Saving the Manhattan Project.

[Bill Dunlap]

I received a request to reproduce a Manhattan fan cage using a sample. When I opened the box, I was met with a real problem.

 

The center piece was a stamped ring

instead of a solid ring. I don't have a punch press and tooling to make these, so If I couldn't figure out a way to fab this up, I would have to return the cage and not accept this project. Searching around my toolbox, I found a huge tube socket for the sprocket nut on one of my bikes. It was the right size.

 

 

I rounded the end of it on my belt sander and radiused the inside with my moto tool.

 

 

Taking some sheet brass, I measured it up and cut it to size.

 

 

 

Using hammer and dolly method, I folded the edges around the tube socket, stopping to frequently anneal the brass so it wouldn't crack and split.

 

 

 

 

At this point I used my drill press to push the center through inside the tube socket.

 

Now I had something that would work.

 

 

Success. I saved the project. The rest is just like any other cage, with rings and spokes.

 

 

 

Cheers,

Bill

[Dave McManaman]

Holy cow! Ingenuity at its best. Thanks for sharing the pics and narrative. 

[Geoff Dunaway]

 Hey Bill,  I need one of those cages here in Arkansas if you'd be up for that exercise again. Thanks in advance for your consideration.

[John Landstrom]

I’d venture to say Bill wins the “MacGyver” award this month !!  Well done Bill.  
 

I sneaked a peak at him working on his newest project……..making a Tesla Cybertruck out of an old gas cylinder !   Stay tuned !!……..

 

[Steve Butler]

Your work is always top shelf and you just kicked it up a notch!   Well done Bill.   

[Bobby Gaines]

Great Job Bill! Like the way you think.

[Dave Hoatson]

Great job. 

[Mel Lagarde]

An outstanding and super creative thinking to get a wonderful outcome.   Wow.  Superb work and thank you so much for posting this for all of us to learn.  

[David Kilnapp]

OK, so now I'm even more impressed by your craftsmanship (if that were possible, Bill). Very clever indeed!

 

[Doug Wendel]

Hey Bill,

I'm always impressed by your work.  I have one of your Emerson open ring cages.

Have you ever made or repaired brass Emerson cages (e.g. 11xxx - 21xxx models) -- the ones with the big lead center blob holding the spokes together under the badge?  I have one of these cages that has lost it's center blob (the wires were loose in it, so I melted it off).  It looks to me it would require a jig to hold the spokes in place and some sort of sand or silicone mold to pour a new lead center blob.  I've never heard on someone making these cages or doing such a repair, but I have need.

[Jerry Van]

1 hour ago, Doug Wendel said:

Hey Bill,

I'm always impressed by your work.  I have one of your Emerson open ring cages.

Have you ever made or repaired brass Emerson cages (e.g. 11xxx - 21xxx models) -- the ones with the big lead center blob holding the spokes together under the badge?  I have one of these cages that has lost it's center blob (the wires were loose in it, so I melted it off).  It looks to me it would require a jig to hold the spokes in place and some sort of sand or silicone mold to pour a new lead center blob.  I've never heard on someone making these cages or doing such a repair, but I have need.

I'll stick my neck out here and reply to the question of a mold to cast lead in. Molten lead is not really all that hot. I've used molds made of wood in the past. There will be a bit of smoke but nothing so bad that it ruins the casting.

[Jerry Van]

1 minute ago, Jerry Van said:

I'll stick my neck out here and reply to the question of a mold to cast lead in. Molten lead is not really all that hot. I've used molds made of wood in the past. There will be a bit of smoke but nothing so bad that it ruins the casting.

Let me correct what I've just stated above. I have used wood as a mold for molten BABBIT, not lead. Molten lead is much hotter. My apologies. 

 

Also, how do you edit a posting here????

[Bill Dunlap]

I haven't had to make one of those yet. I have repaired loose ones by adding solder to them while heating just the spoke. Works great.