Nautilus out of an I-Beam - Questions on Bending

[VaughnT]

Imo, you're using your scrolling forks wrong. I've made and used quite a few of them over the years, but they don't work well in an application like yours.

What I'd opt for instead is a closed system that operates like a mobile Hossfield bender. 1" bars of mild steel spaced to fully clear the entire i-beam, welded to a pair of arms that are some 4' long or even longer. The bottom crossbar is positioned on the outside of the beam directly under the solid flange and acts as the fulcrum around which the metal bends. The upper crossbar should bite into the flange that's on the moving section of beam.

Does that make sense?

Anyhow, with the scrolling wrenches tied together, they support each other and get the job done a lot smoother.

[Shootr]

Hmmmmmm.....







Still a lot of cleanup to do, as well as figure out a mount or base. I also need to figure out if/how to tighten up the radius where indicated - as I progressed I kept going back to fine tune the shape, but once I passed a point of no return I couldn't figure out how to adjust things inside the coiled area.



But still very pleased with the progress.

[Shootr]

Imo, you're using your scrolling forks wrong. I've made and used quite a few of them over the years, but they don't work well in an application like yours.

What I'd opt for instead is a closed system that operates like a mobile Hossfield bender. 1" bars of mild steel spaced to fully clear the entire i-beam, welded to a pair of arms that are some 4' long or even longer. The bottom crossbar is positioned on the outside of the beam directly under the solid flange and acts as the fulcrum around which the metal bends. The upper crossbar should bite into the flange that's on the moving section of beam.

Does that make sense?

Anyhow, with the scrolling wrenches tied together, they support each other and get the job done a lot smoother.

Very clear - thank you for the idea.

[tapwelder]

Looks really good.

[tapwelder]

Tack Weld or pin it to the table. Rotate it as needed. Make sure you can access your welds to grind remove them.

[CAVEMANN]

Hey, I worked in the copper industry for nearly 25 years, 9 years in Ajo, as a diesel lo, where are you located??comotive mechanic, & 15 at Hidalgo Smelter in New Mexico as a loco mechanic, , machinist apprenticeship & machinist, left Hidalgo & copper in 99 when the smelter shut down

[Shootr]

Hey, I worked in the copper industry for nearly 25 years, 9 years in Ajo, as a diesel lo, where are you located??comotive mechanic, & 15 at Hidalgo Smelter in New Mexico as a loco mechanic, , machinist apprenticeship & machinist, left Hidalgo & copper in 99 when the smelter shut down

I'm based in Phoenix, the properties I take care of for my company are all the Arizona Freeport ones. I don't much physical labor anymore, mostly surveys and audits of the conveyors - troubleshooting issues for them.

[12V71]

Hey, I worked in the copper industry for nearly 25 years, 9 years in Ajo, as a diesel lo, where are you located??comotive mechanic, & 15 at Hidalgo Smelter in New Mexico as a loco mechanic, , machinist apprenticeship & machinist, left Hidalgo & copper in 99 when the smelter shut down

That's why I asked you about ALCOs sometime back, I was under the assumption you worked for ASARCO, my bad. They had RS-3 ALCOs.

[Shootr]

May be a little on the small side, but possibly have found a base for the nautilus:



3/8" thick x 24" diameter - little over 50lbs. Once I figure out the balance points on the steel I'll have a better idea if it will work or not. But for $25 I couldn't pass it up...

Oh yea, fooling around with filters last night...

[BD1]

Determining balance point is nice with overhead chainfall for lifting. A tree limb can be handy too. Fortunately, with steel a couple of tacks will hold.
Safety is a issue with something that heavy.
It's turning out nicely.


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[LtBadd]

Nice work, waiting to see the finished piece.

[chickenfarmer]

This is awesome, keep up the good work! We are excited to see it standing!

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[Shootr]

Determining balance point is nice with overhead chainfall for lifting. A tree limb can be handy too. Fortunately, with steel a couple of tacks will hold.
Safety is a issue with something that heavy.
It's turning out nicely.


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Now if I just had a tree... I wonder if the neighbor will loan me his - not a lot to choose from here in the desert !

[VaughnT]

Gotta say, I was one of those doubters, but you really proved yourself with this one!

Never would have guessed it'd come out looking so sweet, especially with the filtered shot!

Very much looking forward to seeing what's next.

[Shootr]

This is awesome, keep up the good work! We are excited to see it standing!

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Nice work, waiting to see the finished piece.

Gotta say, I was one of those doubters, but you really proved yourself with this one!

Never would have guessed it'd come out looking so sweet, especially with the filtered shot!

Very much looking forward to seeing what's next.

I really appreciate the positive words. I know I can be mule stubborn sometimes (like insisting on bending rather cut/weld this effort) but whatever I seem to be doing, it'll either work, it'll work but with consequences, or it'll fail. But whatever the outcome, I learn something(s) for the next time. (Took three tries to get the portaband stand to work lol).

I should add that my trial/error approach only pertains to things non-structural and in no way could possibly cause harm to anyone or anything.

[shortfuse]

Shootr, I just got around to reading your thread from the beginning. I have to say, that at the start I thought "...what has this guy gotten himself into??" After seeing all the suggestions and the steps that you took to fab this thing out, I have to now say, you did a spectacular job doing something that large, that you had never done before and ended up with a work of art. Job well done!

[Insaneride]

It's freaking awesome.

I read this whole thread. Thanks for sharing. Shootr, you said something about cutting the second wing or web (what you call it) and weld back? I would use a copper backer and fill in the stress crack with ss or SillBronze. I would fill the crack with SilliBronz if your panting. The load is on the fatter end. That round plate looks like a good base. I think you need to find the fulcrum or center of balance tho. Just make it concentric.

[VaughnT]

Ya know, another tool I just "designed" in my mind and think could be handy is basically a spin on the ol' nut-splitter or gear puller.

You create a frame that's got a 6-1/2" clearance so you can slip it in place around the I-beam, and then use a drill to drive a wedge down into the cut you've made. The angle of the wedge dictates how much spread there'd be, and you could swap out wedges so you could have something with a thin taper for starting and then something with a thicker taper for pushing that last bit.

Once you get the bend started, you could even swap out the wedge for a bit of round bar.

[Capt B]

I was skeptical from the beginning as well but very well done. Love the filter pic.

[Shootr]

Yay, no more killing myself trying to lift and move stuff! (I posted the details in the "Shop Layout" forum).

NOW I can finally finish this sucker - super easy to find the balance point and play with ideas before committing to the base. I like the little hoop and leaving the end uncut - makes it look lighter I think.





And again, thank you for the encouragement and positive comments - it's been a rewarding few weeks!

[Shootr]

When I go to weld this, should I heat up the plate first and then weld the I-beam to it? (HF Flux core 125) Should the wire speed be on the faster or slower side to get the best penetration?

[Shootr]

Drum roll please...





I did use a portable torch to preheat the base plate, as the first attempt to tack it looked really cold. The rest of the welding went pretty good, for a HF FCAW (I did do the DCEN modification on it though). Don't be too harsh - but providing full disclosure lol!




Bonus shot from the missus...



Next project - cleaning and organizing the garage .

[BD1]

Awesome job !!! That turned out great.
Hard to believe what a guy can make in a few hours.


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[Welder Dave]

You should get someone with a portable welder to come over and weld it for you. The nautilus looks neat but the bottom looks unfinished. I probably would have cut the beam on an angle and welded the full beam to the plate without the pipe for support. Kind of a gravity defying type of thing.

[tapwelder]

The connection point is fine provide IF the weld is sound . The weld/machine is suspect. I would agree with finding somebody to weld it. Or get a larger welder. Is the ring welded providing support?