7/15/03.This is cold rolled steel that is straight and clean for bending aluminum.
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7/15/03.The small mill/lathe I have is not big enough to mill a 45 deg. angle the entire 8' length of the brake, so I had to make an extension to the mill bed.
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7/15/03.A tilt table is used to set the 45 deg. angle and hold the clamp beam for a 45 deg. trimming the entire length of the beam.
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7/15/03.The tilt table mounted to the bed extension to allow the work peice to clear the larger parts of the mill.
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7/15/03.This is how the 6" wide steel is mounted to the mill for milling a 45 deg. angle on one edge.
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7/15/03.These are all the machined parts which make the brake work - many thanks to Aaron Carr. It's time to start some assembly.
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7/20/03.After many hours of trimming, moving, setting up again, one-8' section is complete. One down, one to go.
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7/18/03.Here's a view from the other end with the stand to support the weight of the steel.
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8/3/03.After many hours of hand-cranking my small mill, here are the two 8' sections in place ready for welding.
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8/3/03.Here is the clamp beam welded together.
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8/3/03.After much experimenting, I found the right speed for the wire feed and the welds started to look decent.
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8/3/03.Welded from the back side, one endplate is in place per the specifications from Larry McFarland's drawings.
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8/5/03.Now in the home-stretch, I have most of the material to make the dolly.
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8/6/03.The dolly almost finished and ready for the final welds on the cross member.
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8/6/03.The dolly on wheels.
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8/15/03.A modified version of the support brackets - consists of only two parts each side of Channel.
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8/15/03.A hole is "match drilled" through the first channel into the brackets.
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8/15/03.This is the completed dolly minus some spacers inside the channel sections.
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8/16/03.I used some scrap 4" pipe for the spacers and tacked them to the back beam.
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8/16/03.The end plates welded in place with the clamp beam in place.
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8/17/03.Some of the adjustment parts installed. Also, the angle at the bottom of the end plate is supposed to be drilled and tapped and screwed to the bottom, but I chose to weld it.
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8/18/03.More parts added. I got some more steel today for the bed plate and the bending plate.
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8/20/03.Ain't that great? What's so great about that? The bed plate is on with the holes drilled and tapped and countersunk and the screws installed.
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8/21/03.A notch is required for the bed plate to miss the pivot bolt head.
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8/21/03.A view of the notch after the bedplate is installed.
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8/22/03.After installing the pivot bolts I noticed some "slop" in the movement, so I built up the bolt, then turned it down to the precise diameter.
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8/23/03.Making some serious progress. It's up to about 400 lbs. Now if I can just talk someone into helping me lift it back up.
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8/23/03.A closeup of the tension bar welding.
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8/24/03.The nose bar has been drilled, tapped and mounted to the clamp plate.
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8/24/03.The Dolly is stripped of moving parts and primed. What color does this thing want to be?
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8/25/03.How about....Green.
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8/25/03.Milling a 1/8" radius on the nose bar.
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8/30/03.The adjusting and clamping parts all in place.
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8/30/03.Done! I bent some thin and thicker aluminum with excellent results.
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7/15/03.This is cold rolled steel that is straight and clean for bending aluminum.
7/15/03.The small mill/lathe I have is not big enough to mill a 45 deg. angle the entire 8' length of the brake, so I had to make an extension to the mill bed.
7/15/03.A tilt table is used to set the 45 deg. angle and hold the clamp beam for a 45 deg. trimming the entire length of the beam.
7/15/03.The tilt table mounted to the bed extension to allow the work peice to clear the larger parts of the mill.
7/15/03.This is how the 6" wide steel is mounted to the mill for milling a 45 deg. angle on one edge.
7/15/03.These are all the machined parts which make the brake work - many thanks to Aaron Carr. It's time to start some assembly.
7/20/03.After many hours of trimming, moving, setting up again, one-8' section is complete. One down, one to go.
7/18/03.Here's a view from the other end with the stand to support the weight of the steel.
8/3/03.After many hours of hand-cranking my small mill, here are the two 8' sections in place ready for welding.
8/3/03.Here is the clamp beam welded together.
8/3/03.After much experimenting, I found the right speed for the wire feed and the welds started to look decent.
8/3/03.Welded from the back side, one endplate is in place per the specifications from Larry McFarland's drawings.
8/5/03.Now in the home-stretch, I have most of the material to make the dolly.
8/6/03.The dolly almost finished and ready for the final welds on the cross member.
8/6/03.The dolly on wheels.
8/15/03.A modified version of the support brackets - consists of only two parts each side of Channel.
8/15/03.A hole is "match drilled" through the first channel into the brackets.
8/15/03.This is the completed dolly minus some spacers inside the channel sections.
8/16/03.I used some scrap 4" pipe for the spacers and tacked them to the back beam.
8/16/03.The end plates welded in place with the clamp beam in place.
8/17/03.Some of the adjustment parts installed. Also, the angle at the bottom of the end plate is supposed to be drilled and tapped and screwed to the bottom, but I chose to weld it.
8/18/03.More parts added. I got some more steel today for the bed plate and the bending plate.
8/20/03.Ain't that great? What's so great about that? The bed plate is on with the holes drilled and tapped and countersunk and the screws installed.
8/21/03.A notch is required for the bed plate to miss the pivot bolt head.
8/21/03.A view of the notch after the bedplate is installed.
8/22/03.After installing the pivot bolts I noticed some "slop" in the movement, so I built up the bolt, then turned it down to the precise diameter.
8/23/03.Making some serious progress. It's up to about 400 lbs. Now if I can just talk someone into helping me lift it back up.
8/23/03.A closeup of the tension bar welding.
8/24/03.The nose bar has been drilled, tapped and mounted to the clamp plate.
8/24/03.The Dolly is stripped of moving parts and primed. What color does this thing want to be?
8/25/03.How about....Green.
8/25/03.Milling a 1/8" radius on the nose bar.
8/30/03.The adjusting and clamping parts all in place.
8/30/03.Done! I bent some thin and thicker aluminum with excellent results.