BEIL0014 Digital Making -- Assignment 2 Project: The 1:1 Scale Fuel Tank

  After coming back from the mid-break, the assignment 2 is released. In this project, we are required to form a group and craft a template of 1:1 scale motorcycle fuel tank. It is a big assignment and we are given more than 1 month of time to do it.

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

BEIL0014 Digital Making -- Project 4: The Blister

This is the last week's task before the break, and we were being assessed on shaping and forming the aluminum sheet into the Blister. 

Material Preparation: Aluminum Sheet, Scrap Timber, Melee Hammer, Corking Tool (from scrap timber), CNC Wood Templates of the Blister Shape.

Step 1: Before we actually began to the hammering, tutors demonstrated us to use CNC Cutting to get the wood templates of the blister shape. I chose a skinny shape and just wanted to experiment on dealing with small corners where requires corking tools. Then I crafted a customed corking tool with scrap timber for later steps.

Step 2: Clamping aluminum sheet between 2 wood templates (with the same shape), screwed and bolted the templates tightly together, so while I hammered the whole aluminum sheet would keep flat except the shape of the middle part.







 After clamping.






Step 3: After placing the prepared sheet on the sandbag, I started hammering with a small melee hammer to get a rough shape.








Step 4: After getting a rough shape, I started to hammer the corner with the corking tool to get a clear edge of the blister shape.










Step 5: Repeat Step 3 & 4 for a couple times, I crafted another smaller corking tool to get the shape of the pointy end edge of the shape. Keeps repeating the hammering process to get a fine tune for the model.







Finish Product










Model with all the tools I used.

BEIL0014 Digital Making -- Project 3: The Tray

This week's task is focused on a tray: an open box-shaped form which has radiused corners. The main technique we were using is called Hammer Forming.

Material Preparation: Aluminum Sheet, Scrap Timber, Timber Template, Steel Rule.







This time I paired with a friend to make trays together. We decided to make both trays with an aluminum sheet of 200mmx110mm, the setback is 10mm ( it is also the depth of the tray), inner radius is 15mm (by using 30mm circle timber template), so the outer radius should be 25mm (by using 50mm circle).

Step 1: Make the Hammer Forming Buck with scrap timber. Mark out the timber with the same size of the tray. Form the radius of the edge with a Disc Sander.








Step 2: Mark out the aluminum sheet with the decided dimensions. Cut the piece with Hand Lever Shear.









Step 3: Clamp the aluminum piece with 2 Hammer Forming Bucks, tight it up with Bench Vise. Using planishing hammer slowly hammer down the edges of the piece.









Step 4: While hammering, the corner of the tray is quite difficult to get even & smooth. I used a rounded surface like a dolly to smoothen the corner.








Step 5: Repeat Step 3 to form the shape and smoothen the corner.









 The result after hammering. the tray fits perfectly with hammer forming buck.








Step 6: After hammering, especially the corner of aluminum tray expanded on open edges. I decided to use File to polish the edges to make them even.










Finish Product

Join with another tray to see the match.