Angle the Deflectors

We started making parts! After months of designing, planning, analyzing, sourcing parts and buying materials, we finally started making parts. The front end wheel supports are involved, so we started there. The front structure has multiple tubes at multiple angles that all have to fit together as snugly as possible. Most of the sculpture and pilots' weight will be supported by these tubes, so getting them right is critical.

To make it harder, the cuts on either side of each tube are perpendicular to each other. There's even one tube that has cuts in two different directions on the same side. I always say, "You're only as good as your tools," and this was no different. There's no way I could do this without specialized tools.

I had already bought a tube notcher that would allow me to cut the 30° and 60° notches that I needed, and 1-1/2" and 2-1/4" hole saws. I already owned a digital angle finder that I could use to set angles accurately on the tube notcher. To align the two ends correctly, I'd get to use my newest tool--a digital level.

I started with the front two tubes, since they had the most occurences of the same cut. I set the notcher at 90° using the digital angle finder and cut the large arcs.

Then I taped 2-1/4" tube pieces snugly into the notches, so I could balance the digital level on it (Thanks to our machine shop captain for the great tip). The other side of these tubes needed 1-1/2" notches that were perpendicular to the first cuts. After I measured the angle of the drill shaft, I rotated the "T" until it was 90° to the drill shaft and cut the outside notches.

Aligning the tube to finish the long notch on the lower, rear tube

Cutting a 1-1/2" notch 

I repeated the steps until all the profiles were cut. It took several hours over some weeknights and a weekend.

 

Fit check - lower tubes

I would have been done sooner, but I screwed up the 60° cut on the lower rear tube. I convinced myself the alignment was correct, but it actually was backwards. And that's how it goes sometimes. I had to buy more tubing to make the correct part a few nights later. But they're all cut now. 😎

Next, we need to make the brackets and plates that make up the front wheel knuckles, formerly known as the CV axle brackets. The knuckles will support the wheels while allowing them to pivot around an axis. These parts will be made on the CNC mill, which is a topic for the next post.

May the Fourth be with you!

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