STAGE A: Preparation
The main objective of the assignment is the preparation before crafting the shape: how to create an aluminum template from a real fuel tank, which has the same shape and size.
Tools: Camera, Autodesk Recap (Photogrammetry), Fusion360 Slicer, Adobe Illustrator, Laser Cutting machine, 6mm thk. plywood boards.
Step 1: Forming the group of 9 and choose one of the 3 fuel tank models.
The other 8 group members' blog links are listed below:
Moonjin Kim
Eu Gene Hyun
Louis Yu Tak Cheung
Iverson Chun Yat Chiu
Yixuan Zhang
Yihui Wang
Wing Yan Chick
Alex Sostres-Roberts
The fuel tank model we agreed to chose is Harley 883 Iron.
Step 2: After we decided the model, we need to create a same 3D digital model. As the first approach, we decided to use Autodesk Recap (Photogrammetry). We took multiple pictures of the fuel tank from different perspectives.
Step 3: After uploading the pictures into Recap, it automatically generates the pictures into a 3D model. Then I input the dimension of the real fuel tank, fix the unnecessary parts and smooth the surface.
Step 4: In order to make the template, we need to use Slicer for Fusion360 to turn the 3D model into an assembled template with multiple 2D plans. Once we convert the model into Slicer, we chose the template with 30 parts (15 horizontal & 15 vertical) later could assemble together as the same scale fuel tank model.
Step 5: We then generate the 2D sheets into PDF file, put into Adobe Illustrator and set the line weight & colour of the sheets for Laser Cut.
Laser cutting process.
All template sheets.
Step 6: Following the assembly instructions, we assembled the parts together. The interlocking space is quite tight, so we used a soft melee to gently hammer the pieces together.
Assemble progress.
Finished Plywood Fuel Tank Template
STAGE B: Dividing the Model
On this stage, each of us needs to work in a group of 3 (within the original group of 9) to make the model together.
The other 2 group members are:
Moonjin Kim
Eu Gene Hyun
Tools: Masking Tape, Marker, Knife, A3 Size Paper, Aluminum Sheets, Hand Lever Shear.
Step 1: Wrapping.
To divide the model into 3 parts for the 3 members, we use Clean Wrap to cover the model up to get a smoother and enclosed surface for pattern making.
Wrapping process.
After wrapping
Step 2: Pattern Making.
After got an enclosed model, we used paper to layer over to divide the model and get an approximation of the dimensions of the panel that each of us is going to shape.
Step 3: Cutting the Shapes.
Then we divide the paper pattern into 3 parts, including 2 longitudinal sides and 1 part cover up the top and the back. We used a marker to draw out the lines and cut the paper patterns.
As we get the aluminum sheets, we trace over the outlines with flattened paper patterns and cut off the shapes on aluminum sheets.
Tracing the shape
Shapes on sheets
Cut out the selected part with Hand Lever Shear
STAGE C: Creating the Model Part
On this stage, I am required to work individually on my selected part, craft the shape that fits with the model, and later join the parts together with 2 other members to fit together.
Tools: Aluminum sheet, Melee Hammer, English Wheel, Dolly Tool, Plywood Model Template.
Step 1: Mark out the deepest point and areas.
The shape of this part is quite similar to an irregular bowl, so I decide to use the same technique as I did in the first project. I marked out the point i need to hammer.
Step 2: Hammer the marked area to get an initial shape.
Hammering process.
Initial approach
Step 3: Curve the overall shape.
The shape of this part runs with 2 irregular curves: horizontally and vertically. the top & 2 horizontal ends have a greater gradient of curving. So I decided to use English Wheel to carve out multiple times to get the overall form.
Step 4: Repeat Step 2 & 3, measure the shape multiple times with the plywood model.
As before, we need to work back and forth multiple times the allow aluminum expand and craft patiently to achieve a better result.
Finished product
Fitting with the plywood model.
Step 5: Join the parts together and cut off unnecessary edges.
STAGE D: Polishing & Finishing Up
On the last stage, we find out the surfaces are quite lumpy because it was hard to control the hammering as its an irregular shape. We decided to polish the surface to remove the hammer marks & scratches.
Tools: Wipe, Silver Polish.
Polishing
Finish Product
