High-tech meets old school

[whmachine]

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IMG_5802.jpgKerry has been after me for a long time to document some of the processes we go through in building the tractor parts. Because of existing competition, every step will not be shown, but a general idea of what it takes to make a large, low crown panel that matches the factory part.
These techniques can be applied to anything, especially parts with lots of shape, reverses, and varying radii.
As the saying goes, anything can be done with time and money...

Recently, we had a request to duplicate a hood that was damaged in a engine failure situation. Original parts are very hard to find in good condition for this particular model, but we managed to locate an original to work from.

as you can see, there is quite a bit of shaping to be done. The problem area, and something we have always struggled with, is the variable radius along the edges. It blends smoothly from a 2-1/4" R to a 1-1/4" R
This part is roughly 7 feet long

[whmachine]

By the way, if you want to see what caused the damage, here is a link

https://www.youtube.com/watch?v=F7mPJj53w6U

This will be a work in progress, so be patient

[whmachine]

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hood wire.jpgThe first plan of attack is to digitize the original hood. I have experimented with several methods of digitizing over the years including, but not limited to: Kinect scanner, photogrammetry, laser, portable CMM, software that takes series of pictures and attempts to build a model, touch point probes, non- contact scanners, etc.
They all have limitations and downsides. Some are cheap, some are not. Most are laying in a corner.
For this project, we will use a contact point probe called a Proliner. I have no affiliation with this company, and am always looking for something better.
First step will be to collect the points then clean them up in another software package so a surface model can be made. This step can take several hours...

[whmachine]

once we have a good surface model, it can be sectioned for the buck to be cnc router cut out of plywood.
Since this will be a multiple part run, I wanted something precise and durable to form and planish the edges where they would be symmetrical.
I took both edges, joined them together, and created a surface for a hammerform. This will be hardwood, cut on a cnc mill, using data directly from the drawing.

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[Kerry Pinkerton]

I only understand about every third word of the technology you're describing Mike but I'm sure you now understand why we(I) were having so much trouble building that hood top with no surface information during the class I gave you and John. You've come a LONG way. Your latest tractor is a work of art!

[whmachine]

Thanks Kerry, it has been a tremendous challenge to learn all of this and apply it to a marketable product. Thanks to all of you at the meets who, knowingly or not, helped to place some of the missing links to make all this come together.

The technology is out there, the problem as I see it, there is not one software solution that will take you from gathering data to creating a buck. At least not yet. This was done using a combination of 5 different software packages, and 3 years of R&D, meaning lots of scrap, frustration, and wasted money on products that simply will not perform as advertised.

A wise man told me one time, education costs money, no matter how you get it...

[whmachine]

from the collected data, we now have an accurate buck, and a hardwood hammerform

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[whmachine]

using special inserts for wood, we can attach the panels to the hammerform, and begin the shrinking and shaping

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[whmachine]

from the buck, we can get a cut pattern, and using the english wheel, make the hood top fit the buck

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[Ken Hosford]

Wow to the Pmax color and mods .I have cursed the frame for being in the way many a time Wow