I cut a foam mock-up of the steel base. I needed that to verify the dimensions for the next step in machining, which was to cut the diameter down, leaving a small section on the outside edge for the lip. The rest will be hand shaped. I'll probably also make a pattern off the foam mock-up base to mark the actual steel hemisphere for cutting the recesses.
http://toddperkinsdesign.com/images/...ldpics/309.jpg

Incredible work and is truly art in motion. Subscribed and thanks for sharing your skills with all of us, it's very inspirational and motivating.

Your name rocks BTW :thumbsup:

Wow, thanks! :cheers: Those are encouraging words - helps one keep going through the inevitable burnout phases. :thumbsup:

I think I'm having fun now... :D



I could say the same about you! :lol: :thumbsup:

I kind of reluctantly entered my CAD workshop today, to resume work on the grille. The reluctance is because this is the kind of stuff I love doing, and hours, then days, have a way of disappearing while I'm in there. The ball-n-socket bar mounts are finished, and the bar cores can now be produced. I decided to machine them. When the ShopBot is working properly, I am able to get the accuracy I need and these will be cut from plastic, then laminated with carbon fiber, so I can keep the feed rates reasonable enough to not be on the machine forever.
http://toddperkinsdesign.com/images/...ldpics/310.jpg

The reason I am bouncing around so much is to get all the major parts sorted out and underway, so that as the car goes together there won't be anything that completely stops progress in its tracks. As I work on assembling the car, I am able to identify the needs for each area, step back and address them, then move forward a few more steps toward a roller. No matter how much planning you do, some things just can't be determined until the car becomes more of a tangible reality; like sitting in the driver's seat and thinking through actually driving a car that has never existed before. It's a really fun, rewarding, process.

Next up, the grille shell. That's where the time-space warp can occur. I'm tying a rope to my ankle; if you don't hear from me - pull... :lol:

I think the shell is also going to be cut in plastic, and then cast in aluminum, then plated. The smallest radiuses in the sockets will require an 1/8th" ball-end mill, which means it's going to take a while to cut, even in softer materials. If necessary, I'll split it into four sections (for each half, eight total) and glue them together. First I'll try separating the socket machining operations from the rest of the shell, and tricking the ShopBot into getting the job done quickly. Again, the point is to try to develop processes Columbus Idea Foundry members can use, with the available equipment; and help market its offerings and capabilities.

Holds nose, and jumps... :willy:

Coming up for air... the basic shape has been sorted out - now it's time for details!
http://toddperkinsdesign.com/images/...ldpics/311.jpg

I have to cut all the socket openings (they're in there, ready to shine), add the lower mounts, and then begin sculpting the wings for the top mount. I cannot wait to share my Todd vision for the wings and motor meter.

I might have to rethink my original plan for bolting the front and rear halves together. It was supposed to have lots of bolts in counterbored holes, running around the shell; but I don't think I want to break up the shape now. I'm thinking about having fewer, exposed, external, bolt bosses on the inside between some of the sockets. I was also supposed to bend the whole deal, but I am going to try it straight first.

Don't let the CAD model fool you either, this thing is tiny. It's only 15-1/2" tall, and 1-1/2" deep.

I taught a welding class today and my intention, afterwards, was to go out for a little R-n-R. I decided to eat first, to finally sit for a few minutes, and then opened Rhino... Needless to say, I never went out, but I did get the socket openings cut. :rolleyes: :D
http://toddperkinsdesign.com/images/...ldpics/312.jpg

I've never seen so much work on one car.... Love how it's coming together.

:thankyou: Greg! :cheers:

I'm using this opportunity to run freely in creative design to simultaneously redefine the term "OCD"! :willy: :rofl:

[QUOTE=toddshotrods;452615]We tried kinking one on a hydraulic bending and stamping machine the metalworking guy in the complex has, but it mangled one of Amanda's perfectly machined ends, so we've resorted to a good ol' pie cut. The remaining gap is intentional, to be filled with weld; and a gusset plate will be added on the inside of the bend.
http://toddperkinsdesign.com/images/...ldpics/243.jpg



I was concerned that I wasn't going to like these pieces, but really do, now that I see them on the car. I wasn't so sure I was going to like the round tubing in the mix of stamped, cast, and fabricated steel parts.

[QUOTE]

Just a thought... why not make these control arm struts using the I-beam style construction like the (former) shifter mount? That could be a more graceful shape, match the look of the LCA and fit the overall design theme.

Hey droptop! Thanks, I did consider a fabricated strut, either I-beam like the lowers or boxed sheet metal like the uppers (will ultimately be), and haven't ruled it out. I am curious to see if I can make the tubular struts look right. Basically, just challenging myself. If it doesn't work, I will tuck my tail, and start fabricating... :lol:

Some things on this project are hard to communicate as there was never a comprehensive set of art renderings. Being the owner and builder, I can see everything in my head clearly, so I just do enough art to communicate job tasks to the Team members, and verify some ideas before investing tons of time in them. Most are just byproducts of working so much in CAD. The goal for those tubular struts is to add enough gusseting and blending that they begin to take on the cast look, but still tie into the caged race theme thing.

Again, that's the bright idea - if it doesn't work, I'll be the chump with the tail stuck up his... :walkingdog: :rofl: