An Introduction: Chris Collins and Morris Tilly Project

[jack neville]

A heavy steel base was cut which had a 5mm template plug welded to it.
The small pieces to fabricate the movement mechanism was also lazer cut. I got a few extras done just in case.

[jack neville]

Three 10mm template pieces were tacked together and positioned over the 5 mm piece and then clamped together. I welded small positioning tabs around the outside to locate the top template. I added loops for lifting as It was getting pretty heavy. Heavy angle iron was drilled and positioned over the templates to clamp the die together. I then drilled and tapped into the heavy plate for the bolts to secure the angle iron. My gantry allows me to move anything anywhere easily which came in handy for drilling the heavy plate.

[jack neville]

So that was the female part complete. The male part I used 25mm steel bar. The ends were rounded of in the lathe and a cross piece welded in situ in the female template. Some 10mm flat bar added to reinforce the round bar and then it was ready for a test on a piece of scrap.

[jack neville]

I have to say I was very satisfied with the result. The pressing was very uniform and the lines on the underside very defined and exact.

[jack neville]

So I cut a piece of sheet to size and gave it a go. I allowed a few extra mm all round in case the pressing pulled in slightly. It didn't seem to move at all so once it was done it was a simple matter of scribing around the top template and cutting out with tinsnips.

[Ian Mastin]

Love your work mate! It looks great I think you are on a winner their one little tip use's some oil on the forming tools it will help.

[jack neville]

It would seem a lot of effort just to press out two seat bases but I will get more out of the die. The seat base frame is light right angle fold in 2mm steel. I will use the top template to form that angle around. Also the seat legs have the same profile as the front of the seat base and are made of 3mm angle iron. I can use the same template to form them.

I have since convinced Nick to give me lessons in CAD drawing.

[jack neville]

To prepare for the seat base frame I had a piece of 2mm strip folded to the correct dimension. I ground a round edge on the top of the template to accommodate the curve of the strip of now angle. I was able to use the cross cavity to anchor clamps and supports to secure the angle and with a bit of heat worked the angle around the template. It puckered in the corner as is went which I expected and it was just a case of heating the pucker up and hammering it down.