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The punch is pressed down 0.5 mm and the angle profiles are thus formed.



The result is not so bad. However, you can see that the squeezed ends of the lower profile are slightly bent downwards.



I correct this by using a new mould and reworking the punch. In the foreground of the following picture you can see the new mould, in the background the old one. The end of the profile is now no longer pressed down into the void, but onto a stop surface.

The result is now convincing.



And this is what it looks like when the angle profiles are on top of each other



Bernhard

Hello Bernhard,

once again a clever solution from you!
Did you anneal the profiles before pressing?

Brilliant. -- Russ

Hi Bernhard
I am randomly working on a project, which in the (then!!!) youthful overconfidence originally was planned in brass. Your ingenious technique is what I would have required !

I have to realize again, that it's quite better for me to go on with my CAD attempts...

Quote from: fspg2 on July 23, 2024, 09:52:37 AMonce again a clever solution from you!
Did you anneal the profiles before pressing?

Frithjof, with the modified tool I was able to squeeze the profiles without prior annealing. Before the modification, the setting was critical. If I pressed a little too deep, the ends of the profiles were sheared off.
However, annealing is still an option for series production. I'll have to see how quickly the tool wears out. It's not hardened at the moment.

Quote from: Peter_T1958 on July 24, 2024, 12:22:40 AMI am randomly working on a project, which in the (then!!!) youthful overconfidence originally was planned in brass. Your ingenious technique is what I would have required !

Peter, a great piece! The vertical angles also seem to have been squeezed out. I'm itching to build this.

Bernhard

Quote from: Bernhard on July 17, 2024, 11:53:35 PMWith Volker's help, I'm sure I'll get somewhere.

Bernhard,

did you receive my PM? My 5 Cent so far: I used usual clear nail lacquer, diluted with acetone and then 'dropped' it in place. The boss reduces volume as the acetone evaporates. You have to push the boss a bit around or add some acetone at the edges to achieve a somewhat even surface. It may work with glossy lacquer and an air brush, too, but I think the critical point is the need for a rather big amount of applied color.

Cheers,
Volker

Clever tooling!

The ends of the stiffeners on riveted bridges were hot forged.  If you anneal the brass before forming it will work easier.

Amazing work!

Before we continue with the main girders, here is a small update on the signs on the front tower. It was already clear to me that the design of the signs was not professional because I only have modern fonts in my graphic programs. Volker quickly noticed this too, and he offered to redraw the signs and print them out on photo paper straight away.
He succeeded perfectly, as the following before/after comparison shows. The fonts and font widths are now much better.





As he recommended, I coated the signs with transparent nail varnish and then aged them with wash.



And this is what the new sign on the front foot looks like.



Thanks again, Volker!

I also made a missing part for the front tower: this is probably a protection to prevent ore from falling out of the grab onto the roof of the larry car.



Actually, the whole thing consists more or less of two U-channels. I wanted to bend these profiles 20 x 4 x 0.5 and 151 mm long from 0.5 mm sheet metal. To do this, I cut two bending grooves in the sheet metal with a 92° cutter. However, the bending then failed miserably due to the lack of a suitable bending tool.
I therefore milled the profiles from a 4 mm plate. That produced a lot of chips, but it worked right away.

Now solder the connecting plates with the resistance soldering device, ...



... and the part is finished.



The only thing missing is the paintwork.



Bernhard

Outstanding. And, as he does with everything, Volker did a beautiful job on your signs. This is the first time we've seen your model with paint, too. Nice weathering. -- Russ

Inspirational.