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How Would You makes this?

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Stub Mandrel25/03/2012 21:35:38
4311 forum posts
292 photos

This took a little thought and a lot of patience - and several tries!

How would YOU make it?


JasonB25/03/2012 21:43:13
6435 forum posts
650 photos

Looks like its been punched out so would have to make a rectangular punch and space out a row of holes, step over for the next row and then back for the next etc.


Ian Phillips25/03/2012 22:07:00
1190 forum posts
49 photos

If this is something you have already made it appears to have had a hard life after you finished it with a distressed/crumpled look!

Its hard to tell from the picture what size it is, or what the material is. If its painted metal then the holes might be smaller than 2mm so drilling them on a milling machine would not be too onerous.

Is the material curved in two planes, like a mudguard? that would explain why the fenestration does not look to be on the centreline.


Keith Long25/03/2012 22:36:59
591 forum posts
4 photos

Think I'd look VERY seriously at photoetching.


_Paul_25/03/2012 23:47:49
543 forum posts
31 photos

Looks like brass?

I might have made a die block for the flypress perhaps not with all the holes say an inches worth then press index press..... ad infinitum


JasonB26/03/2012 07:27:42
6435 forum posts
650 photos

The bit of a metric scale in the bottom right makes it easy to see what the size is and how would you drill the rectangular holes on a mill?

Yes I thought brass as well.


Edited By JasonB on 26/03/2012 07:27:59

Ian Phillips26/03/2012 08:29:21
1190 forum posts
49 photos

I was beginning to think I had a different picture to everyone else, then I zoomed in! I am still not quite sure what we are looking at, it could be a bit of brass shim but I'm not sure what the original poster wanted to know.

Reading Neil's post again it seems like he has already made the part, in which case he posed the question as a sort of puzzle or test. It would have been better at the outset if he had said so or at least give us a some details of what we were supposed to be helping with.

I saw the metric(?) scale in the background but without knowing how far back it was it was not easy to see its size relationship to the yellow plate. Some of the holes, which I can now see are rectangular) seem to be only partly formed, or are they blocked with paint?


Ady126/03/2012 08:42:24
1564 forum posts
209 photos

Looks like its about 5cm square x 6cm

2" x 2.5" approx

and it's been fabricated....

My inital thought was wire mesh which has been painted, then blown with compressed air to maintain the holes

...but it looks like it's been fabricated...and the holes have accuracy


It's the sort of pattern you could create on a sheet of soft metal with an industrial sewing machine which was fitted with a square needle


The alternative would be to make up a die punch block of square needles kind of thing, a lot of work for one job.


There seem to be scratches on each side of the mesh block, like it's travelled across something hard so I will go with the sewing machine guess

Edited By Ady1 on 26/03/2012 09:00:51

Ady126/03/2012 09:14:41
1564 forum posts
209 photos

To do it by hand I would clamp a piece of wood on the bottom

Brass in the middle

and wire mesh on the top as a template

Then punch the holes individually with a square awl

Would take a few goes to get it right

NJH26/03/2012 16:51:28
1727 forum posts
123 photos

I would ask Neil

Brian Dickinson26/03/2012 17:55:32
62 forum posts
13 photos

Punch it but make sure the die takes the correct amount of metal otherwise if it take less than its own area you will end up with stretching.



Stub Mandrel26/03/2012 20:29:27
4311 forum posts
292 photos

Like this:

Brian is very right - the unhardened die plate got nibbled avway by the punch... hence distortion.

But by making the spacings one and two turns of the handwheel apart, it wasn't too tedious even with two annealingas and flattenings.

I called upon the spirits of copper-bashing (or at least those of my long-gone grandfather the coppersmith) and ended up with something a bit like this after some planishing:

The flash & polish makes it look worse than it is, but I may try a last anneal and planish. This is what it is meant to look like (yes I know it isn't dead to scale!):

Thing is, when painted will it look better than some wire gauze or mesh? The alternative is, as suggested, etching.


Brian Dickinson26/03/2012 21:10:54
62 forum posts
13 photos

The bits below the running board look like a Hunslet i was watching at Porthmadog yesterday shunting flat trucks onthe new line that crosses the road.


I wanted to measure it up but they said i could not as it was working!


I will have to catch it when there not looking



Edited By Brian Dickinson on 26/03/2012 21:11:14

Bogstandard227/03/2012 10:35:52
725 forum posts

An easier way would be to use a method we used for simulating rivets on litho plate.

That is using a wheel in a holder with points sticking out of it, like clock wheels, and running it up the plate, perfectly formed and perfectly straight lines of equally spaced either dimples, or holes if pressed a little too hard, all in a matter of seconds.

I think they can actually be purchased for doing jobs such as this.



Edited By Bogstandard2 on 27/03/2012 10:38:38

Cornish Jack27/03/2012 11:13:15
385 forum posts
22 photos

John (Bogs2) - those wheels are, apparently, used for imprinting patterns on cloth for cutting. Presumably available at most haberdashers - if such a thing exists nowadays!!



Bogstandard227/03/2012 12:01:43
725 forum posts


I am the original Bogs, but when I tried to access my account, the software on here made a real b***s up of it, so I couldn't access it, so had to rejoin using a different name, and I have been trying to get my avatar recognised for well over a month, but it seems like no one looks at the needs of members any more, but who cares as long as the advertising keeps pouring in and making what we want to see and do even more annoying and complicated. I can't even post links or pictures into posts like I used to be able to.

Are we going backwards?

BTW, thanks for the info, I knew we had access to them very easily many years ago, I just couldn't remember where. They would easily press through litho plate and brass shim, making those tell tale long slots.


David Clark 127/03/2012 12:23:20
2917 forum posts
100 photos
11 articles

Hi Bogstandard2

I do check Avatars.

All are passed if they are non commercial, not Wallace or Gromit or the Tea drinking monkey or similar.

regards David

Edited By David Clark 1 on 27/03/2012 12:23:39

JasonB27/03/2012 12:26:49
6435 forum posts
650 photos

Looks like you will have to get someone to take of Photo of you and Bandit and use that then Johnwink


JasonB27/03/2012 12:26:57
6435 forum posts
650 photos

Double post

Edited By JasonB on 27/03/2012 12:27:24

Ian S C27/03/2012 14:04:23
4356 forum posts
145 photos

The wheels with the star points are called tracing wheels, found in dress making equipment shops/departments. I have some (with different tooth spacing) used by leather workers, for marking stich spacing, these are made of much higher quality steel than the tin plate ones used by seamstress's. Do'nt know where, or if you can get these now, the belonged to my Grandfather, and possibly his father before that, they were leather manufacturers in Dunedin NZ up till WW2 when Grandpa retired.

Neil, what do you use under the metal as you punch the holes? Ian S C

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