Million Dollar Skunksworks Kirkham

[David Kirkham]

Here you can see how we "pin and dowel" the tools together so they are perfectly aligned. We machine the "dowel" right into the steel part because the raised boss of the dowel is very delicate and can be damaged easily. In this tooling stainless, it is extremely durable.

[David Kirkham]

This is a close up of the back side of the clamp die. Even though the picture sucks, there is a hole bored into the aluminum block to accept and locate the steel clamp block.

[David Kirkham]

These are the backing blocks for the dies. There is no reason to make them from hardened steel as there is little pressure on them when you are only bending 3/4 tubing. Besides, they are heavy and hard to deal with when they are made out of solid steel. If I were going to bend a million tubes, I'd make them out of hard steel.

Incidentally, this is what they call "hard" and "soft" tooling. Soft tooling is easier to make and costs less, but doesn't last as long. "Hard" and "soft" is an industry standard term.

[Hoofa]

You'll notice the 17mm socket welded to the threaded rod, for no slip action. And the duct tape on the threads of the gas pipe handle, for maximum protection of the operator.

[David Kirkham]

Hoofa,

I sure wish I would have had thought of that years ago in Poland! It sure would have helped. Sometimes the simplest ideas are the best.

Here is a picture of Joe. He is in charge of keeping the place going while I am buried on this car.

[Hoofa]

Joe is pretty cute, but lets stick to cars n tools. I see my tube is out, What does Joe think of it?

[db replicas]

Originally Posted by David Kirkham

Here is a picture of Joe.

He sounds much taller on the telefone.

[David Kirkham]

We fiddle with the tube all the time. Notice it is right out there to keep an eye on it. When we finish with this car we will get back to other fun things.

David

[David Kirkham]

Here we are lining up the variable radius rollers. All these tools have to be held in square in place in all 3 dimensions...it can get quite tedious. If they are not lined up, the bending machine is so powerful it will simply crush the tube at worst, and leave a nasty line in it at best. Nasty lines are horrible stress raisers.

Notice the collet I made last week in place and doing its job of holding the tube in place. It also orients the tube if we need it to.