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Scratch Build – In Progress Project: Hush! - Updated 11/5/2022 :)

Discussion in 'Project Logs' started by Monkey Puzzle, 17 Jul 2009.

  1. Monkey Puzzle

    Monkey Puzzle Minimodder

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    Pro-tip: if you plan on polishing something to a near mirror shine (or as best as possible) do not first get it material blasted.

    It's quite a large hefty case (don't be fooled by the scale from the cat, who is a large Maine C-oon cross). It weighs something like 25kg iirc without the aluminium frame, and the copper back wall would need supporting to sand easily with power tools. This calls for a jig!

    [​IMG]Screenshots_2022-05-11-22-50-04

    I constructed a wooden slatted support frame that the pipes on the copper wall would sit between and then slide in a supporting plate, to allow the copper wall to sit horizontal without the pipes scruffing, and a large 10mm thick plate of aluminium to be drilled for the copper wall to bolt down onto and rest on to keep it flat for sanding.

    To get at the copper wall behind the copper pipes I used a 3" sanding disc rotary padworking up the grits of hook and loop attaching sanding paper discs (400, 600, 800, 1000, 1200, 1500, 2000 then polishing compounds on soft wool pads/mops then cellulose thinner to clean) powered by a variable speed drill. To get clearance to avoid the pipes, the sanding pad shank was replaced with a longer bolt with the same thread. To avoid the weight of the copper from damaging the polester resin covered end boxes I bolted two heavy duty polypropylene stacking boxes together to act as a table sitting inside to take the weight, with a neoprene pad cut around the PP crate shape/lattice, and taped in place to give friction to stop it sliding.

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    Last edited: 12 May 2022 at 02:25
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  2. Monkey Puzzle

    Monkey Puzzle Minimodder

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    The turquoise patina in those last shots was from trying to get the copper shiny chemically with a hydrogen peroxide containing liquid. That didn't work. Did look quite nice though in a way, but it's shiny we want!

    [​IMG]20210822_175028_Edited
     
    Last edited: 12 May 2022 at 00:50
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  3. Monkey Puzzle

    Monkey Puzzle Minimodder

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    It's a dusty business this sanding, and I'd need a spray booth for the lacquer. I made a spray booth with 12 x 1m long16mm diameter wooden poles, some cheapy cast aluminium 16mm pole corner connectors, some thick polypropylene 2m wide sheeting and heavy duty tape, and two cheap high speed 8" extractor fans, ducted to exhaust to a large 170 litre plastic storage trunk half-full of water (the idea being much of the dust would be caught by the water) with the air ducted down to flow across the water surface by sheets of thick polystyrene, exiting the top of the large box via a large hepa filter (~25cm x 35cm) , followed by an activated charcoal filter layer (both replacement filters for air filter units) added after that as final stage when needed for volatile organic compounds from cellulose thinner use and spraying). The wall of fans is 9 x gentle typhoons to blow across the sanding surface or help ventilate the room when needed.

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    One of these and good ventilation still needed!

    [​IMG]20211101_130618
     
    Last edited: 12 May 2022 at 00:38
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  4. Monkey Puzzle

    Monkey Puzzle Minimodder

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    The rotary sanding disc/wool pads got the central bit up to a mirror shine. The tubes and between them on the copper wall part was done by wrapping fine grit sandpaper around a 6mm square bar of tool steel, and the pipes by using perhaps 2-3cm wide strips of microfibre cloth soaked in brasso and flossing the pipes wrapped between pipes like you'd imagine a system of pulleys.

    [​IMG]20220124_125827

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    Click on pics above for videos.

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    Last edited: 12 May 2022 at 02:35
  5. TerHorstCustoms

    TerHorstCustoms Minimodder

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    I hadn't seen this log before, the looks epic! :jawdrop:
     
  6. Cheapskate

    Cheapskate Insane? or just stupid?

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    I noticed you back about a month ago and was wondering if we would see this rig again. :D I NEVER thought you would polish it. It looks fantastic.
     
  7. Monkey Puzzle

    Monkey Puzzle Minimodder

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    Hehe. More to come!
     
  8. Monkey Puzzle

    Monkey Puzzle Minimodder

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    There's a good reason why you thought that - it's absolute insanity!
     
  9. Monkey Puzzle

    Monkey Puzzle Minimodder

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    So, the back wall and pipes was tricky to polish with the sanding/polishing pads on the drill, and with polishing the pipes with sandpaper strips and brasso on strips of microfibre cloth. The radiator fins and pipes inbetween were another matter - the gaps are too small to get power tools in to sand easily, and flossing the copper pipes of the backwall only involved 96 of them.

    I had tried using sanding discs on a dremel to sand the radiator fins/plates near the surface, but the handmade slightly wonky nature of them from making the radiator meant they were often slightly off perfectly flat so this didn't really work very well.

    I found this handy mole clamp- think it's meant for clamping for welding, but works very well for straightening wonky 0.9mm copper fins!

    [​IMG]20211031_224433

    The gap between the fins is around 9mm - I used sandpaper wrapped around a long 6mm square bar of tool steel to sand between the fins, and strips of sandpaper of p1000 or p1200 around 7-8mm wide, cut from standard 230mm x 280mm sheets of wet'n'dry paper with a paper guillotine.

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    Not perfect, but the sanding with the wet'n'dry-wrapped bar did get the fins nice and pink in the centre.

    It's actually quite quick to thread the wet'n'dry strips around the pipes, and the sanding for each one took maybe 10-15 seconds. There's 48 6mm diameter pipes running between each set of fins, and 74 fins in total, and sanding each needed sanding twice (up and then down from the other side. Thank God for podcasts and audiobooks: This took a while....

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    (Vid)


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    [​IMG]20220216_015928 Video - excuse the extractor fan noise!

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    [​IMG]20220217_225553 (shiny, noisy video!)

    That's all for now folks :happy:
     
    Last edited: 17 May 2022 at 02:37
  10. Cheapskate

    Cheapskate Insane? or just stupid?

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    At least we know WHY you were gone so long now. :lol: You didn't really have it in storage. You've been sanding this whole time.
     
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  11. Monkey Puzzle

    Monkey Puzzle Minimodder

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    Curses, rumbled!
     
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  12. kim

    kim hardware addict

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    Impressive sanding session indeed :jawdrop:
     

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