|
|
 Posted 2/2/2017 7:38:33 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I put a copy of this post here because this method of axle alignment might be useful to someone with a similar build problem.
Fitting and aligning the two front axles accurately can be quite a trick, given the weight and awkwardness in its distribution. So I have decided to cut the 3" DOM heavy wall tubing into two parts from each Tumbler arm axle.
The two bevel cut 3" DOM tubing pieces are half of each axle from each side. These two pieces will be slipped over each end of a straight 2" pipe (alignment jig). This assembly will be slipped though a 3" hole at the end of each Tumbler arm. This will keep the two 3" DOM axle parts in alignment while they are welded securely in place. Once the welding is finished the pipe will be removed and the two 1' long 2" diameter DOM heavy wall tubes will be slipped into the already welded axle halves. Then the other halves of the axles with end assemblies will be slipped over the 6-inches of protruding tubes. This way I can rotate and/or shorten the axle assemblies as I will. Once I am satisfied with length and rotational aspects I will deep weld the two axle pieces together. I machined the 45 degree ends for welds in preparation for welding. vertigo
|
|
|
|
| Posted 2/3/2017 5:33:08 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I put a copy of this post here because this method of axle alignment might be useful to someone with a similar build problem.
Fitting and aligning the two front axles accurately can be quite a trick, given the weight and awkwardness in its distribution. So I have decided to cut the 3" DOM heavy wall tubing into two parts from each Tumbler arm axle.
The two bevel cut 3" DOM tubing pieces are half of each axle from each side.
Today I cut the holes at the end of each Tumbler arm and assembled the inner and outer first half of each axle.
Next step will be to cut an alignment pipe and since the pipe's inside diameter is a little oversize I will use metal tape to enlarge the inner tubes to enable a tight mating. vertigo
|
|
|
|
| Posted 2/4/2017 6:34:34 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I put a copy of this post here because this method of axle alignment might be useful to someone with a similar build problem.
Fitting and aligning the two front axles accurately can be quite a trick, given the weight and awkwardness in its distribution. These two pieces will be slipped over each end of a straight 2" pipe (alignment jig). This assembly will be slipped though a 3" hole at the end of each Tumbler arm. This will keep the two 3" DOM axle parts in alignment while they are welded securely in place.
What I thought would be 2-hors work turned into 6-hours. Before starting I re-leveled my Tumbler frame. Ended up using a 2" pipe and as we know 2" size pipe means it has an inside diameter of 2". That is unless it is heavy duty fence pipe which has 2-1/8 inside diameter. So, I had to shim the 2" diameter inside DOM tubing with metal tape to bring it up to 2-1/8" so as to have a tight fit into my 2-1/8" inside diameter pipe. Then I used a 2 x 2" 1/4" wall square tube to clamp both Tumbler arms in unison and shimmed both to level. Next step will be welding.
vertigo
|
|
|
|
| Posted 2/10/2017 5:53:36 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I put a copy of this post here because it may be of use to someone who is building or planning to build a Bat Vehicle.
Used my Milwaukee metal cutting circular saw to cut the main Tumbler arm shock mounts from 1/2" thick sheet steel. It took 5-minutes to cut them both. This is an amazing tool with many practical applications to Bat Vehicle building, especially the Tumbler and S v V DOJ Batmobile. vertigo
|
|
|
|
| Posted 2/23/2017 5:30:05 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I put a copy of this post here because zinc casting can easily be used
to make Bat Vehicle parts by replica builders. Zinc melts at 787.2
degrees Fahrenheit (419.5 degrees Celsius) and is malleable at 212-302
degrees Fahrenheit (100-150 degrees Celsius). Zinc can be cast in many
types of molds and that includes high-temp silicone. For the best
castings use SHZ ZINC 99.995% pure. Zinc casting kits are sold online,
as are books on how to make molds, and casting metal.
Ever wonder why most Hot Wheels cars, Action Figure chess pieces, war
game 3” soldiers, decorative keyrings, costume jewelry, and many other
figurines and toys are made from die cast zinc instead of plastic?
Zinc Alloy Die-casting benefits over Plastic Injection Molding
◾Longevity-some zinc/zinc alloy statues are over a thousand
years old. There are toy soldier sets still around from the 1600s.
◾Better precision
◾Smaller draft angles
◾Smaller and longer cored holes
◾Thinner wall sections possible
◾Superior tensile strength and elongation
◾Far superior impact strength
◾Better machinability
◾Better formability
◾Lower casting costs
◾More finishing options
◾Vastly superior stiffness
◾More consistent properties
◾Better precision
◾Much lower process costs for thicker section components
A wide range of polymers and polymer alloys are available and each of
these has a range of properties dependent on such as factors as the
degree of polymerization and type and quantity of fillers and
pigments. Compared to metals therefore, the properties of plastics are
much more dependent on their source.
Plastic injection molding is the most commonly used production process
for complex shapes that will only be subjected to very low stresses in
service. The main problem with subjecting plastic moldings to more
elevated stresses is their relatively low elastic modulus. Even glass
fiber filled plastic injection moldings have much lower elastic moduli
than metal die-castings. Hence, for parts demanding even moderate
rigidity, plastic moldings must inevitably be much thicker than metal
parts. Increasing the wall section of a plastic injection molding not
only increases the material content and its attendant cost but also it
dramatically increases the time required to mold the part. Process
costs increase in line with cycle time, hence plastic moldings become
increasingly uncompetitive as rigidity requirements increase.
|
|
|
|
| Posted 3/1/2017 6:13:37 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
put a copy of this post here because of zinc casting's potential usefulness in making Bat Vehicle parts.
Building materials selection will most likely play an important part is planning and building decisions.
SO, Why is aluminum not used instead of zinc for making die cast toy
cars, such as Hot Wheels, figurines, 3' war game toy soldiers, key
rigs, and high end Batman related sculptures, such as high end
Batarang display pieces.
Advantages of Zinc Casting over Aluminum Die Casting
If you’re considering aluminum die casting, there are several reasons
why Zinc die casting could be a better option for you.
10 x’s greater tool life
A Zinc die’s tooling life can be more than 10 times longer than that
of an aluminum die! Lower casting temperatures for zinc are easier on
tools because they create minimal thermal shock and prolong die
casting tool life. With dies costing upwards of $50,000 each, having a
long lasting tool can represent a significant cost savings.
Low melting point = cost savings
Zinc melts at 787.2°F whereas Aluminum melts at 1,221°F. This gives
Zinc an advantage because casting can use a process called “Hot
Chamber” casting which is quicker as well as being less costly than
“Cold Chamber” methods.
Faster cycle times = better pricing
Using the Hot Chamber process also gives Zinc a major advantage over
Aluminum because the hot chamber process goes so much quicker than
Cold Chamber. In cold chamber, Aluminum needs to be manually poured
into the die either by hand or using a robot. Using hot chamber
casting, the molten liquid zinc is shot into the die using a highly
pressurized “plunger” which systematically shoots the zinc through the
die.
Thinner wall stock
ZAMAK alloys have exceptional casting fluidity. It’s possible to cast
walls in ZAMAK as thin as .25 inches. Thinner, stronger walls results
in smaller and lighter products with lower costs.
Less machining required for tight tolerances
Zinc die casting has tighter tolerances than Aluminum or plastic die
casting, which often eliminates the need for additional machining.
When no additional machining is needed, it’s called “Zero Machining”
manufacturing. This is one of the major advantages of Zinc die
casting.
Superior for decorative finishing
ZAMAK alloys have a better surface for finishing because Zinc comes
out of casting with a smoother skin. Because Aluminum has to be so
much hotter than Zinc, the thermal shock from being put in a die
produces a part with a surface that can be more pitted. Chrome finish
amplifies every defect in a part, which makes Zinc much easier to
finish compared to Aluminum. Zinc die casts can be easily polished,
plated, painted, chromated or anodized.
Tough durability
Zinc alloys are some of the strongest and toughest materials for die
casting. Neither plastic, gray cast iron, or Aluminum withstand
impacts as well as Zinc alloys do.
Sometimes aluminum casting is the best choice but not usually for the
home caster looking to make a few pieces. Usually the home or small
shop caster is better off machining aluminum from solid stock for a
few pieces and many shops do large production machining with CNC mills
and lathes.
|
|
|
|
| Posted 3/9/2017 6:04:46 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
Here is an outstanding book on universal problem solving techniques
and strategies written in easy to understand language that is well
suited to the needs of the Bat Vehicle planner and builder.
Print out the table of contents.
Mark beside the ones you have used.
You will find that you have already used many of those listed.
Engineering Problem-Solving 101: Time-Tested and Timeless Techniques
by Robert Messler
Provides detailed engineering analysis, and lays out versatile
problem-solving methodologies. Written by an "engineer who teaches,"
with more than 20 years of experience as a practicing engineer and
numerous awards for teaching engineering, this straightforward,
one-of-a-kind resource fills a long-vacant niche by identifying and
teaching the procedures necessary to address and resolve any problem,
regardless of its complexity. Engineering Problem-Solving 101:
Time-Tested and Timeless Techniques contains more than 50 systematic
approaches spanning all disciplines, logically organized into
mathematical, physical/mechanical, visual, and conceptual categories.
Strategies are reinforced with practical reference tables, technical
illustrations, interesting photographs, and real-world examples.
Table of Contents
1. Engineers as Problem Solvers
2. Problem-Solving Skills versus Process versus Techniques
3. Using Equations (Plug-and-Chug)
4. Approximating and Estimating
5. Interpolating and Extrapolating
6. Checking
7. Dimensional Analysis and Reconciling Units
8. Using Similarity and Ratios
9. Using Indexes or Indices
10. Scaling
11. Sensitivity Analysis (of Parameters)
12. Response Curves and Surfaces
13. Numerical Analysis and Methods
14. Dimensionless Quantities or Parameters
15. Assumptions, Constraints, Conditions, and Cases
C. PART TWO: Physical/Mechanical Approaches to Problem-Solving
16. Reverse Engineering
17. Material Property Correlations
18. Proof-of-Concept Models
19. Experimental Models and Model Experiments
20. Test Models and Model Testing
21. Mock-ups and Masters
22. Prototypes and Rapid Prototyping
23. Trial and Error
D. PART THREE: Visual, Graphic, or Iconic Approaches to Problem-Solving
24. Sketching and Rendering
25. Tracings and Transfers, Templates, Lofting and Lines-Taking
26. Graphing and Graphical Methods
27. Layouts
28. Flow Diagrams and Flowcharts
29. Causal Diagrams or Cause-and-Effect Diagrams
30. Decision Trees
E. PART FOUR: Conceptual or Abstract Approaches to Problem-Solving
31. Brainstorming: Process, Methodology, and Technique
32. Using Analogs
33. Dissecting Problems: Decoupling and Coupling, Zooming In and Zooming Out
34. Working Problems Backward and Inverse Problems
35. Functional Analysis and Black Boxes
36. Morphological Analysis and Morphological Charts
37. Storyboarding
38. Iteration and the Iterative Design Process
39. Closing Thoughts
40. Approximating and Estimating
41. Interpolating and Extrapolating
42. Checking
43. Dimensional Analysis and Reconciling UnitsIn Summary
44. Using Similarity and RatiosIn Summary
45. Using Indexes or Indices
46. Scaling
47. Sensitivity Analysis (of Parameters)
48. Response Curves and Surfaces
49. Numerical Analysis and Methods
50. Dimensionless Quantities or Parameters 51
51. Assumptions, Constraints, Conditions
52. Reverse Engineering
53. Material Property Correlations
54. Proof-of-Concept Models
55. Experimental Models and Model Experiments
56. Test Models and Model Testing
57. Mock-ups and Masters
58. Prototypes and Rapid Prototyping
59. Trial and Error
60. Sketching and Rendering
61. Tracings and Transfers, Templates, Lofting and Lines
62. Graphing and Graphical Methods
63. Causal Diagrams or Cause-and-Effect Diagrams
|
|
|
|
| Posted 3/10/2017 6:33:11 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
| What is really important about this book is that 99.99 % of all engineering problems have been solved with these strategies and methods and that all these are contained inside one book. It is also relevant to solving problems across most specialties. From bridges to Bat Vehicles this book can contribute much to your problem solving methods and strategies. Used copies at Amazon run 33-50.00. vertigo
|
|
|
|
| Posted 3/13/2017 5:00:53 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
I am using these gloves to protect my hands from grease and oil while
rebuilding my fronts axles. Worked in grease for several hours and
when I was done I pulled off the gloves and my hands were as clean as
they were before I started. I'll never go back to working in grease
and oil again bare handed. These cost a little more than a dollar a
pair. If you are tired of the mess left on your hands while working
with wheel bearing grease and other oils, grease, resins, etc., then
these might be for you.
I buy mine from GEMPLERS.com
Nitri-Dex™ 9-mil, Nitrile Gloves
The 12"L Nitri-Dex 9-mil, Nitrile Gloves offer you increased chemical
resistance without the bulk of a heavier weight glove. Revolutionary
disposable gloves are R & L hand specific and feature tractor-tread
grip for keeping a firm hold even when wet.
They have extremely good sensitivity that allows them to pick up a
grease covered washer or sewing needle from the floor. The unique
9-mil thickness and 12"L give you a new choice for many applications
from agriculture to automotive. Sold as a bag of 25 pairs. USA made.
Similar gloves are available for other chemicals, resins, solvents,
etc. with more options and greater mil thicknesses.
|
|
|
|
| Posted 3/14/2017 6:41:38 PM |
|
|
Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232,
Visits: 5,166
|
|
Here is the best wraparound face shield I have found.
I rarely use safety glasses or goggles anymore as my primary
protection since finding this product.
The level of protection is just so many times greater with this shield.
Stray metal fragments from grinding and saws are still the number one
eye injury causes for workers in metal fabrication. Around 5-10% of
these are injured even though they are wearing safety glasses. Reason:
The safety glasses didn’t have side protection and the metal fragments
entered from the non-protected sides and/or from above or below, when
the worker had their heads, tilted down or up, too much.
Additional worker eye injuries come from splashes and stray droplets
of fuels, oils, solvents, greases, paints, resins, chemicals, etc.
I also used mine when working on mills, lathes, metal cutting circular
cutting chop saws, etc.
Uvex WRAPAROUND FACESHIELD
Face Shield is contoured for superior protection and visibility
The Uvex Face Shield is extremely lightweight and features a contoured
design for superior face protection and improved visibility.
Ratcheting headgear allows you to fully adjust the shield for a
comfortable and secure fit, while the soft breathable headband keeps
you cool and dry in hot environments. Easy-to-replace face shield
window can be changed in seconds. Meets ANSI Z87.1-2010. USA made.
These cost $35.65 for uncoated window and $51.20 for
Hardcoated/Anti-Fog window from Gemplers. Anyone who has worked for
some length of time with grinders, saws, routers, drills, sanders,
mills, lathes, etc., in wood, metal, plastics, resins, liquids, etc.,
can usual recall several near misses from damage to their eyes.
Wraparound Face Shields and/or goggles are CHEAP AT THE PRICE when you
really consider how much your eyes are worth to
you!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
|
|
|
|