UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING, AND SPECIAL TECHNIQUES
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UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING,... Expand / Collapse
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Posted 8/26/2017 10:14:23 AM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
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I placed a copy of this post here for the benefit anyone that might be
able to use this information in planning and/or building a Bat
Vehicle.

How about adding an afterburner cold flame special effect?

Part Three: Exhaust Nozzle Basics

I received at email asking for information on nozzle designs and how
to prevent freeze up.

The two major problems he referred to are related to allowing the CO2
to exit at high speed, so any snow that forms doesn't block it up and
how to best produce turbulence in the exhaust gas/snow mix.

For many years these were problems with the CO2 fire extinguishers
until they were finally resolved in 1975 by the Brooks Equipment
Company.

Given that their CO2 exhaust nozzle design has not been improved on,
this would appear to be the best place to start when designing a Bat
Vehicle afterburner exhaust cold flame special effect.

If I were building this effect I would start with an intact CO2 fire
extinguisher horn and surround it with three-six small high intensity
lights with a mix of orange, yellow, and red filters.

The mix of colored filters and gas turbulence would give the effect a
pulsing flicker flame effect. One could even set up a pulse flicker
control on the lights themselves. The sophistication and effectiveness
of the afterburner cold flame special effect is only limited by the
user’s imagination.

Carbon dioxide fire extinguishers

Artwork: A typical carbon dioxide fire extinguisher. From US Patent
3,901,322: Fire Extinguisher Discharge Horn by Jack Winston, Brooks
Equipment Co., Inc., August 26, 1975, courtesy of US Patent and
Trademark Office. Photo-image attached.

The CO2 fire extinguisher horn is designed very carefully to stop two
major potential problems: It allows the CO2 to exit at high speed, so
any snow that forms doesn't block it up, and creates uniform gas/snow
turbulence. This typical design from a patent by Brooks Equipment in
the 1970s solves both problems.


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Post #159321
Posted 9/3/2017 8:00:36 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
I placed a copy of this post here for the benefit anyone that might be
able to use this information in planning and/or building a Bat
Vehicle.
Worked on designing an upper U-bar double shock mounting bracket and created a wood pattern.
I decided to post the steps of making a custom mount for anyone that may not be familiar with this method.
So,
Step One: Design and make a life-size wooden pattern. vertigo


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Post #159358
Posted 9/5/2017 7:09:05 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
I placed a copy of this post here for the benefit anyone that might be
able to use this information in planning and/or building a Bat
Vehicle.

Fedicane
“I am, however, having issues locating the proper rims and/or someone
who can make the rims i need for the rear. I want 16.5x12's but i can
work with 17x12's. Seems they are going to have to be custom as i have
yet to locate any of those sizes as duallies. Any tips or links would
help a lot.”

There are no dually factory made steel wheels for 16.5 X 12.
The original movie Tumbler used 16.5 x 12 shell wheels with welded in
dually centers and no wheel adapters.
gez1967 acquired some of the original tires mounted on custom dually rims.
In this case his photo images are worth many thousand woods.
Look at his build in Tumbler build section titled: UK Batman Tumbler builder
See his photo images of these at:
Post # 150055
7-27-2016  4:56:27 AM
In the past custom wheel companies have quoted these wheels between
1000-2000.00 each.
Judging from your building and welding skills I would imagine that you
could weld them up yourself.
PS: Your Tumbler build looks outstanding and your workmanship of
exceptional quality.  vertigo
Post #159384
Posted 9/7/2017 7:09:10 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
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Received an email asking if the oxygen/acetylene cutting torch was obsolete.

Never underestimate the effectiveness of cutting with an oxygen/acetylene torch.
In the right hands this 200 dollar torch can make accurate cuts in 1/8 to 2 inch steel.
You will probably never make a cut in steel more than 1/2 inch thick for most Bat Vehicle builds.
I cut my Tumbler's four front axle support brackets from 1/2 inch plate steel in around 1-hour.
An oxygen/acetylene torch can cut 1/2 inch steel plate at an accurate cut rate of approximately
three inches per minute. The only problem with cutting with an oxygen/acetylene torch is that it puts a lot more heat into the metal being cut than plasma. Not to good for cutting sheet metal but it cuts 1/8 to 1 inch thick steel like a hot knife in butter for about ten percent of the equipment and consumables costs of a good plasma torch.

After some practice most can accurately cut to within 1/16th inch of
the part lines. The usual method is to cut close to the part line and
then finish to the part line with a grinder. I prefer to cut for
accuracy in bright sunlight for the best visibility.  You can buy an
oxygen/acetylene welding/cutting torch with regulators and hoses with
effective cutting range up to 2 inches thick steel delivered for
around 250.00. Then rent or buy the oxygen and acetylene cylinders.
You could also buy a compact tote system with tanks delivered for
around 400.oo that can cut up to ½” steel.     Vertigo


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Post #159404
Posted 9/10/2017 8:09:59 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
I placed a copy of this post here for the benefit anyone that might be
able to use this information in planning and/or building a Bat
Vehicle.
Worked on cutting pieces for upper U-bar double shock mounting.
I decided to post the steps of making a custom mount for anyone that may not be familiar with this method.
So,
Step Two: Cut out parts.: In this case I cut the pieces from 1/2" plate steel with an oxygen/acetylene torch.
Note: To effectively cut straight lines I clamp a straight edge. Usually a 3/4" square piece of bar stock.
Note: The torch tip does not touch the metal being cut but rather is held approximately 1/4" above the metal being cut while guided against the straight edge.

The three reasons Oxygen/Acetylene torch out fits are still used is portability, reliability, and cutting ability.
No electricity required. I have used the rig seen in the photo image in some pretty remote locations to cut and gas-weld repair damaged off road vehicles.

Step three: Drilled shock mounting holes and bolted them together.
Step four: Used hand grinder to shape and contour the laminated metal pieces.
Step five: I will weld the pieces of the mount together.
Step six: I will then weld the finished mount to the U-bar. vertigo


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Post #159411
Posted 9/13/2017 6:49:51 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
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I placed a copy of this post here because it might be of some use to
someone planning to build or actually building a Bat Vehicle.

SELF-EVALUATION INVENTORY

What Tool Using Skills / Available Options do you have available for a
Bat Vehicle Build?

I have listed many tools below that may be useful to a Bat Vehicle
Planner and/or Builder.

The best way to think about tool using skills is to think about them
as currently available problem solving options. The more tool using
skills you acquire the more Bat Vehicle problems solving options you
have.

Tool using skills are also about practice (improved ability through
practice) and the degree of tool using sophistication. How much
experience you have using a particular tool and how effective you are
is using the tool to solve build problems.

How many can you use?
Are there any you need to get familiar with or become master of?

Check yourself against the tool inventory listed below, circle/mark,
and decide if you are FAMILIAR, GENERAL USER, or MASTER of the tool’s
potential for solving Bat Vehicle building problems.

MEASURING and DRAWING TOOLS
English Rulers
Metric Rulers
Scaling Conversion Rulers
Protractor
Inclinometer
Square
Triangles
Compass
Pantograph
Enlarging/Reducing grid squares
Enlarging Projectors
Paint or other similar photo programs that come with most computers
PhotoShop
CAD Computer Aided Drafting
Mechanical and Laser Probes
Template Concepts
Tracing
Scaling up and down

HAMMERS
Claw
Ball Pein
3 LB Masonry
5 LB Sledge
10 LB Sledge
Dead Blow
Chipping

BASIC TOOLS
Hand Held Screw Drivers
Battery Powered Drill/Driver
Socket Sets
Wrenches-open/boxed
Crescent Wrench
Pipe Wrench
Allen-Hex-Torx-Star wrenches and Drill/Driver Bits
Nut Drivers
Pliers
Vice Grips
Channel Locks
Lock Ring Pliers
Safety Wire Pliers
Cutting Diagonal Pliers

CUTTING TOOLS
Exacto Knives
Utility Knife
Files
Rasps
Wood Cutting Hand Saw
Metal Cutting Hack Saw
Coping Hand Saw
Wood Chisel
Metal Cutting Chisel
Air Hammer with Chisel
Motor Driven Bench Jig Saw
Hand Held Motor Driven Jig/Sabre Saw
Reciprocating Saw
Wood/Metal cutting Band Saw
Horizontal Metal Cutting Bandsaw
Metal Cutting Chop Saw
Metal Cutting Motor Driven Hand Held Circular Saw
Wood Cutting Compound Miter Saw
Hand Held Motor Driven Router
Bench or Free Standing Router/Shaper
Metal Cutting Milling Machine
Wood Cutting Lathe
Metal Cutting Lathe
Oxygen/Acetylene Cutting Torch
Plasma Cutting Torch
CNC Plasma Cutting Table (can also use other tools)
CAM Computer Aided Machining

WELDING
Oxygen/Acetylene Gas Welding Outfit
Arc Stick Welder
MIG Welder
TIG Welder
Spot Welder
Plastic Welder

DRILLING, TAPPING and DIE CUTTING TOOLS
Hand Powered Drill
Powered Hand Drill
Drill Press
Threading Taps
Threading Dies

GRINDING / SANDING TOOLS
Hand Held Power Driven Angle 4-5 inch Grinders
Hand Held Power Driven Angle 6-9 inch Grinders
Hand Held Power Driven Straight Line 3-5 inch Grinders
Hand Held Power Driven Die Grinders
Hand Held Power Driven Dremel Tool Grinders/Cutters
Bench / Pedestal Motor Driven 6-12 inch Grinders
Metal Cutting Surface Grinder
Hand Held Power Driven Rotational Disk Sanders
Hand Held Power Driven Orbital Disk Sanders
Hand Held Power Driven Belt Sanders
Bench / Pedestal Motor Driven Sanders
Bench Mounted Motor Driven Band Knife Grinder/Sander

AIR TOOLS
Air Hammer
Drill
Sander
Grinder
Paint Spray Guns
Sand/Abrasive Blasters

OK. What tools did I miss?
Post #159427
Posted 9/14/2017 7:35:01 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
Here is tool that eliminates most of work when file working in very
tight places.

Milwaukee Bandfile — 5.5 Amp, 2300 FPM, 1/2in. x 18in. Size, Model# 6101-6

This is a really nice tool. It is definitely one of those tools that
you don't use every day, but when you need it, it's worth every penny.
The head can be rotated to position the file in whatever position you
need, which is a really handy feature.


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Post #159438
Posted 9/14/2017 8:34:39 PM


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Last Login: Yesterday @ 7:53:39 PM
Posts: 497, Visits: 939
Speaking of tools.......

I had given up on the idea of milling foam parts from huge blocks of foam because it was too cost prohibitive. But after spidey4fun's post about a guy that was milling car parts from regular foam insulation I started rethinking that idea. Smaller blocks of foam could be milled separately and then assembled together! It doesn't have to be milled out of one huge block with a giant machine.

However, even small CNC machines are expensive. But there are some nice kits out there. I'm seriously considering this one. https://www.buildyourcnc.com/item/cnc-machine-blacktoe-v4-2x4
Post #159440
Posted 9/15/2017 2:19:33 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
sly
"I had given up on the idea of milling foam parts from huge blocks of foam because it was too cost prohibitive. But after spidey4fun's post about a guy that was milling car parts from regular foam insulation I started rethinking that idea. Smaller blocks of foam could be milled separately and then assembled together! It doesn't have to be milled out of one huge block with a giant machine.
However, even small CNC machines are expensive. But there are some nice kits out there. I'm seriously considering this one. https://www.buildyourcnc.com/item/cnc-machine-blacktoe-v4-2x4."

Looked at the kit. Very nice for 4,000.oo Have you searched for used machines? Like, Torchmate, Routermate, etc. When I was researching them out I found 2 x 2 and 2 x 4 used Torchmate complete with computer on EBay for 5 and 7,000.00. Biggest problem with all these, and the kits too, is Z axis cutting depth. It usually falls just short of 6 inches. Once I get started on the physical building of my DOJ Batmobile I have plans to convert my 4 x 4 Torchmate by elevating it 2 feet above the bottom cabinet and switching out the automatic Z axis depth height control for a deep cutting Z axis some where in the range of 18-24 inches. Complete CNC foam cutting router tables are also sold online with a deep Z axis already installed. vertigo

Post #159441
Posted 9/15/2017 7:32:19 PM
Supreme Being

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Last Login: Yesterday @ 7:29:22 PM
Posts: 1,467, Visits: 2,450
Placed a copy of this post here for anyone that may be able to benefit from it planning to and/or physically building a Bat Vehicle.
Used an angle grinder to grind dual shock mount sides to shape, then welded them to a 3/8" thick, 2" wide flat bar. Cleaned up welds with the angle grinder and welded the finished dual shock mount to the U-bar. vertigo


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Post #159448
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