Ferrari forming underway
Now that I had made a start the previous week, it was business as usual. The other three group members all had major assessments due this week so I was left by myself to work on the project, which worked out rather well. Since I had made considerable progress last week on the first two panels, I decided to start the third.
- I began again by running the metal through the English Wheel along the shorter width to get a subtle curve. I generally start with a fairly high pressure to form the shape and then work backwards if necessary. I also combine this with the nylon mallet and the sand bag to fix the edges up. The tail of the Ferrari peaks up along this curve, similar to the torus, and therefore needed to be bent to try and get the correct curve for upper part. This was a rough bend to get the process started. I'm finding that due to the methodology I've applied in my approach, I'm able to use the English Wheel for 90% of the forming. As you can see in the first image below, I used the wheels to lock the tail in, and using my hands, manually manoeuvred the correct angles. I found this to be the easiest method working with an already curved surface. As I continued, I routinely trimmed the metal to ensure the shape was in accordance with the MDF sectioned model. In the second photo you can see stresses forming in the bottom and top corners. This was a result of the pointed end of the nylon mallet and some aggressive striking into the sandbag. As the metal curves out, it also curves down towards the edge before peaking back up. I had a bit of trouble perfecting this shape as the metal really wanted to deform in the wrong places, however perseverance and patience got me there in the end.
- As you can see, I achieved the correct shape and the panel is 90% complete. I ended up taping it in place to help align with the other components, and because people kept moving around the table knocking things. Things to be worked on for this part to be completed include: file and sand the ends to remove any burrs, straighten up the bottom edge to achieve a perfect bend, hammer out the pits and imperfections right at the end, and a final sand and polish.
Seeing as I was fairly happy with the overall shape and dimensions of the bottom piece, I quickly moved onto the next connecting piece. It's weird making progress in the class and not being behind, some groups still hadn't finished the MDF model..
- This is what I was working from the previous week. It's hard to tell from the photo as the image is solid, however the metal is curved in three planes. It also might look easy as it's seemingly flat, however this probably took the longest amount of time due to the fact that there's no rigid shape to hold form, so every movement shifts every other angle of metal. Talk about frustrating.
- In the photo bottom left, the way the light hits the metal partially hides the very exact curves present. I was a tad lost figuring out how to achieve the bend in the middle without losing the curve I finally managed to create. A few times I attempted it on the English Wheel and actually lost the shape and had to re-start, however the process of working the metal gave it greater malleability which I believe helped in the end. Similar to the previous process above, I rolled the metal half way, stopped, then maintaining the curve with my hands bent the bottom down. Repeat this process for the length of the piece and was able to achieve the downward bend of the roof peak. You can also see the the bottom edge of this component is slightly raised and will be fixed next week. In addition to this, the edges need to be smoothed as well, along with a general sand and polish. The shell of the roof is really starting to take shape.
From the previous week, I would say the front windscreen was almost done. The top section was slightly raised and the edges weren't curved enough, but overall I had achieved the desired shape.
- By the time I was up to the front piece basically all my tools had been taken from other students which really slowed the process down. I also had to contend with people constantly changing the English Wheel rollers and more people in the work room (as the deadline gets closer). I managed to get on and start working the shape again. Originally I lost the uniform curves I had by attempting to tuck the centre edge down, due to the fact it's holding the force in the bend so any movement will pull the metal back into alignment. I eventually got it back with a lot of rolling and hand forming.
- Similar to the last piece, it needed additional bending to lessen the angle, which I started with the English Wheel and by hand. At this point another group which looked to have about 10 members came to my work bench and just stood in the way so I gave up for the day. The below photos show the overall progress that was made. It's clear that the windscreen piece needs a little bit more work and a few angles are off, however I was happy with the shape and the overall progress I made. I ended up leaving the pieces taped up on there so I don't have to carry them and risk squashing them. Also might help my group members see my progress whenever they start.
The way this assignment is structured, the projects all look fairly similar. One thing I've noticed and a few people have mentioned it to me as well, I seem to be the only person who has divided the section up. Everyone has opted to try and shape the whole roof section in one piece. Granted there will be no joins, to do this would be extremely difficult and wouldn't achieve the same result.
- Due to the fact I started late, I didn't have enough time to work with the roof as one piece. (Before extension was given).
- Another group who have already had an additional couple of weeks chose this method for the roof, and even with all that extra time the curves aren't as evenly shaped, the folds aren't straight and the metal has a real rough, uneven surface texture.
- When I chose this piece I made the decision it would be silly to do it in one piece as there are too many different angles and curves and folds to create one perfect component. This would also limit my ability to use the English Wheel, hence eliminating the tool to get the best result. When everyone is using the hammers I get more time on the wheel, so win win. Also the metal wasn't large enough, which is the main determining factor.
- I took the photos below of another group's roof component. I'm not sure who this belongs to or how long they've spent on it, and although it's early stages you can see the issues I've raised which reinforces my selection method. Regardless of how much they work that piece, it will never be perfect as there are too many conflicting forces acting against each other. And for this classic Ferrari, it deserves to have a smooth, contoured surface.
Just as a side note: When modern cars are made, well those that are metal and not some cheap form of plastic crap, they're normally done by means of pressed metal, as the video below shows. This is the most accurate way of achieving perfection as the male and female moulds and generally a hydraulic press leave no room for any variation. This is not to say that car bodies aren't made by hand forming any more. The second video below shows just that. However it's worth noting that the pieces they make don't have multiple conflicting angles and curves. You won't see a whole roof panel made in one go, besides the point that it wouldn't have enough strength without joints, it's not a practical shape. So I carried that methodology into my metal forming and hopefully it will pay off the next two weeks to produce an outstanding product.
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