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  #41  
Old 02-24-2016, 12:08 AM
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Robert, I have not used Neil Dunders louver tooling. My tries have been with home made dies without a lot of luck with louvers on a radius surface.

I like what you are doing, looks like it will probably work. Will wait to see the results you get. I really like your clamp and guide system, at some point I will build something like yours.

I really enjoy your posts and learn from them, thanks for sharing your work with us.
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  #42  
Old 02-24-2016, 09:40 AM
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Joe, was your issue with the louver trying to flatten out the crown or the corners of the punch leaving marks or ??


When we did the relatively flat hood sides, we experimented with the depth of the initial punch and found if you punch too much it tends to stretch the material being pushed through excessively where you get a nice wavy line that just ruined your efforts. Then we backed off this setting slightly, and it worked well. On this highly crowned panel, I would surmise that we could get away with and possibly need a bit more on that initial punch as we should need slightly more stretch given the louvers "wrap around" a radius in panel.

Thoughts?
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  #43  
Old 02-24-2016, 10:49 AM
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Robert, The problems with shape varied from not enough shape in the corner/ends to flat tops that didn't match of a good louver. I have to admit that I didn't spend enough time trying to resolve the problem because I wasn't for a job, I was just trying to see how radius louvers could be punched.
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  #44  
Old 02-24-2016, 06:00 PM
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Rob!
It will be interesting to see how you tackle it, I'm also thinking it may flatten the crown.
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  #45  
Old 02-25-2016, 10:25 PM
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With the wheel hub faced, the flange is trimmed...



The attachment bracket....





Pressed back together...





"test run" videos:

https://youtu.be/zsDe02QEmyo

https://youtu.be/1JB4kHLbjQc



Material clamps should be here tomorrow, so we'll try and get some louvers punched next week.
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  #46  
Old 03-01-2016, 11:01 PM
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Worked on some louvers tonight, wanted to get some practice pieces done to see how well our "theory" might fare.

Kyle cutting an inside lip off the clamp before cutting it in half..





Meanwhile I got the holes (and some spares for height adjustment) drilled in the wheel hub flange...





Clamps added...





We used a "squaring plate" to align the panel for louver angle..



The punch needed some relieving to insure the corners didn't hit the inside radius of the panel...







Cleaned up the grinder marks with a Scotchbrite pad..





Looking at the louvers...


Action shots:


https://youtu.be/EEyI10qb4BI







We have some more relieving to do on the tooling to eliminate some marking, then we'll do one more practice piece before breaking into the good stuff..
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  #47  
Old 03-01-2016, 11:39 PM
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Joe, to clarify our initial punch process, given the outward radius, we added 1/4 turn to the height adjustment. On the flat panel this much added caused the wavy punch, on this one it worked well, no waves and also didn't seem to pull in the "crown", so I'm pleased with the results..
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  #48  
Old 03-02-2016, 12:23 AM
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Robert, I am impressed with your progress and results so far, much better than I got. The pullmax dies look like that is the tool to use. I am sure you can work through the marking issues. Glad you don't have a pulling issue. Looking forward to seeing the next trial and what your results are. Thanks for showing you progress.
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  #49  
Old 03-02-2016, 09:41 PM
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Robert!

Your a engineering genius.
Those louvers turned out awesome, I was wondering how you were going to get around the tight arc with tooling, but you come up trumps.......Well done.
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  #50  
Old 03-03-2016, 06:07 PM
Charlie Myres Charlie Myres is offline
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Really nice work Robert!

An excellent example of a master-designer at work.
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