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-   -   Battle of Britain Spitfire Homage (https://allmetalshaping.com/showthread.php?t=20083)

Stretch 11-06-2020 11:41 AM

Battle of Britain Spitfire Homage
 
Hi folks - it’s been a while... hope you are all ok in these strange times!

I was recently commissioned by a customer to create a kinetic Spitfire sculpture for his father’s 60th birthday. He’d seen a similar sculpture created by Richard Cresswell here in the UK. Anyway, I took a look at the project and decided I could create something similar, albeit “only” six and a half feet tall!

I’ll post all of the build pictures on here and discuss how I made it, what I learned from it and highlight one or two “mistakes” I made and how I ratified them.

Metal shaping is all about learning. I’m 53 now, and make more then my fair share of mistakes, but luckily have just enough experience to dig myself out of the hole I dug! Sometimes it’s best to put the hammer down, put the kettle on and think, think think. The solution will normally present itself, but... only after a breather to regain all rationality!

Anyway, let me start. The customer presented me with a beautiful Spitfire model, which I could use for scaling and measurements.

https://i.postimg.cc/2ykLf8b4/E5-AAA...8-C7094-D5.jpg

Stretch 11-06-2020 11:44 AM

So, in the first image I’m playing with the fuselage shape. The Spit needs to look like it’s at speed in a fully banked turn. I’ve taken the dimensions from the model and transferred the data on to sheet steel. To help draw the outline, I’m using magnets and bendy thin wood...

Stretch 11-06-2020 11:50 AM

The outline is then transferred onto 0.080” aluminium, taking into account the dimensions required to make the fuselage from two halves:

https://i.postimg.cc/Bvv1yvFH/107015...C605-C2955.jpg

Stretch 11-06-2020 11:55 AM

I then cut out three blanks from 0.080” aluminium: two for the fuselage halves a third to create a central reinforcement plate, to give rigidity to the structure:

https://i.postimg.cc/nhjy14RD/1584-D...D8495-FCF4.jpgupload images

Gareth Davies 11-06-2020 11:56 AM

Subscribed. Will be interesting to see how this progresses.

Stretch 11-06-2020 12:10 PM

The two halves of the fuselage are placed flat together and then seam welded all of the way around. I then fully anneal both sides of the flat form. I’m using a technique I played with a while back, which for want of any better description I’m going to call pressure annealing.

A simple piece of tube - the diameter of my compressed air blow gun - is then welded to the outside edge. This will allow compressed air to blow in the centre - similar to hydroforming. Then... compressed air is blown into the two halves and - voila - the shape of the fuselage takes form. Now, and here’s the slight tricky part that’s not without some pitfallls... I use the oxy-acetylene to anneal where I want the shape to form whilst on the fly. Essentially, I’m keeping the structure under pressure with air at shop pressure (under 100 psi - yep, that low), and coax the shape to form with judicious annealing.

https://i.postimg.cc/0y9s9McM/3-C4-C...01-FC21059.jpg

Stretch 11-06-2020 12:15 PM

As you can see, a lot of the shape is already created and it’s a relatively simple process. Yes, it’s a long way from a finished article, but 80% is there and the beauty is you have two identical halves!

https://i.postimg.cc/k5QVHt1j/241927...-D12-D47-A.jpg

https://i.postimg.cc/1zrtB1X2/DF5-FC...-F6-C51527.jpg

Stretch 11-06-2020 12:22 PM

The two halves are then bandsawed apart, the welds filed off and it’s time to smooth out and refine the shape. The weapon of choice here is my trusty air planisher. I’m using an acetal upper hammer in a homemade tool. This is to avoid damage marks to the aluminium.

https://i.postimg.cc/SRNDR4Yh/8-ED55...777-C56756.jpg

https://i.postimg.cc/P5B3409W/A1-C6-...EC6-B2-A63.jpg

Stretch 11-06-2020 12:58 PM

The nose was a tricky section. The pressure forming came up short here, mostly due to the extreme amount of shape. A little traditional beating was definitely necessary...

https://i.postimg.cc/761hZCp5/520-AC...E1-D12-A49.jpg

Stretch 11-06-2020 01:01 PM

Time to get medieval on its ass! A bit of old school stump shrinking and shaping. Obviously both sides (halves) need to match...

https://i.postimg.cc/Hs9N9pCb/EAA72-...72-BB17680.jpg


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