Now that you have seen the concept models it is time to get into the nuts and bolts of making this. So the first step is cutting the 16 gauge sheet metal to the proper size. This is no easy task as we do not know what the starting size is. So we cut the flat to the basic die size. These are cut in lots of 10 pieces on a friend’s shear. Then we press them. The first set of pressings will give us a basic idea how to proceed.
About now you ask why sets of 10. There is a certain amount of movement of the sheet metal on the die as no stops have been placed in yet. Using ten stampings allows us to verify the how the stamping looks. Once this initial set is completed we now adjust the size of the flat to give us the overage required we need for overlap. So there is another 10 pressings for the scrap bin. Now we look at the stamping to see where we can remove metal and if any cuts need to be made in the blank to give us the correct and proper looking final product. A master is made to work from.
At this point a flat sheet of 16 gauge is taken to the water jet people and cut for the proper shape. Again all we do is 10. Once cut they are all pressed. Now we should be very close to what we need. If the pressings are correct we then cut up the complete sheet and press the complete run. Now, as for what we do with all the extra pressings. They are used for a variety of items. Some are used for testing the amp and time settings on the spot welder.
Now onto some pictures of press operations…
This is a side view of the same set up.
Starting of the pressing cycle.
Now with both halves of the receiver pressed it is time to do the touch up work. The receivers are placed in a mandrel and all the angles tightened up and prepped for spot welding. Each set of receiver halves is clamped together with this mandrel inside to ensure that all the corners are nice and square and the angles completely formed.That is it for today. The next post will be adding the side support pieces and setting up for the first milling operation.