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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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Reproducing a forged part
I need to reproduce a medium sized truck part from the 40's.
The original part had steel channel supports with various bends (90, 45deg) and radii (1 in, 4 in) made of 1/8th in steel. I looks like an 'S' made of steel channel. Best I can tell is that the original parts were forged. No shop I talked to would touch the part due to cost of dies etc. They assumed that I would not spend the money (which I would have if they even produced a quote). ANyone have a source of practicle info on bending thick steel with a plug mold (correct term?) type setup? Thanks. |
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"P. Farber" wrote in message
... I need to reproduce a medium sized truck part from the 40's. The original part had steel channel supports with various bends (90, 45deg) and radii (1 in, 4 in) made of 1/8th in steel. I looks like an 'S' made of steel channel. Best I can tell is that the original parts were forged. No shop I talked to would touch the part due to cost of dies etc. They assumed that I would not spend the money (which I would have if they even produced a quote). ANyone have a source of practicle info on bending thick steel with a plug mold (correct term?) type setup? Thanks. Well, it actually sounds like a stamping, rather than a forging. Reproducing the part by any kind of forming, in 1/8" steel, with 1" radii, would involve enormous tooling expense. However, you probably can have a perfectly serviceable replacement made by weld-fabricating strips of 1/8" sheet, probably MIG-welding it together. It still isn't going to be cheap, if you need to have someone else do it all. Welding/fabricating experts no doubt will chime in here shortly and explain the practical ways to get the pieces cut, welded, and finished. BTW, what is the part, a frame cross-member? -- Ed Huntress |
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Ed Huntress wrote:
"P. Farber" wrote in message ... I need to reproduce a medium sized truck part from the 40's. The original part had steel channel supports with various bends (90, 45deg) and radii (1 in, 4 in) made of 1/8th in steel. I looks like an 'S' made of steel channel. Best I can tell is that the original parts were forged. No shop I talked to would touch the part due to cost of dies etc. They assumed that I would not spend the money (which I would have if they even produced a quote). ANyone have a source of practicle info on bending thick steel with a plug mold (correct term?) type setup? Thanks. Well, it actually sounds like a stamping, rather than a forging. Reproducing the part by any kind of forming, in 1/8" steel, with 1" radii, would involve enormous tooling expense. However, you probably can have a perfectly serviceable replacement made by weld-fabricating strips of 1/8" sheet, probably MIG-welding it together. It still isn't going to be cheap, if you need to have someone else do it all. Welding/fabricating experts no doubt will chime in here shortly and explain the practical ways to get the pieces cut, welded, and finished. BTW, what is the part, a frame cross-member? -- Ed Huntress I think Ed is on track . Weld it up . I used a 50 ton press to form 1"X2"X1/8" channel . In a more open bend with home made dies . The dies took no time to make but there was a fair bit of distortion . For my application did not matter . Luck Ken Cutt |
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I don't know where you are but You may want to check with Joe @
www.merlimfgco.com . I don't see it on his web page but he does reproduction parts for old cars and locomotives. I know him form the Capital District Blacksmiths, he host a demo for us every year. I don't know how busy he is but a phone call might work better then e-mail. Good luck Andrew V "P. Farber" wrote in message ... I need to reproduce a medium sized truck part from the 40's. The original part had steel channel supports with various bends (90, 45deg) and radii (1 in, 4 in) made of 1/8th in steel. I looks like an 'S' made of steel channel. Best I can tell is that the original parts were forged. No shop I talked to would touch the part due to cost of dies etc. They assumed that I would not spend the money (which I would have if they even produced a quote). ANyone have a source of practicle info on bending thick steel with a plug mold (correct term?) type setup? Thanks. |
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What was the part originally used for? S shaped... maybe a bracket on
the engine, or part of the suspension? In many cases you can replace complex pieces with simple flat plates, if you've no need to to look original and don't mind the extra weight. Tim. |
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On Tue, 22 Feb 2005 00:20:40 -0500, "P. Farber"
wrote: I need to reproduce a medium sized truck part from the 40's. The original part had steel channel supports with various bends (90, 45deg) and radii (1 in, 4 in) made of 1/8th in steel. I looks like an 'S' made of steel channel. Best I can tell is that the original parts were forged. No shop I talked to would touch the part due to cost of dies etc. They assumed that I would not spend the money (which I would have if they even produced a quote). ANyone have a source of practicle info on bending thick steel with a plug mold (correct term?) type setup? Thanks. Without knowing the truck part you are talking about at all (I'm guessing some sort of A-arm from the description) one way to functionally reproduce a curve in bent square tubing like that would be to fab it together as a box beam yourself. Can you throw a picture or two in the Dropbox? Have raw pieces for the sides of the curved box beam made by cutting them out of flat plate with a plasma, water-jet or laser cutter, hand bend strips of flat stock with a Hossfeld or roller bender to match the curves for the flat sides, and weld together to taste. (If it's a compound curve, both pieces would need to be CNC cut from plate, then hand bent for the flat bends.) If you do a nice job of grinding the welds, after paint they would be hard-pressed to tell it from bent tubing. And I'd guess a lot stronger than the original bent tubing of the same gauge, since the sides remain flat and parallel. Does the part really need to be curved? Or can it be simplified using cut and welded angle 'bends' on the square tubing, with gussets or fishplates to spread the load? If you need custom A-arms to get the vehicle back together and running (and are not looking for a Concours D'Elegance win for a 100% accurate restoration) that will do. Do more searching - if you come up with a way to duplicate the part easily and make their availability widely known, you could make a nice little cottage industry selling them. People ram cars into curbs and break suspension bits all the time... And someone else might have gone through the same trouble already. (One big problem with selling them, though - you need product liability insurance. Welcome to our sue-happy society.) -- Bruce -- -- Bruce L. Bergman, Woodland Hills (Los Angeles) CA - Desktop Electrician for Westend Electric - CA726700 5737 Kanan Rd. #359, Agoura CA 91301 (818) 889-9545 Spamtrapped address: Remove the python and the invalid, and use a net. |
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