Popular Post paulbrook Posted July 2, 2019 Popular Post Share Posted July 2, 2019 (edited) After quite a while since I first started with this project where other priorities got in the way, I have now picked up the pace on my AC restoration and thought that others might be interested if I posted a picture or two along the way. I have loads of pictures of progress so far hosted on a site called "photobucket": a link to the first album of pictures of my AC is here http://s484.photobucket.com/user/RustyTrucks/library/Mack as advertised but you should be able to navigate around my particular bit of Photobucket for lots and lots more. Just nearing completion is the restoration of the radiator which had suffered greatly from electrolytic corrosion of the aluminium top tank. after a little investigation my son Dan decided to get radical and designed, 3d printed the patterns and cast 2 new sections that he then welded into place to restore the strength and integrity of the tank. All the pictures can be seen here http://s484.photobucket.com/user/RustyTrucks/library/Mack AC Restoration 2019 but I have added a "before" "during" and "after" to this post just to give a flavour. Next job is to machine down the flywheel a bit, fit a starter ring and convert the engine to electric start - more to follow! Edited July 2, 2019 by paulbrook 9 Quote Link to comment Share on other sites More sharing options...
Swishy Posted July 2, 2019 Share Posted July 2, 2019 Well dun Gr8 Stuff gunna take me a while to view all them pix keep up the good work n pix thanx in advance cya Quote Link to comment Share on other sites More sharing options...
Dirtymilkman Posted July 3, 2019 Share Posted July 3, 2019 Wow.........gonna be lots of hours. Very awesome. Quote Link to comment Share on other sites More sharing options...
41chevy Posted July 3, 2019 Share Posted July 3, 2019 (edited) I wondered how you were doing. Last post had the chassis primed and on wheels outside you shop. How long and cost on the #D printing? Paul Edited July 3, 2019 by 41chevy Quote "OPERTUNITY IS MISSED BY MOST PEOPLE BECAUSE IT IS DRESSED IN OVERALLS AND LOOKS LIKE WORK" Thomas Edison “Life’s journey is not to arrive at the grave safely, in a well preserved body, but rather to skid in sideways, totally worn out, shouting ‘Holy shit, what a ride!’” P.T.CHESHIRE Link to comment Share on other sites More sharing options...
JoeH Posted July 3, 2019 Share Posted July 3, 2019 Your son has some talent! Quote Link to comment Share on other sites More sharing options...
paulbrook Posted July 3, 2019 Author Share Posted July 3, 2019 10 hours ago, 41chevy said: I wondered how you were doing. Last post had the chassis primed and on wheels outside you shop. How long and cost on the #D printing? Paul Dan has not sent me the bill yet! But the way he went about making the patterns was fascinating. First, he chopped out the rotten buts then set them up on a rotating table before scanning them with a laser scanner to form a 3d digital image. He then "cleaned up" the image to create a digital 3d image of what the repair part should look like. He then scaled it to account for the shrinkage when the part was cast before 3d printing the pattern using a foam that burns away as the molten metal is poured in. A simple sand mould casting was then pretty easy. He tells me that one of the advantages of the "lost" foam is that it tends to smooth out the casting surface - much more like die casting. I will ask him how long it took. 1 Quote Link to comment Share on other sites More sharing options...
41chevy Posted July 3, 2019 Share Posted July 3, 2019 3 hours ago, paulbrook said: Dan has not sent me the bill yet! But the way he went about making the patterns was fascinating. First, he chopped out the rotten buts then set them up on a rotating table before scanning them with a laser scanner to form a 3d digital image. He then "cleaned up" the image to create a digital 3d image of what the repair part should look like. He then scaled it to account for the shrinkage when the part was cast before 3d printing the pattern using a foam that burns away as the molten metal is poured in. A simple sand mould casting was then pretty easy. He tells me that one of the advantages of the "lost" foam is that it tends to smooth out the casting surface - much more like die casting. I will ask him how long it took. I'd appreciate that. I did see the Cummins water pump housing for the 1940's Indy car that was 3D metal printed and held a few Mercedes metal printed parts for a 300. Sounds like a good possibilty for a few of my Packard parts. Quote "OPERTUNITY IS MISSED BY MOST PEOPLE BECAUSE IT IS DRESSED IN OVERALLS AND LOOKS LIKE WORK" Thomas Edison “Life’s journey is not to arrive at the grave safely, in a well preserved body, but rather to skid in sideways, totally worn out, shouting ‘Holy shit, what a ride!’” P.T.CHESHIRE Link to comment Share on other sites More sharing options...
JoeH Posted July 3, 2019 Share Posted July 3, 2019 If The Big Six from Macungie goes missing I didn't steal it and Dan doesn't have it for 3D replication! Quote Link to comment Share on other sites More sharing options...
ekennedy21 Posted July 3, 2019 Share Posted July 3, 2019 Guess why they never produced that big 6? Quote Link to comment Share on other sites More sharing options...
1965 Posted July 3, 2019 Share Posted July 3, 2019 1 hour ago, ekennedy21 said: Guess why they never produced that big 6? That story has been on here; can’t really remember it all. Bad timing of it & at buyout maybe? Quote Link to comment Share on other sites More sharing options...
ekennedy21 Posted July 3, 2019 Share Posted July 3, 2019 There was no place for it in their lineup. They put their eggs in the V8 basket for big power. Unfortunately, economies of scale come into play in production and more offerings equate to higher prices all the way through. Quote Link to comment Share on other sites More sharing options...
1965 Posted July 3, 2019 Share Posted July 3, 2019 5 minutes ago, ekennedy21 said: There was no place for it in their lineup. They put their eggs in the V8 basket for big power. Unfortunately, economies of scale come into play in production and more offerings equate to higher prices all the way through. Myself I’d rather had the V8. Quote Link to comment Share on other sites More sharing options...
yarnall Posted July 4, 2019 Share Posted July 4, 2019 Good work. I’d like to know what a tank like that would cost. I paid $1000 for a good use one and was glad to find it but would have liked to pay less. Yours looks nicer. Mike. Quote Link to comment Share on other sites More sharing options...
fxfymn Posted July 4, 2019 Share Posted July 4, 2019 Gary Mahan has had reproduction tanks made. Might be worth checking with him. Quote Money, sex, and fire; everybody thinks everyone else is getting more than they are! Link to comment Share on other sites More sharing options...
paulbrook Posted July 5, 2019 Author Share Posted July 5, 2019 On 7/3/2019 at 8:00 PM, 41chevy said: I'd appreciate that. I did see the Cummins water pump housing for the 1940's Indy car that was 3D metal printed and held a few Mercedes metal printed parts for a 300. Sounds like a good possibilty for a few of my Packard parts. I did not know you had a Packard. I have been dallying around buying a WW1 5t Packard from a guy I know in France for a few years now - but never plucked up the courage (besides I have too many projects as it is!). The 3d stuff that Dan is specialising in is a kind of half-way house: rather than try and print the final part he is printing the pattern from which a part can be cast, which makes it really cost effective. Many foundries can now print patterns, so if we want something casting out of some exotiv material we can simply email the file for the pattern to the foundry and they can then do a one off at little more than the cost of actually casting the thing. Quote Link to comment Share on other sites More sharing options...
paulbrook Posted July 5, 2019 Author Share Posted July 5, 2019 11 hours ago, fxfymn said: Gary Mahan has had reproduction tanks made. Might be worth checking with him. We were going to try that, but actually what we have now is the original but (virtually invisibly) repaired. On these old trucks much is so simple to make, like the cab, but over the years I have tended to want to try and use an original replacement or repair the original part if I can, even if that is harder than just, say, cutting a new cab side out of a sheet of metal. That said, sometimes only new will do! 2 Quote Link to comment Share on other sites More sharing options...
paulbrook Posted July 5, 2019 Author Share Posted July 5, 2019 On 7/4/2019 at 4:01 AM, yarnall said: Good work. I’d like to know what a tank like that would cost. I paid $1000 for a good use one and was glad to find it but would have liked to pay less. Yours looks nicer. Mike. All up I would guess about $3-400 for all this (like I say, I have not seen the bill yet!) but that involved all the set-up work. Now he has the files digitally I guess that subsequent repair sections would be much cheaper. We have done some work on another project (a WW2 Armored car) that is very rare. There is a similar one being restored by a group over on your side of the pond and we have been able to share all sorts of digital files which they can take to their local laser cutters, machine shop or foundry. I say take - they can email the files with the click of a mouse and the finished parts simply arrive in the post. That's what happens when you get some of these clever young folks involved 2 Quote Link to comment Share on other sites More sharing options...
41chevy Posted July 5, 2019 Share Posted July 5, 2019 9 hours ago, paulbrook said: I did not know you had a Packard. I have been dallying around buying a WW1 5t Packard from a guy I know in France for a few years now - but never plucked up the courage (besides I have too many projects as it is!). The 3d stuff that Dan is specialising in is a kind of half-way house: rather than try and print the final part he is printing the pattern from which a part can be cast, which makes it really cost effective. Many foundries can now print patterns, so if we want something casting out of some exotiv material we can simply email the file for the pattern to the foundry and they can then do a one off at little more than the cost of actually casting the thing. https://www.bigmacktrucks.com/topic/55276-new-tow-rtruck/?tab=comments#comment-413074 Quote "OPERTUNITY IS MISSED BY MOST PEOPLE BECAUSE IT IS DRESSED IN OVERALLS AND LOOKS LIKE WORK" Thomas Edison “Life’s journey is not to arrive at the grave safely, in a well preserved body, but rather to skid in sideways, totally worn out, shouting ‘Holy shit, what a ride!’” P.T.CHESHIRE Link to comment Share on other sites More sharing options...
paulbrook Posted July 5, 2019 Author Share Posted July 5, 2019 34 minutes ago, 41chevy said: https://www.bigmacktrucks.com/topic/55276-new-tow-rtruck/?tab=comments#comment-413074 Now that is a thing of beauty.. 1 Quote Link to comment Share on other sites More sharing options...
Vladislav Posted July 5, 2019 Share Posted July 5, 2019 Great job! Honestly if I were doing such fixing i would worry about the welded areas on possible leaks, cracking in the future etc. So purchasing a completely new cast part makes sence. On the other hand such repair is much more interesting entertainment. And if all go smooth you will be prouder and keep the fun. Quote Никогда не бывает слишком много грузовиков! leversole 11.2012 Link to comment Share on other sites More sharing options...
paulbrook Posted July 5, 2019 Author Share Posted July 5, 2019 1 hour ago, Vladislav said: Great job! Honestly if I were doing such fixing i would worry about the welded areas on possible leaks, cracking in the future etc. So purchasing a completely new cast part makes sence. On the other hand such repair is much more interesting entertainment. And if all go smooth you will be prouder and keep the fun. One thing's for sure - Dan's welds don't leak! He is a structural design engineer in the nuclear industry and really knows his stuff but also has a small company that do "impossible" engineering. So I think that the tank will be good for a hundred years or so. He did talk me through casting a new tank, and there is plenty that can go wrong with that too! Here is another of his masterpieces 1 Quote Link to comment Share on other sites More sharing options...
JoeH Posted July 6, 2019 Share Posted July 6, 2019 (concrete delivery driver, ranting about DIY engineers) I've found that with engineers they usually think they know everything, but when push comes to shove they tend to be controlling of those of us who know how to do our jobs, which slows me down from getting their delivery done so I can keep my schedule. Concrete in particular you just have to jump in and get it done. It's labor intensive, and there's no way around that sometimes. But that radiator looks great! Dan has talent! If he welded it himself I'm doubly impressed, engineering theory is one thing, but the skill to make it happen requires a different talent. Haven't met many engineers with both. Quote Link to comment Share on other sites More sharing options...
paulbrook Posted August 11, 2019 Author Share Posted August 11, 2019 On 7/6/2019 at 1:19 AM, JoeH said: (concrete delivery driver, ranting about DIY engineers) I've found that with engineers they usually think they know everything, but when push comes to shove they tend to be controlling of those of us who know how to do our jobs, which slows me down from getting their delivery done so I can keep my schedule. Concrete in particular you just have to jump in and get it done. It's labor intensive, and there's no way around that sometimes. But that radiator looks great! Dan has talent! If he welded it himself I'm doubly impressed, engineering theory is one thing, but the skill to make it happen requires a different talent. Haven't met many engineers with both. His latest bit of work for me, machining the AC flywheel to take a starter ring gear, can be seen here. Before doing it he had to adapt both the chuck and the gap block. 1 Quote Link to comment Share on other sites More sharing options...
mowerman Posted August 14, 2019 Share Posted August 14, 2019 Man alotta work excellent ... bobSent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
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