 16 gauge aluminum templates and then cut the foam with a hand held 6 inch hotwire with questionable success. I finally printed the layout on label paper, stuck it on the foam and just cut out the shape on the bandsaw. Overkill, maybe but it sure worked well.

I'll drop them off at the foundry over lunch tomorrow.
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  #47  
Old 09-14-2007, 10:00 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

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TMann's next car:
http://bioage.typepad.com/.shared/im...0/opelflex.png
Come to think of it, I'd like one myself.
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Kumo, is this a hint you made it to Frankfurt?
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  #48  
Old 09-14-2007, 10:07 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

TMann, make the complete foam hinge first to see if the geometry will work.

The process you're speaking of is Lost Foam. I've been familiar with it for years. It's nice to have a small foundry nearby that will do it for you. Make several of those foam pieces to select the nicest ones. Sometimes they may not be as pretty as you like. I'm sure the tensile strenght won't be a problem. They look pretty robust.
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  #49  
Old 09-14-2007, 10:33 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

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TMann, make the complete foam hinge first to see if the geometry will work.
I made them straight off of the Berkut drawings I have so as long as everything else is contoured the same (little bevel in the back edge of the canopy frame at the hinge point, etc.) I should be good.

Yeah ........ it's amazing what you remember from high school shop class.
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  #50  
Old 09-14-2007, 10:37 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

WOW Tmann - your skill with a band saw are way better than mine, i cut fat and sand to shape
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  #51  
Old 09-14-2007, 11:20 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

Yeah ..... in retrospect, I could have set up a hotwire like a bandsaw, put my template on the topside of the foam and cut.
Downside ..... it a little overkill for such a single function kind of thing.
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  #52  
Old 09-14-2007, 11:37 AM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

Thats really cool, cannot wait to see the results from the foundry.
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  #53  
Old 09-14-2007, 02:40 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

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Kumo, is this a hint you made it to Frankfurt?
Nah, I wish, I almost made it to Deggendorf in Bayern to buy a Mercedes Benz Vaneo (the van cousin of the A-Class, the 1.7 liter turbo-diesel engine of which Thielert use as the base of their Centurion aviation diesel) but reason prevailed. It would be cool to have the same engine in the car and in the plane, but, house first, new car second. I use the Renault Twingo so rarely anyway, that in the soil gathered between its tires and the curb a flower has grown and bloomed, really.
As regards the Opel Flextreme I've linked to, I'm always amazed by the amount of talent wasted in corporations like GM. Now that's the car they should be producing worldwide and first and foremost in the US, instead of their current lineup of Hummers, Tundras and related Behemoths. This is a car I'd be honored to buy, while I wouldn't be caught dead in a full-size US GM model. With Opel in Germany and Isuzu in Japan, GM have the know-how, why don't they put it to use before it's too late? How many more car manufacturing jobs can the US afford to lose?
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  #54  
Old 09-17-2007, 08:14 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

I asked the foundry to hold off on the pour until I get some new forms to them. I used some blue extruded styrofoam and cut some more shapes Saturday. The blue foam sands and machines better. Now it's just a matter of whether or not they can pour with this type of foam.

I'm hoping to have a couple of aluminum hinges by end-of-day tomorrow.
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  #55  
Old 09-17-2007, 08:50 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

Well, in either material- you've band-sawed some groovy shapes there!
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  #56  
Old 09-18-2007, 01:26 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

Quote:
As regards the Opel Flextreme I've linked to, I'm always amazed by the amount of talent wasted in corporations like GM. Now that's the car they should be producing worldwide and first and foremost in the US, instead of their current lineup of Hummers, Tundras and related Behemoths.
Sorry about drifting from TMANN's spotlight but this needs answering. GM does have great talent. Not so wasted. What's wasted, at least our view, is the beauracy and mentality brought on by a hundred years. It's amazing the mind set here. It's like another culture. Lots and lots of waste. About the cars, those behemoths sell well here in the US as long as the baby boomers are still alive. People here are not ready to buy Opel diesels here until they're forced to. The X and Y gens are catching on. With GM's engineering talent I can say there's some real exciting things coming on the horizon. I can't say more, it's GM confidential.

TMANN, castings are my gig. My ears go up when someone says cast aluminum. To think I hated metal shop in 8th grade. Keep us posted okay?
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  #57  
Old 09-18-2007, 02:56 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

That was exactly my point, after all Opel is GM, Suzuki is GM, Isuzu is GM, Saab is GM, etc. etc. The talent is there, the knowhow is there, what are they waiting for? Robocop coming to Detroit?
Sorry for diverting the thread, these are really nice hinges, can't wait to see them in Aluminum.
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  #58  
Old 09-18-2007, 06:16 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

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Sorry for diverting the thread, these are really nice hinges, can't wait to see them in Aluminum.
Well ....... I just got back from the foundry and I wish it had gone better. The hinges poured okay but they distorted some. They had a tendancy to twist.
Sooooooo .......... back to the bandsaw. This time I'll make them out of wood so they can make a clam shell type of mold from my form. The hinges they cast cold have been straightened on a press but I don't want to chance it.

The casting process they used seemed pretty cool but the "C" shape along with the thickness did not lend itself well to this process.

Hopefully, I'll have a finished product by the weekend.
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  #59  
Old 09-18-2007, 06:24 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

The carbon hinges of my canopy made by Uli Wolter show a distinct double T section, maybe that's what's needed. I imagine that would be difficult to machine, easy to cast. Want some pictures of my hinges?
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  #60  
Old 09-18-2007, 06:37 PM
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Default Re: N200LZ: Chapter 18 - Canopy Hinge

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Want some pictures of my hinges?
Sure ...... I'd never turn down information.
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