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  #11  
Old 03-11-2011, 01:19 PM
David Gardiner David Gardiner is offline
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Here is another back to back photo of the original shell and the one I made.


David
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  #12  
Old 03-11-2011, 01:28 PM
David Gardiner David Gardiner is offline
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So here is how I made the swage around the filler neck. As I said the shell had to be fully made and dressed out before I put this in so it had to be right first time.

I turned this tooling out of some nylon offcuts I was given a while back. It took me two attempts to get it right.


It was used in a flypress to press the swage once the hole had been cut



The swage had to be deeper at the front of the shell than at the back so it was far from straightforward.



I did a few test pieces in ally then in brass (not cheap to throw in the bin after but the only way to be sure it would work.)

I got it pretty close to what the original was.

David
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Last edited by David Gardiner; 03-11-2011 at 01:34 PM.
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  #13  
Old 03-11-2011, 02:00 PM
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Richard K Richard K is offline
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David,

Very nice way to do the top opening. What size is the final inside diameter (finished) and what size hole did you have in the blank.

I've been self studying press working of metals for last 2 years just as a matter of interest. I am seeing a lot of techniques used in punch press and their dies are very applicable to the sort of work we do. That filler neck die is a perfect example.

The results you achieve continue to fascinate me and many others. The neat part is that you are able to do so with common tools.

Thanks for sharing these valuable lessons.
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  #14  
Old 03-12-2011, 02:19 AM
Torsten Torsten is offline
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Super job you have done with the new shell David.
When I see the old shell I can't stop thinking that it could have been saved. Wasn't it possible to just replace the damaged part?
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  #15  
Old 03-12-2011, 02:58 AM
Sollis Sollis is offline
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David!
Grille shell looks very very nice man !
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  #16  
Old 03-12-2011, 04:01 PM
David Gardiner David Gardiner is offline
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Richard I will have a look at my tooling Monday and get back to you.

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  #17  
Old 03-12-2011, 04:07 PM
David Gardiner David Gardiner is offline
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Torsten, the shell would have been repairable before the other guy got hold of it. (possibly) The problem is you can do several days work and then discover that you cannot metal finish the repair because the metal is too thin. Or it can go to the polisher and he can polish through it. It is a safer bet to make a new shell.

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  #18  
Old 03-12-2011, 05:02 PM
David Gardiner David Gardiner is offline
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Sollis. Thank you! glad you like it.

David
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  #19  
Old 03-13-2011, 12:05 AM
Dyce Dyce is offline
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That's what I had in mind David. The time spent making the tool will pay you back in the future.
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  #20  
Old 03-14-2011, 05:58 AM
David Gardiner David Gardiner is offline
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Quote:
Originally Posted by Richard K View Post
David,

Very nice way to do the top opening. What size is the final inside diameter (finished) and what size hole did you have in the blank.

I've been self studying press working of metals for last 2 years just as a matter of interest. I am seeing a lot of techniques used in punch press and their dies are very applicable to the sort of work we do. That filler neck die is a perfect example.

The results you achieve continue to fascinate me and many others. The neat part is that you are able to do so with common tools.

Thanks for sharing these valuable lessons.
Richard the hole in the shell is 4 1/8" and I cut the hole at 3 1/2" but I did a test piece at 31/4" and that also pressed out OK the inner flange was longer than needed though. If I had not cut the hole first the metal would have pulled from the outside of the panel distorting it.

David
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