Mason Caradice Design
Below are picture of the processes i used in order to create one full scale model of the fixing between the frame and plstic and the other is an appearance model in the scale of 1:5 which i made by following my technical drawing the best i possibly could.
Modelling
Hover over the picture in order to get a description
Before i started to bend the thicker rods i made a mock up frame using a 3mm copper rod. I did this to get the best way to bend the rods and to get used to bending then and to get a feel of what to do for the actual model.
I clamped the 5mm mild steel rod in the vice. I measure how long i would need the section. i measured 16mm short each time to get the correct length as the curves measured 16mm.
I slid a piece of metal tubing over the rod while bending it as this would give me the best possible bend as it allowed me to only bend the part i wanted bending and kept the rest straight.
You can see that the tube only allowed the rod to bend where i wanted it to.
I created two identical sides and both match my technical drawing.
I the brazed both sides together creating one frame. As shown in the picture the frame was very accurate even though i only used my hand to bend the tubing and no machines.
I brazed 1mm sheet metal strips across the frame in order to create the very small fixings.
I then cut the strips with the band saw so that all was left was little tags to fix to. I then Brazed 2 1mm sheet metal strips across the front for the A3 card holder. The brazing is now finished.
I used the sandblaster to clean the surface down to ensure that the paint sticks to the model correctly.
I then primed my model so that when i painted it silver it had a nice finish and stuck to the model correctly.
I then painted the frame silver. I cut a strip the width i need out of 1mm clear PETG and glued it too the tabs as fixing with a nut and bolt was not possible.
The fixings of the model are not to the correct dimensions as it would be nearly impossible to make them with the resources available to me in the workshop as they are too small.
Full scale fixing model
1:5 Scale appearance model
I used the tube bender to bend the 25mm tube 90 degree. If the tool wasn't missing most of its part then the bend would be a lot smaller as there are attachments that help this normally.
I sourced a 3mm mild steel strip and cut it down to the correct size using the gelatin.
I then filed both corners in order to round the corners of to give it the look that is on my final concept.
i then used the milling drill to drill a hole precisely where i wanted it.
I sourced a 6mm nut and bolt and fastened it through the hole in the place i wanted the nut so it was in place to Mig weld them together.
With some assistance the bolt is welded to the back of the fixing.
By using the grinder i did my best to clean up the weld for a better apperance.
I now had to weld the fixing onto the frame so i used magnet to hold the pieces in the correct place ready to weld.
With some assistance the fixing was now Mig welded to the frame. the idea weld would be to arc weld it.
I glue 2mm and 3mm plastic together in order to gain 5mm plastic sheeting i the rounded the corner off with the band saw and drill a hole for the nut to go thorough.
I then drilled in the plastic slightly with a 8mm drill piece in order for the nut to counter sink into the plastic. The fixing is very secure and will hold any object that will fit on the plinth.
While making my model i have learnt some valuable skills such as brazing and fabricating a metal fixing. The processes i used will not be used to manufacture the real thing it would be Arc welded instead of mig welded as it gives a better and stronger finish. it would also not be painted as it has a shiney chrome finish.