"Steve W." wrote in message
...
Tim Wescott wrote:
I'm working on a project (it's a visual pun -- because if you're
going to name an engine part after a body part, it should look like
the body part, right?)

Basically I'm making a model airplane muffler (of a style called a
_tongue_ muffler, hence the near-obsessive search for a solution
just to make a god-damned PUN) by soldering two aluminum shells
together (see pictures). Later I'll solder the shells to a base
that bolts to the engine. If I just make one shell a little
undersized compared to the other and squeeze them together, I have
a honkin' big seam that I'll need to fill and file to get
everything looking nice.

So I'd like to make a shell, then roll a little bead in it, then
solder everything together.

But I can't find any little bead rollers!!!

So, does anyone have any suggestions for what to do (other than
perhaps to abandon the project, or see a good shrink?) I'm
thinking that for a roller all I need are a pair of little wheels
that are machined with the correct 1/32" step, rounded to fit the
interior of the shell, running on bearings in a block and geared
together.

Does that sound about right, or is there something I'm missing?
I'd like to make the amount of squeeze between the rollers at least
somewhat adjustable -- are there any known-good ways to do that, or
is it unnecessary?

Thanks in advance.

The pictures are he

https://docs.google.com/file/d/0B5lS...jajVqTWc/edit?
usp=sharing

https://docs.google.com/file/d/0B5lS...DcllvVWs/edit?
usp=sharing


How about a bit more primitive method? Grab a pair of flat nosed
pliers and use a dremel to grind a notch in one jaw face. Then
solder a piece of correct sized round stock in place on the other
jaw. Place aluminum in jaws, squeeze and you have a bead, For
corners use needle nosed and go slow. Good use for the cheap dollar
store tools.

--
Steve W.

A blacksmith's spring fuller:
http://i1047.photobucket.com/albums/...1/702c6b1f.jpg