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Member postings for Carl Wilson 4

Here is a list of all the postings Carl Wilson 4 has made in our forums. Click on a thread name to jump to the thread.

Thread: Turning aluminium
15/07/2017 21:48:45
Cheers for that. Going to do that once I'm back from the outlaws.
Thread: Corrosive liquids. ...................................
15/07/2017 17:29:20
It's a fairly straightforward procedure to get a Home Office EPE licence. I looked into it as I was trying to get hold of some high concentration hydrogen peroxide.
Thread: Turning aluminium
15/07/2017 12:32:33
Yup.Understand the grades etc. Just ordered some CCGT inserts from APT in Glasgow, my usual go to. Will try them next week when I'm back from hols. Well, going to see the outlaws....
15/07/2017 12:03:38
Sorry Andrew and Chaps/Chapesses, forgot to say I'm using CCMT inserts.

Used these before on ally and was OK but maybe I just got lucky. My feed rate is pretty quick but I will increase it. I will try the inserts you suggest as well. Thanks!
15/07/2017 11:31:32
Greetings. Some advice please. I'm sure this has been asked before so won't waste too much of your time.

I'm turning a large diameter (150mm) piece of 6082 T6 bar. I'm getting long, spiral stringy chips that are jamming up the tool every so often.

I'm using SCLCR inserts set at centre height. Does anyone have any tips to improve my chips?
Thread: Model Engineer - Citizen Scientist
03/07/2017 16:59:51
The Engineering Council in the UK controls this sort of thing through various professional bodies.

You start off at Engineering Technician, all the way up to Chartered Engineer. Technician Engineer is somewhere in the middle. That's me.
03/07/2017 10:57:01
It's certainly true that most citizen science is of the observational kind. That said it is astonishing what you can learn from careful and attentive observation.

The BBC have a citizen science esque competition each year to identify a project and promote it. It us usually nature table level science, or something media friendly. For example one year someone won assistance with a project to see if there was anything in the optics of the claim that black clothes make the wearer appear slimmer. I know. But it has mass appeal and makes the science "fluffy" enough not to put the average viewer or listener off.

In terms of amateur engineering, great strides are being made in the design and construction of propulsion systems for launching cubesats and in the cubesats themselves. Amateur rocket engineering is quite a big thing in the US and mainland Europe.
Thread: Shop vac recommendations please
27/06/2017 22:04:37
Got a machine mart ash vac as previously stated. Works a treat. Recommend it. Also does for hoovering the car.
27/06/2017 20:39:58
I have a relatively cheap and cheerful ash vacuum cleaner from machine mart. It is robust and has good suction.

Being an ash vacuum it is designed for rough service. It sucks up swarf etc no bother.

Edited By Carl Wilson 4 on 27/06/2017 20:40:43

Thread: Sheet metal roller, ideas?
15/06/2017 21:04:47
6082 is required by the end application. Sounds like I got the term caldera totally wrong. Although I guess a volcano is a truncated cone..

Thanks Colin for your suggestion. Plenty to think about.
15/06/2017 00:26:46

Hello John,

Thanks for the information. I can get hold of a set of rolls that can cope with 2.5mm thick aluminium. So I can re-jig my design to account for the available tools (have a decent margin on safety factor) or I can use a bit of extra grunt for the extra 0.5mm.

14/06/2017 11:55:49
Very interesting about the oil cans. Nice drawings from the sheet metal book. I also worked a lot with sheet aluminium, stainless and titanium when I was an aircraft technician.

Machining the nozzle is an option as I say. I will still be making a rolled cone though which will be the close out panel for the cooling slots.

I may well have got the term "caldera" wrong. I seem to remember seeing it used to describe a truncated cone. Then again I may have imagined it. It happens.
14/06/2017 09:26:54

Thanks for all the posts. I can get a set of rolls that will cope with 2.5mm thick ally plate relatively easily. I had already considered the possibility of turning the part from a large blank, and indeed i may still do this. Just looking at all the options.


14/06/2017 02:36:44

Thank you very much for all the replies. John, it is Metal Craft I was thinking of but they don't seem to do a suitable machine. I seem to remember seeing a set of rolls that you could fit into a bench vice that could be then stowed when not in use.

Duncan, your plan is sound, however I would like to get hold of a set of rolls because I may want to do more such work in the future and also I might get my calculations wrong! It is far less embarrassing to have to go back and make another part myself than to have to ask someone else to do it again!

Ian - I think I may have used the wrong terminology. I meant that I need to fabricate a truncated cone. I looked at the caldera cones on the net and they seem to be some sort of camping stove, like a Trangia. I thought the term caldera was the name for a truncated cone shape. What my truncated cone is for is a rocket engine nozzle. It will be 3mm thick 6082 plate.

A few years ago now I was in a shipyard where a new cone shaped fairing for an azimuth thruster was made. The ship that the thruster belonged to had lost the original part in an accident involving a large submerged log off the coast of Equatorial Guinea. The fairing was made from 1 inch thick steel plate. the cone was laid out in the flat on the plate using standard sheet metal techniques. Then the pattern was profile burned out. The resulting bit of plate was then rolled in a large set of powered rolls. Once the cone was formed, it was seam welded while still in the rolls - the rolls being the perfect jig to hold the part while it was welded. Then one end of the bearings for the rolls were removed - the rolls being designed to do this - and the cone was slipped off. When I say slipped off I mean using an overhead gantry crane on to a waiting forklift. The cone must have weighed a quarter of a ton.

So I was thinking about doing this but on a much smaller scale. Although I would not weld my cone in the rolls because I think I'd like to joggle the seam and TIG weld it on both sides to get a nice strong joint. TALAT among other places recommend this type of joint in aluminium plate.

I will keep looking for a set of little rolls.

Thanks again,


13/06/2017 15:12:09

I'm looking to get hold of a sheet metal roller. I need to fabricate a caldera cone small end 100mm large end 170mm length 130mm. Wall thickness 3mm. One end of the rollers would be handy to be detachable to get the cone off once formed.

Any recommendations? I remember there is a place based in Hull makes such tools. Can't remember the name though!

Thanks in advance,

Thread: File Renovation
04/06/2017 11:53:27
Really interesting and thanks for posting.

I gained a healthy respect for files during basic engineering training at Raf Halton. The first thing we had to make was a rectangular block with all edges square, with four drilled holes, some tapped, and make studs for the tapped holes.

The Corporal instructor showed us the finished product, all nice and squared up. Then he gave us each a piece of round bar and the files....
Thread: Knowledge
03/06/2017 20:10:02
Lathework, a Complete Course, by Harold Hall, is a fantastic book. Also Harold Hall's website is a mine of information.

There are lots of great tutorials online too. I often find its easier watching someone do it over reading a description. LH Sparey's book is worth reading too. Filled with lots of little nuggets of info. One such being the use of old bearing races as parallels.
Thread: Citroen and his gears
03/06/2017 19:01:07
Yes exactly that. Each gear is selected by operating a band brake. In the later versions of these boxes (as used on buses, railcars and early diesel locomotives) the band brake was engaged by a pneumatic cylinder. Some types used hydraulics.

I remember the hiss on buses and when I used to take diesel railcars from Marylebone out to Wendover in the late 80s too. Those railcars were in their twilight years then.
03/06/2017 18:38:18
There you go SCG set up by Walter Gordon Wilson and John Davenport Siddeley. Sorry I don't mean to hijack this thread....
03/06/2017 18:31:00
So what's that gearbox from then? I love a nice gearbox. My personal favourite is the product of my namesake, the Wilson pre selector. Originally used I believe on Daimler cars. Later versions could be found in buses and diesel railcars. Listening out for the tell tale hiss as the pneumatic cylinders engaged band brakes to change gear. Also some early diesel loco's had them. Wilson's design was made by SCG or Self Changing Gears. I think they were sometimes known as "pneumo-cyclic".

Edited By Carl Wilson 4 on 03/06/2017 18:32:47

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