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 12/4/2018 5:39:43 PM
Has NO LIFE!!

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Last Login: 2 days ago @ 5:26:26 PM
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Here is a self aligning tap.
Tap starts out with diameter of tapping pilot bit.
This tap will cut threads that are true as the hole that was drilled.
To get the most accurate drilled hole you need to us a drilling jig.


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Post #161426
Posted 12/7/2018 6:21:12 PM
Has NO LIFE!!

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Last Login: 2 days ago @ 5:26:26 PM
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Cut 8 1-1/2" pieces from 3/4" aluminum bar.
Machined knob base and portion below that protrudes through plastic steering wheel.
Drilled center hole through knobs.
Drilled and tapped side set screw holes.
Tested fitted knob bases in steering wheel holes.

Still need to:
Machine and knurl ends of knobs and cut tapers.
Tap threads in knob center holes.
File and polish knobs.
Installl knobs in holes and use washers and screws from backside to finish their installation.


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Post #161432
Posted 12/8/2018 5:40:37 PM
Has NO LIFE!!

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Placed a copy of this post here for anyone planning to and/or building a Bat Vehicle.

Currently machining the knurled metal knobs.
They are quite labor intensive.
In case you are unable to find the original knobs I have attached a copy of the machinist drawing for mine.
You can take the drawing to your local machine shop or send it to one of the online custom knob makers.
Given their labor intensive requirements I would expect them to charge you between 25 to 50.oo for machining each knob. vertigo


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DOJ Batmobile steering knob plans.jpg (8 views, 212.73 KB)
Post #161450
Posted 12/9/2018 5:28:41 PM
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Last Login: 2 days ago @ 5:26:26 PM
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Placed a copy of this post here for anyone planning and/or building a Bat Vehicle.

Finished machining and knurling ends of knobs.
Cut tapers and threaded center holes on two of the knobs.
These two knobs are complete.
Installed these two knobs in holes and used washers and screws from backside to finish their installation.

Still need to machine taper and center hole thread the remaining six knobs.


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Post #161456
Posted 12/10/2018 4:57:15 PM
Has NO LIFE!!

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Last Login: 2 days ago @ 5:26:26 PM
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Problems with tap gumming up while cutting threads in aluminum?

PRACTICAL MACHINIST
"A few things to check:
Use a good kerosene type cutting fluid. Tapmagic or the like. (not pipe cutting fluid.)
Others have their own special cutting fluid brand/type.
Drill the holes with the right size pilot bit.
Use a 2 flute spiral tap, tin coated works best.
Use a decent to good tap, not something from the local home center. (can use in a pinch though)
Use a guide of some sort to keep the tap straight. (I like the magnetic base type.)
I also use an old drill press with the motor removed and a handle on the spindle."
FWIW
Lenord
[ 09-04-2005, 09:41 PM: Message edited by: Lenord ]
Post #161466
Posted 12/11/2018 5:41:07 PM
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One more piece of information about tapping threads in aluminum.
In a situation where you don't have access to the right tap and kerosene it is still possible to tap threads.
Its is possible but slow and time consuming.

There is a method to cut threads with cheap taps and no kerosene for lubricating the threading process.
Butter, margirine, candle wax, etc., for lubrication.
Cut threads backing up every quarter turn, until tap beguns to bind, but no more than a couple of turns.
Back the tap out.
At the end of the tap you will find aluminum caked up between the flutes.
Use a sharp pointed tool to scrape the built up aluminum from between the flutes.
Repeat every two complete turns of the tap.

Post #161475
Posted 12/11/2018 5:42:10 PM
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Machined the center hub today.
Still need to drill the five bolt holes around the hub and this part will be finished.


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Post #161476
Posted 12/12/2018 5:29:33 PM
Has NO LIFE!!

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Thanks for the color observations sly.
Kind of like the look of the stainless steel hub and aluminum knobs.
Drilled the five evenly spaced holes around the center hub.
Used a milling machine with a rotary table chuck to drill and counter bore the recessed holes.


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Post #161486
Posted 12/13/2018 5:11:21 PM
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Received Batman Begins trilogy related insignia and hub centers from China.
Takes around a month to receive items ordered from China on eBay.
Used a hub center to make horn button.
The insignia are cast in zinc with chrome plating.


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Post #161500
Posted 1/5/2019 9:50:12 PM
Has NO LIFE!!

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Received an email today asking about the difference between Permatex copper and nickel anti-seize lubricant compounds.

I have used both copper and nickel and both are safe for Aluminum and steel. One offers higher heat protection before it breaks down. As for the actual melting temps for copper and nickel, actual copper melts at 1983 Deg-F while Nickel melts at 2647 Deg-F.

Copper Anti-Seize and Lubricating Compound is a general purpose anti-seize lubricant that prevents seizing and galling caused by high temperatures, heavy loads, vibration and corrosion. This unique formula has a smooth texture, fine particle sizing and familiar copper color, making it an excellent choice for closely fitted parts that need extreme lubrication. Regular use of Copper Anti-Seize will increase performance and prolong equipment life.
II. Applications
Recommended to lubricate fittings, bushings, flanges, headers, nuts, screws, studs, threaded surfaces, pipes, plugs, and manifolds to prevent seizing and galling of surfaces.
III. Features & Benefits
• Copper-Based. Safe for use on both ferrous and non-ferrous metals.
• High Temperature Resistance. Protects parts up to 1800° F.
• Electrically Conductive. Does not insulate and interrupt current flow.
• Good Choice for Use on Soft Metal Applications. Does not compromise integrity of soft metals.
• Will Not Harden. Heat aging won’t affect lubricity of product.
• Facilitates Fast & Easy Disassembly. Saves time in taking apart components.

CRC Nickel Anti-Seize and Lubricating Compound is a nickel-based formulation that is free of copper, lead, sulfides and chlorides. This premium high temperature lubricant protects metal-to-metal applications from seizing and galling caused by high temperatures, heavy loads, vibration, chemicals and corrosion. Chemically inert nickel formulation is safe for use with most chemicals that are unstable with copper. This product has extremely high temperature capabilities and excellent chemical resistance. Regular use of Nickel Anti-Seize will increase performance and prolong equipment life.
II. Applications
Recommended to lubricate metal-to-metal applications where a clean, chemically inert, copper-free formulation is necessary. Will not poison catalyst beds, reaction chambers, or special alloy fittings. May be used on fittings,
bushings, flanges, headers, nuts, screws, studs, threaded surfaces, pipes, plugs, and manifolds to prevent seizing and galling of surfaces.
III. Features & Benefits
• Copper-Free Formulation. For use where a clean, chemically inert and stable lubricant is required.
• Extremely High Temperature Resistance. Protects parts up to 2400° F.
• Electrically Conductive. Does not insulate and interrupt current flow.
• Good Choice for Use on Soft Metal Applications. Does not compromise integrity of soft metals.
• Safe For Use on Both Ferrous and Non-Ferrous Metals.
• Will Not Harden. Heat aging won’t affect lubricity of product.
• Resistant to Mild Detergents & Alkaline Wash. Protects against rust and corrosion.
• Facilitates Fast & Easy Disassembly. Saves time in taking apart components.
Post #161542
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