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  1. #1
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    Default FOR THE LOVE OF MDF,REDGUM and Metal,

    This hall table has been on the back burner for a long long time,a seriously long time like a few years possibly longer, I think you get the idea.
    One of those nagging ideas I wanted to try .
    I had actually started the top about a year ago

    The MDF Design test top,
    The top end rounds are 3 pieces of 32 mm MDF screwed and glued together to form a rectangle 125 mm square by 230 mm long.
    This was then mounted on to my metal lathe and turned down to a 125 mm cylinder.

    These were than mounted on a quick and dirty sled and had a rebate of 32 mm removed from one side on both end rounds.
    These are now spaced apart 1200 mm.
    Once that huge mess of MDF dust had been cleaned up ,and I could once again see my creative zone floor and walls.

    Another piece of my priced 32 mm MDF was cut down too 230mm by 1070 MM.

    These are now glued and screwed to the rounds finishing that part of the top making the top 1200 mm long overall by 230 mm wide.
    Once that was all put aside ,another piece of 6 mm mdf was cut too 230mm and stuffed in between the two rounds with yet more 32 mm to act has a spreader bar.
    The speeder bar is to create an upside down curve on the 6 mm MDF.
    If this all sounds confusing ,it was even harder for me to try and write it all down.

    Especially ,considering it’s now after dark and I’ve been drinking, well 2 mouth fulls of a cider.
    But ,if you look closely at the pics and squint you get the idea.


    So ,once that was done ,and I sat with it for quite awhile pondered it ,poked it ,thought maybe the proportions were out.
    Then concluded that I liked it .
    Job done .

    Moving right along ,well about 12 months
    Today was the MDF base Metal form day.

    For the non metal heads in the audience .
    I first needed to construct a timber (yes MDF is timber in my book [emoji849])form or Buck depending from we’re your from.
    This is used to test fit the metal panels I intend to make next to form the sculptured base.
    When I say make,these will be beaten out of either sheet steel(.8 mm or aluminium 1.2mm thick)
    The juries out on weather I should use steel or aluminium ?
    Steel is harder on my delicate beautiful body !
    Aluminium is nice and softer, but I would have to get a third party involved to weld up the panels.
    Cause I can’t weld aluminium [emoji849][emoji849]
    Tho I could learn maybe [emoji849][emoji849].


    So the base piece was cut from 18 mm MDF approval from Sal was given on the shape .
    And next the vertical spine was sketched out on, yep your good,more 18 mm MDF.
    These were then screwed together once that was done, the form ribs were started one at time, ruff sketched viewed adjusted then attached to the spine with pine blocks 100 mm apart each.
    Mirrored on both sides
    Ending with 7 ribs in total.
    Hope that all makes sense.

    The next stage will be to lay some thick paper over the form to figure out were to make the panels, and to give me a ruff paper pattern to use to cut the metal out with.
    Next stage will be beating the sheets to shape and 100 plus tests on the form (hence all this beautiful MDF sheet stuff.
    The form is just a tool to check panel shapes with!
    Then painted in high gloss black!!

    The next exciting episode will be anywhere between now and about 386 days away.
    Tho Sall is quite keen,very keen to see this done soon.
    What’s with the REDGUM all that 32 mm top was just to check visuals

    The top is going to be hacked out with blood sweet and raw cider from one large chunk or REDGUM
    O you want pictures I guess [emoji6]




    Cheers Matt,

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  3. #2
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    May 2011
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    Default

    Hi Matt, just a comment on what appears to be an interesting design, instead of trying to beat the metal into shape, try to find someone who makes car body panels. They would have an English wheel, I don't know if you know anything about them, but metal is rolled between 2 rollers and stretched/shunk acording to the wheels fitted. It would be a lot quieter for Sal too.
    Have attached a link to help you make one if you wanted to.
    https://www.instructables.com/id/Design-and-Build-an-English-Wheel/

    Kryn
    To grow old is mandatory, growing up is optional.

  4. #3
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    Default

    Quote Originally Posted by KBs PensNmore View Post
    Hi Matt, just a comment on what appears to be an interesting design, instead of trying to beat the metal into shape, try to find someone who makes car body panels. They would have an English wheel, I don't know if you know anything about them, but metal is rolled between 2 rollers and stretched/shunk acording to the wheels fitted. It would be a lot quieter for Sal too.
    Have attached a link to help you make one if you wanted to.
    https://www.instructables.com/id/Design-and-Build-an-English-Wheel/

    Kryn
    Hi Kryn,
    An English wheel has been on my Xmas list for quite a few years(that’s karma for being an atheist a).
    Your right a wheel would speed the process up a bit,but most shops who have one would rightfully not be yo interested in lending it out.
    The wheels can be damaged easily.
    I used one many years ago when I was learning to make panels as apposed to just reversing bingles which I did for quite a few years.
    So I will be going old school on this one big round log and shot bag plus forming hammers
    Then lots of planninshing.
    I take some pics
    I get Sal to take some pics my arms will be hurting [emoji849][emoji1782].

    Cheers Matt

  5. #4
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    That's why I put the link there, so you could make your own, because once people see the finished table, you going to get some orders and you'll need one then!!!!!!
    Kryn
    To grow old is mandatory, growing up is optional.

  6. #5
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    Quote Originally Posted by KBs PensNmore View Post
    That's why I put the link there, so you could make your own, because once people see the finished table, you going to get some orders and you'll need one then!!!!!!
    Kryn
    Kryn
    I’m sorry I didn’t actually check the link till after I posted my fault.
    I can be inpatient [emoji849][emoji849].
    But yes making one would be fun
    But they actually need to be incredibly stiff
    If I win lottery
    This is one is coming home


    Cheers Matt,

  7. #6
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    Due to stuff far far above my basic comprehension.
    My last post has gone faraway.

    Sunday just been ,I woke at the crack of dawn,well a little bit after the crack of dawn.
    I then proceeded to indulge myself in a bit of garden variety stimulants in the liquid form called coffee.

    After the coffee had hit the right stuff I ventured out to creative zone,an feel finally at the age of 47.5 my dearest mother will finally be proud of 5 of number 6.
    All those times I was cheated out of precious play time by my evil older siblings and made to be a dress makers manaquine while my dearest mother worked her latest New Idea pattern into reality.
    Have paid dividends .
    The MDF form is now sporting its brown paper pattern good enough for what I need to raffle trace on to some steel.
    Won’t get me any prices even at the blind school dressmaking class.



    An finally after much deep thought, I’m going to man it up ,eat great amounts of spinach ,invest in the Deep Heat factory and use steel .8 mm on the base not aluminium.
    Reason being ,as stated above I can quite happily weld steel all day long.
    Aluminium not so.
    So ,doing it in steel even tho it’s a little harder will stop me from having to farm out the welding.
    Seems a lot of metal talk for a Wood work forum [emoji849][emoji849][emoji849].

    Now on to my worst ever piece of timber mutilation , I’ve seen Five year olds produce better works.
    But ,Sunday afternoon was spent hacking this beaters stump out of was lying around including one of three small divets.


    See that’s wood work ain’t it.
    I do promise there is real timber in this hall table scouts honour[emoji1842].

    Cheers Matt,

  8. #7
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    Hi Matt, that hall stand looks a bit like the winged keel of the Australia 2.
    Glad to see that you've got a solid base for the shot bag to rest on.
    Kryn
    To grow old is mandatory, growing up is optional.

  9. #8
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    Default FOR THE LOVE OF MDF,REDGUM and Metal,

    Quote Originally Posted by KBs PensNmore View Post
    Hi Matt, that hall stand looks a bit like the winged keel of the Australia 2.
    Glad to see that you've got a solid base for the shot bag to rest on.
    Kryn

    Kryn,
    Shhhhhhh
    People might think I’m up to no good,

    It does have a winged keel kind of look too it now that you mention it [emoji6].

  10. #9
    Join Date
    Dec 2007
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    Sydney
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    Default Ewheels and metalforming.

    Love the design.
    Ive a couple of mates here in Sinny do a bit of metalforming.
    They use and sell locally made Ewheels.
    I did the pattern for them a few years back, we usually cast them in iron but mines in Al.
    H.
    Attached Images Attached Images
    Jimcracks for the rich and/or wealthy. (aka GKB '88)

  11. #10
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    Default

    Here’s some end product.
    H
    Attached Images Attached Images
    Jimcracks for the rich and/or wealthy. (aka GKB '88)

  12. #11
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    Quote Originally Posted by clear out View Post
    Love the design.
    Ive a couple of mates here in Sinny do a bit of metalforming.
    They use and sell locally made Ewheels.
    I did the pattern for them a few years back, we usually cast them in iron but mines in Al.
    H.
    Thanks Clearout,
    I would seriously love to have an English wheel.
    I’m pretty sure I remember seeing that mention about 4/5 years back.
    Am I right in thinking they go for about $4000 ish

    Cheers Matt.

  13. #12
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    I did post a bit when we made the first few.
    Its in the Metalwork Forum under foundry.
    The cost is around $4K.
    Peter Tommasini is down your way, he’s an amazing craftsman and a nice bloke also.
    The boys up here at Motorretro give classes and you can take stuff in to work on it once you get the basic skills. I don’t know if that’s available south of the border.
    They are on instagram.
    H.
    Jimcracks for the rich and/or wealthy. (aka GKB '88)

  14. #13
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    Default FOR THE LOVE OF MDF,REDGUM and Metal,

    Well today [emoji167][emoji1658]

    There was no way in hell I was going to sit out side, and start shaping the table base, anybody following the Ballarat weather forecast or actually most of Victoria will possibly understand.


    But no fear, there is still some preparations to be done,an thankfully that can be done inside my cosy DRY creative zone.
    Also this being a Wood Work forum, I better show some wood stuff right,
    Mr Bushmillar thank you for inspiring me, Mr Ian Willkie I did mine in about 1 hour ish [emoji6].

    So this is were the fun started today!
    A bumping hammer I picked up a while ago for about $30 AU (That’s one of the Hammers that you use to take a beautiful gorgeous flat piece of metal an make it look like a bag of spuds.)
    New there well over $150 these days, but mine needed a bit of TLC, the head is in the process of getting a grind and polish,the handle it came with was cracked, and had the, standard drive a nail in there to hold the head on fix[emoji849]., it’s now RIP in my creative zone bin.



    The New handle stared off from the scrap bin.
    Was cut out on the bandsaw a little bit of turning a little bit of spoke shaving a little bit of sanding and now enjoying it’s new BLO Coat.
    Not sure of the timber type it is a little light so time will tell if it stands up to job.

    Cheers Matt

  15. #14
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    Matt

    I can see this being a wonderful WIP. It seems to have everything going for it. And a wonderful sub plot (hammer restoration). Panel beating has always been a bit of a mystery to me, but I think right up your alley with your background. Looking forward to all the developments.

    Regards
    Paul
    Bushmiller;

    "Power tends to corrupt. Absolute power corrupts, absolutely!"

  16. #15
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    Matt

    On the sub plot for a moment and as a small digression I can see why we don't get any rain up this way: You blokes in Ballarat are hogging the lot! Back to the sub plot, your bumping hammer has comes up looking very cute ( I can't believe I am calling a hammer "cute"). Very shiny and very purposeful. And the timber is....? I just know you are going to put it to the intended use. Also is that an old design of hammer head as a Google search shows the new hammers looking quite different?

    Regards
    Paul
    Bushmiller;

    "Power tends to corrupt. Absolute power corrupts, absolutely!"

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