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Old 10-07-2014, 07:03 AM
RockHillWill RockHillWill is offline
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Default T57 Bugatti Grill Build

I have WAY too many projects going on. The hand bead roller (parts on order), update power shrinker (rework actuating arm and convert to 'no-mar' dies), adapting mower deck to wife's new tractor, speedster panels and preparing for Peters class in Nashville and on and on, but once in a while something gets done.

I have been working on building a type 57 Bugatti grill for one of Jim Hery's projects and spent some time on it yesterday at the shop of David Bolding (a major contributor to the Redneck Roundup). I had previously traced the front contour while at Jim's and determined that it was not symmetrical, so it was scanned from the centerline and mirrored to complete the profile. I have a 3D scanned model of the grill, but do not have the skills or software to develop it at this point, so I used the Faro scanner at David's shop. Pictures show David setting up the scanner and picking the points. The Faro scanner exported the file in a .x_t file extension that was then inserted into Solidworks, but I found it to be VERY cumbersome the update/modify, so David saved it as a .dxf file and imported it into his water jet software and did hand modifications to achieve a half model. We cut a half pattern and matched it to the cardboard pattern and made a set of adjustments, then made a full copy on the water jet. The last photo shows the result. I will take it to my next trip to Jims and compare it to the original before continuing.

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Old 10-07-2014, 01:14 PM
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Joe Hartson Joe Hartson is offline
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Will, deck on lawn mower should be first on the list, TOP PRIORITY

I am really impressed with what you have been able to do with the water jet. Don't think there are any in my area, wish there was. Nice job on the grill.
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Old 10-07-2014, 01:21 PM
toreadorxlt toreadorxlt is offline
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nice job will. If you need help with the digital end of things let me know. you can send me the digital model (point cloud) of the grill and I can try to make sense of it.
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Old 10-07-2014, 02:16 PM
metalman sweden metalman sweden is offline
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Nice to see that you are busy!

The grill will be great!

Keep the steam up
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Old 10-08-2014, 04:26 AM
Oldnek Oldnek is offline
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it still ceases to amaze me that water was used to cut that out..............How do they get that much pressure to do the work, to slice like butter.
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Old 10-08-2014, 08:57 AM
bobadame bobadame is offline
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The water carries an abrasive powder.
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Old 10-08-2014, 11:37 AM
Mike Rouse Mike Rouse is offline
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Garnet is the abrasive.
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Old 10-08-2014, 11:58 AM
longyard longyard is offline
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Hi Will,
I hope you'll post lots more pictures. I'll be following this thread with great interest.
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Old 10-08-2014, 12:56 PM
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Impressive, for sure. However this seems to be quite a complex procedure to transfer what appears to be a good pattern to a piece of metal and cut it out. Scissors, a pencil and a bandsaw are a lot more practical for the average reader. Probably would be all done in an hour or two.

I am wondering if technology isn't crippling the craftsman in a lot of cases.
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Old 10-08-2014, 06:30 PM
RockHillWill RockHillWill is offline
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Richard, It was only tedious because each of us was unfamiliar with the process. if we had the Faro arm working correctly from the start, it would have been a 2-3 minute procedure followed by a 2-3 minute exchange to a .dxf file and the water jet work took 2.5 minutes to make the left side EXACTLY like the right side. The laying down and tracing the grill took less than one minute for a total of about 8 minutes to accomplish. In the interest of either accuracy or profit, I fail to see the down side of this approach, but I am more than casually interested in how you would achieve this same result with scissors and a band saw in under 8 minutes. Of huge interest to me was the fact that the original grill had been repaired so often that it was not symmetrical left to right and the crank hole was off center and tracing seemed to be a bit inaccurate to me so I chose this approach.

Maybe I have misunderstood, but I was assuming that the folks that buy plans for your shopdog were getting accurate CAD drawings. Will you be supplying cardboard patterns? (kidding of course)

This particular process was free as I have accumulated a great array of friends. Scissors alone are $8.

Bill, do you have a GREAT picture of the 'Bugatti' logo that would attach to this grill shell?
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