Introduction
Task 2 asked students to create a cover for a motor cycle fuel tank, in real life size. This task allowed us to choose from a different selection of tanks. As an initial group of 10, our group consisting of students from landscape architecture, architecture and construction management (myself) we decided as no other group decided to attempt to make the hardest tank. This tank is from a Yamaha IT250.
The task was then to form smaller groups within our groups which is where we split up the parts. The next days at uni and in class consisted of our group taking around 300 photos of the Tamaha IT250 model in order to create a 3D model in Rhino and Slicer where the model could be cut using the laser cutter. Once the model was established, the primary task was then to use our skills learnt over the semester in metal shaping, whilst using various techniques.
Step 1 - Digital Creation of the Fuel Tank
Our group came into uni to take 100's of photos on all different angles of the fuel tank in order to create a photo bank so large that when the photos were put into a computer software the fuel tank would be completely recognised allowing it to be used with slicer and the laser cutting machines. We would take a photo and then move the fuel tank slightly all the way around 360 degrees and we did this about 5 times to ensure that the photos were sufficient. We had to then put the photos on the computer and import them into recap which created the 3D image of the tank. After a model had no gaps and looked similar to the one of the real life model we measured across and added the correct measurements and dimensions exporting the file to slicer and started to prepare for the laser cutter.
Step 2 - Laser Cutter
The file from step 1 (slicer) was uploaded to the computer ready for the laser cutter to create out of plywood, the pieces to be created are those that would then allow us to glue them together to create our own model. The laser cutter was really fascinating and I have never seen one of these work before, it was great to use the technology for my own studies and understand how useful they can be.
Once the plywood pieces were all cut out by the machine, we assembled the pieces and stuck them together with glue. The glue was left to set and then we proceeded to cover the whole model with masking tape to ensure the stability of the model. This would then allow us to trace the surface with paper which takes us to step 3.
Step 3 - Planning the Creation/Paper Tracing
There was some confusion at the start of the planning process as to how Charlie McLeod and I were going to construct the petrol tank out of aluminium. We decided the best way to go about this would be as seen above with 2 wing like objects on the front side with the lid and middle body sitting in between them. The back and sides would be 3 large pieces so it was agreed I would do the front side while charlie did the back side. We also worked very closely with the architecture group who were in a group of 3 (Conrad, Remmy and Jake).
Upon many trial and errors we finally began to make some progress and with help from Gabe and the UNSW staff we started to create what sort of looked like a petrol tank.
Step 4 - Metal Making/Shaping
With my section of the assignment being the two front pieces either side of the middle piece, I started off with my paper cut out and then traced over aluminium which I then cut on the guillotine. The shape was really unusual but resembled aspects of the reverse curve, so instantly I knew that I was going to have to use the English Wheel a lot. I made a very quick practice to understand the shape that was going to come out of it, I tested different ways of hammering on sand bags to see which was more effective and would allow me to decide how I was going to create my assignment. Charlie was hard at work with the back parts so we decided to overhang my parts and then trim them down as we went. This turned out to be very useful as no gaps could then be seen from a birds eye view. The process consisted of constantly going back and forth from english wheel to the model to fit the shape, always trying to perfect those edges or the way the surface bent back, this can be seen through our time lapse below!
These were the results of my part. I am very happy with the result considering different people using their different techniques had to make various shapes and considering they fit so well it was a huge success.
Step 5 - The Finalisation
The complete project overall was really fun but extremely difficult and had to result in a lot of team work and hours of coming into the lab. The mixture of using the laser cutter digital information applications and my own hands to create this tank was really rewarding and I learnt a lot. The completed photos are in my view really incredible and the way we worked as a team was great to see. Below are individual photos of my part and group photos of our works together, fitted to our mould.
Individual Parts:
Group Parts Together:
FINAL PRODUCT
23/5/2018 - Simon Cooper
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