Bill Dunlap Posted March 22 Share Posted March 22 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 10 Quote Link to comment Share on other sites More sharing options...
Dave McManaman Posted March 22 Share Posted March 22 Holy cow! Ingenuity at its best. Thanks for sharing the pics and narrative. 1 Quote Link to comment Share on other sites More sharing options...
Geoff Dunaway Posted March 22 Share Posted March 22 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. Quote Link to comment Share on other sites More sharing options...
John Landstrom Posted March 22 Share Posted March 22 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 !!…….. 1 Quote Link to comment Share on other sites More sharing options...
Steve Butler Posted March 22 Share Posted March 22 Your work is always top shelf and you just kicked it up a notch! Well done Bill. Quote Link to comment Share on other sites More sharing options...
Bobby Gaines Posted March 23 Share Posted March 23 Great Job Bill! Like the way you think. Quote Link to comment Share on other sites More sharing options...
Dave Hoatson Posted March 26 Share Posted March 26 Great job. Quote Link to comment Share on other sites More sharing options...
Mel Lagarde Posted March 27 Share Posted March 27 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. Quote Link to comment Share on other sites More sharing options...
David Kilnapp Posted March 27 Share Posted March 27 OK, so now I'm even more impressed by your craftsmanship (if that were possible, Bill). Very clever indeed! Quote Link to comment Share on other sites More sharing options...
Doug Wendel Posted March 27 Share Posted March 27 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. Quote Link to comment Share on other sites More sharing options...
Jerry Van Posted March 27 Share Posted March 27 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. 1 Quote Link to comment Share on other sites More sharing options...
Jerry Van Posted March 27 Share Posted March 27 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???? 1 Quote Link to comment Share on other sites More sharing options...
Bill Dunlap Posted March 27 Author Share Posted March 27 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. Quote Link to comment Share on other sites More sharing options...
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