Aluminum fan shroud

Sheet Metal Fabrication techniques, questions and help. "Tricks of the Trade"

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Metalman
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Aluminum fan shroud

Postby Metalman » Fri Nov 29, 2013 5:24 pm

Thought the sheet metal section could use some input.
Needed a fan shroud for the table feed motor on the Bridgeport (old type), so I made one from .063 aluminum. I used a process know as hammer forming over a hard wood form. The rim of the blank is gradually shrunk down over the form to make the vented end and the return is welded on.
Attachments
blank&formed.jpg
shrinking.jpg
cap&side.jpg
weldup.jpg
finished.jpg
Ernie F.

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Metalman
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Re: Aluminum fan shroud

Postby Metalman » Fri Nov 29, 2013 5:29 pm

And here it is installed on the motor.
Attachments
installed.jpg
Ernie F.

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Re: Aluminum fan shroud

Postby Harold_V » Sat Nov 30, 2013 1:05 am

Beautiful job! Thanks for sharing.

Harold
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Metalman
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Re: Aluminum fan shroud

Postby Metalman » Sat Nov 30, 2013 12:46 pm

Thank you Harold.
The fan shroud was the finishing touch on the project of getting that old power feed system working.
I fabricated the missing parts with aid of photos you provided me 6 years ago! Better late than never.
The photos were of the center stop bracket with which the stop rod passes. Your photos:
Attachments
center-bracket-1.jpg
center-bracket.jpg
Ernie F.

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Metalman
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Re: Aluminum fan shroud

Postby Metalman » Sat Nov 30, 2013 1:05 pm

Here are some photos of the parts I had to make. Also Had to make one of the sliding clamp stops that go directly on the rod.
I suspect the roll pins you see on the rod were not original and added by a previous owner?
Attachments
HM-center.jpg
HM-center2.jpg
rodend-bracket.jpg
table-stop.jpg
Ernie F.

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warmstrong1955
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Re: Aluminum fan shroud

Postby warmstrong1955 » Sat Nov 30, 2013 4:22 pm

Your fan shroud shows some real craftsmanship!

I'm curious....what kind of hammer do you use?
(I'm assuming you use a hammer...similar tobody & fender work)

?
Bill
Today's solutions are tomorrow's problems.

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Re: Aluminum fan shroud

Postby Harold_V » Sat Nov 30, 2013 4:38 pm

Metalman wrote:I suspect the roll pins you see on the rod were not original and added by a previous owner?

The roll pins are factory installed. They ensure that you can't set the stops such that you can damage the unit by running beyond it's travel.

Harold
Wise people talk because they have something to say. Fools talk because they have to say something.

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Metalman
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Re: Aluminum fan shroud

Postby Metalman » Sat Nov 30, 2013 4:51 pm

warmstrong1955 wrote:Your fan shroud shows some real craftsmanship!

I'm curious....what kind of hammer do you use?
(I'm assuming you use a hammer...similar tobody & fender work)

?
Bill

Despite the name "hammer form" the metal is worked with a hardwood stake, picture about 1/2" X 3/4" X 6" depending on the size of the work, starting from the backup block out. The metal needs to shrink as it is worked around an outside radius. I have also used forms made from metal, hard plastic as well as hard wood and in any case the wood stake prevents stretching (and marring) the metal.
The opposite is true if the form is an inside radius, the metal needs to stretch. On that I sand an appropriate crown on the business end of the stake. The stakes get beat up from the hammering and need to be refreshed or replaced but come from scrap so no big deal.
This works for steel sheet also I have formed up to 16 gauge. I think thicker steel sheet would be a bear.
Ernie F.

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Metalman
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Re: Aluminum fan shroud

Postby Metalman » Sat Nov 30, 2013 4:59 pm

Harold_V wrote:The roll pins are factory installed. They ensure that you can't set the stops such that you can damage the unit by running beyond it's travel.
Harold

Got it. Just seems like they could have been placed to allow more safe travel (a bit wider) but likely done on the side of caution.
It has not been and is likely not going to be an issue. I replaced them as is and that is where they will stay.
Ernie F.

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ken572
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Re: Aluminum fan shroud

Postby ken572 » Sat Nov 30, 2013 5:02 pm

Ernie, :D

Beautiful Workmanship on the Fan Shroud,

as well as your replacement Center Stop Bracket

which also turned out Very Cool.. 8)

Ken. :)
One must remember.
The best learning experiences come
from working with the older Masters.
Ken.


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