UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING, AND SPECIAL TECHNIQUES
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Posted 12/20/2017 5:46:32 PM
Supreme Being

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Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

How to make life size cutting templates from scale models, the old
school way, using a pantograph.

Part Four
3D Pantographs

Have you ever thought “if I only had a 3 axis deep Z 2x4, 4x4, 4x8,
5x10, 10x20 CNC table for plasma cutting steel, routing foam”,
etc.,etc… While we are fantasizing might as well add a laser or
mechanical touch probe to scan our plastic models into a 3D CAD
program. One could easily spend a 100,000.oo on this perfect set up.
OR, you could get real and cast off the CNC mentality that is holding
your mind back from creating your Bat Vehicle dreams and making them a
reality.

Fact is most individual sculptural artists, and Bat Vehicle builders
are really sculptural artists, are not using CNC. The reality is that
99.9 % of all sculptural artists are still using 3D pantographs to
duplicate and/or enlarge their 3D works. Many of these tables are home
made. History shows 3D enlarged statues and other items were being
produced by 1650 on 3D pantographs.

Why?

The minimum table size that provides enough freedom to effectively
work on vehicle size sculpture is a 4’ x 8’ capacity with deep Z. Add
the computer, CAD/CAM program, and mechanical laser probe setup.
Cost:60,000 plus.

A 3D carving/routing pantograph 4’ x 8’ table for use on wood, foam,
and plastic can be constructed for a minimum of 500.00 plus the cost
of a router.

The Bat Vehicle plastic scale models (pictorial blueprints) contain
all the information necessary to make full-size parts. No need for a
computer, CAD/CAM program, and laser/mechanical probe.

The 3D carving/routing pantograph draws its input information from the
plastic model via the tracing stylus (input). Once the pantograph is
adjusted to the desired multiplication factor it becomes an automatic
scale converter that requires no calculations. One needs only to trace
over the model or model part with the tracing stylus and the other
stylus (output) that holds a router automatically cuts the increased
scale part in 3D.

The 3D pantograph design allows it to automatically and accurately
calculate the scale multiplication factor into the movement of the
drawing stylus on X Y Z axis. Thus, zero scale translation errors and
the source of nearly most all errors come from the ability of the user
to follow the lines of the model with the tracing stylus.
(No computer, CAD program, CNC operated machine, or even electricity
needed, except for the router and maybe a work light.

Thousands of 3D carving/routing pantograph plans are available online
for free. Some are sold as kits with patterns.

You need only find a strong design and scale it up large enough to fit
your table size. I plan to build one of these to make the afterburner
and intake parts for my Tumbler and the more complex parts for my
DOJ/Justice League Batmobile. vertigo

Example: Building the 3-D pantograph - YouTube
Video for 3D carving pantographs
https://www.youtube.com/watch?v=vtm4u583YOQ

Detailed 3-D Router Pantographs
plans/Instructions
woodgears.ca/pantograph


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Post #160073
Posted 12/21/2017 5:14:37 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

How to make life size cutting templates from scale models, the old
school way, using a pantograph.

Part Five
Summary Steps

Making 1:1 life size or other scaled drawings and templates. (Usually
used for flat parts)

Step One: Create drawings for each part from your scale model accurate
to the models scale that you want to make a scale enlarged drawing and
template from. Most Bat Vehicle models will be 1:18, 1:24, 1:25, or
1:6. Think of scale models as pictorial blue prints that contain
summarized representations of reality. The more detailed the model the
more information it contains. Scaling is both reference parameter and
potential.

Step Two: Scale up your drawings in steps to lessen the problems
associated with exaggerated errors that are due to slight variations
in measurement and tracing stylus control.

Scale up in steps. First use the pantograph to scale up your model
scale drawings 1:18, 1:24, 1:25 to 1:6. Clean up the edges, straighten
lines, smooth curved lines, and match up intersections.

Next use the pantograph to scale up your 1:6 drawings by three to 1:2.
Clean up the edges, straighten lines, smooth curved lines, and match
up intersections.

Next use the pantograph to scale up your 1:2 drawings by two to 1:1.
Clean up the edges, straighten lines, smooth curved lines, and match
up intersections.

Step Three: Use these 1:1 drawings by transferring them on to stock
material and cut out your parts. You could also make a more robust
template then use it to mark your material.

3D Carving/Routing Pantograph

Step One: Fasten model or model part to table securely to prevent all movement.

Step Two: Fasten wood, foam, plastic or other media to table securely
to prevent all movement.

Step Three: Follow model or model part with stylus.
Seems simple but the feedback systems are in fact much more complex
than the CNC because it is physically operated with a human brain
neuro-physical interface. The CNC can do a great job making accurate
parts but the costs are generally prohibited to individual ownership.
But, other than cutting itself off when it runs into something the CNC
lacks much sophistication in feedback response. On the other hand, the
drawing and 3D carving/routing pantographs have the ability to respond
to the creative eye and hand of the artist at any moment. Near
infinite feedback allow variability in speed, trajectory, track, etc.
and allow artists to finesse their work. Master statues and other art
masters, even the minting masters of coins, are done using a drawing
and/or carving pantographs. Once the master is created it is then
programmed with CAD and mast produced on CAM CNC machines.

For Bat Vehicle building we would prefer CNC but cost prices most of
us away from the benefits. However, the pantograph technology born in
early 1600s still works very, very, well and costs on average less
than one quarter of one percent (1/400th) of the cost of CNC. The
drawing and carving pantographs are not obsolete but still are the
majority norm for enlarging and reducing drawings and 3D forms.
vertigo



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Post #160082
Posted 12/28/2017 5:52:05 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or,
actually building a Bat Vehicle.

Rigidity in thought has taught us to visualize and believe that a CNC
plasma cutting and wood/form router system looks like a table with two
rails that a boom rides on to create X and Y axis.

This company clearly was thinking outside the box when they created a
CNC system with an effective cutting range of 5.2 X 9.8 feet that
sells for 2,458.00. Looks like one would only have to add a deep Z and
build a wood framed table to have an excellent foam cutting table.
Will be researching this possibility further.

Portable CNC Cutting Machine with THC and Supporting Oxyfuel and Plasma Cutting
Portable CNC Cutting Machine
Amazon Price: $2,458.00 & FREE Shipping Effective Cutting Range: 5.2
x 9.8 feet

Effective Cutting Range: 1600x3000M(5.2x9.8ft).

Effective rail width(X axis): 2.2 m (7.2 ft) .

Effective rail length(Y axis): 3.5 m(11.5 ft) matching.

Flame(Oxyfuel) Cutting Thickness: 5-150MM, Max. 200MM.

Supporting Cutting: Flame(Oxyfuel) and Plasma(Plasma Arc Cutting Equipment).

Flame(Oxyfuel) Cutting Gas: LPG/Coal gas, Propane, Acetylene.

Plasma Cutting Thickness: 80amps(1-8mm Piercing Cutting),
100amps(1-12mm/15mm Piercing Cutting).

THC including - Automatic Plasma Torch Height Control.

Flame torch assembly being including.

StarCAM nesting software with Softdog being including.

other necessary accessories.
Note: Does not including Plasma Equipment and Plasma Straight machine torch


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Post #160107
Posted 12/29/2017 8:19:20 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Here are a few photo-images of DIY CNC deep routing wood/foam/plastic systems.


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foamcutter4axis[1].jpg (2 views, 68.03 KB)
Post #160117
Posted 12/31/2017 9:43:37 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

A good use for this machine would be to cut metal Tumbler parts from wood templates.
These are also used with routers, sabre saws, and rotary saws to make wood, plastic, foam, plastic, and to cut parts from pre-cast plastic resin panels.

The Oxygen/Acetylene cutting torch was invented in 1903 by Edmond Fouche and the Oxygen/acetylene Cutter Tracer Duplicator Pantograph was in use by 1904. After the invention of the plasma torch it quickly became interchangeable with the oxygen/acetylene torch.
This tool is still in wide use throughout the world and is much more commonly used than the CNC plasma table. Average cost is 250-300.oo.
Wood patterns are used for short production runs and metal patterns for long runs.

Here is a typical example found on Amazon.
Rotten Leonard's Jalopy Shop Plasma Cutter Tracer, Pantograph

New (1) from $275.00 + $18.49 shipping on Amazon

• Adapts easily to any hand held plasma torch

• Accepts patterns made from almost any material

• Operates on a 48" radius from the stand pipe (not included)

• Quickly and accurately duplicate parts or designs

• Works on the inside or the outside of patterns.

Now, you can reproduce parts quickly and accurately. A plasma tracer
will save tons of time by allowing you to make patterns out of any
almost any material then cut a finished part from steel or aluminum.
If you ever need to make more than just one part this is the tool for
you. vertigo



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Post #160130
Posted 1/7/2018 7:13:46 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

Currently using this method to do a set of full size Tumbler templates for my Tumbler build.

Converting the pictorial blueprint (scale model) into full size templates with step up grid square method.
Steps
Make scale model size drawings on appropriate grid size paper
Example: 1:6 scale tumbler model grid square paper would measure 1-1/4" squares.
Next step: Use 1/4" plywood and draw 7-1/2" grid squares on plywood to scale up to 1:1.
Multiple all the information in each 1-1/4" times six and record this information into each relevant 7-1/2" square. This method will give you full size templates.
Cut the templates out with a sabre saw and they are ready to use. vertigo


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Tumbler-Templates-B.JPG (0 views, 285.14 KB)
Tumbler Template-A (2).JPG (1 view, 186.78 KB)
Post #160150
Posted 1/8/2018 11:43:10 AM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

Bopenstein
"Where did you get the pictures of the panels from?"

They were made by tracing the 1:6 scale Hot Toy's Tumbler model panels.
These were then cut out with a razor knife.
Then these were blacked with a Sharpie black marker.
These were then glued to 1-1/4" hand drawn grid paper.
Then these were used to transfer the images to 7-1/2" grid squared 1/4" plywood sheets.
And that my friend is how you do it 'old school". vertigo
Post #160159
Posted 1/12/2018 7:00:45 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

Here are a couple of photo-images of a few sample finished full-size templates. vertigo


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Post #160183
Posted 1/13/2018 7:29:33 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

Here is a very useful measuring tool that I use frequently.
Most of us have used a ruler and protractor to draw angles.
This unique combination protractor, ruler, and angle calculator, all in one, is from Empire and is sold at Home Depot, etc.
I have used it to calculate intersecting angles and/or to measure existing angle intersections.
Very handy when drawing angular supports brackets. vertigo



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PICT0003 (37).JPG (2 views, 351.03 KB)
Post #160190
Posted 1/19/2018 6:48:42 PM
Supreme Being

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Last Login: Today @ 7:07:54 PM
Posts: 1,821, Visits: 2,717
Placed a copy of this post here for the possible benefit to anyone
planning to, and/or, actually building a Bat Vehicle.

A few more things about Bat Vehicle templates.
Bat Vehicles are symmetrical sculptures.
As such each body panel on one side has a twin part on the other side. But usually not an identical twin.
One flat body panel template is often used to make both the right and left side corresponding parts by just turning it over to make the second part.
Large body parts like the Tumbler's roof panels can be drawn and/or plasma cut with a half template by flipping the panel over from side to side.
Curved and 3D parts require more skill but are in many ways very similar.
(See photo-images of sample templates.)

SYMMETRY
sym·me·try
NOUN
the quality of being made up of exactly similar parts facing each other or around an axis:
synonyms: regularity · evenness · uniformity · consistency · conformity · correspondence · equality · balance · proportions · concord
correct or pleasing proportion of the parts of a thing:
synonyms: regularity · evenness · uniformity · consistency · conformity · correspondence · equality · balance · proportions · concord
similarity or exact correspondence between different things:
physics
mathematics
a law or operation in which a physical property or process has an equivalence in two or more directions.


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Post #160217
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