San Antonio, Texas: Student Metalworking Projects

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  • Student project TM Metalworking Workshop Kent White

    Rod’s project: Taylorcraft L-2M nosebowl

    Rod’s project begins with paper patterns to determine the size of the blanks he will need. 

  • Student project TM Metalworking Workshop Kent White

    Blanks

    Blanks are cut to size, deburred, and marked with the shaping geometry.

  • Student project TM Metalworking Workshop Kent White

    Shaping

    Rod uses a mallet and bag to put preliminary shape into the sections.

  • Student project TM Metalworking Workshop Kent White

    Fitting

    Sections are fit to make a whole complete part.

  • Student project TM Metalworking Workshop Kent White

    Welding

    The individual sections have been trimmed, butted, and are now being welded. Rod asked me to do most of the welding, because he wanted to have very nice weld seems on his finished part, to complement his lovely forming efforts. Rod can be seen here peering over Kentís shoulder while he welds.

  • Student project TM Metalworking Workshop Kent White

    Trimming

    The upper and lower halves of the nose bowl have been welded and planished and are now matched together for trimming.

  • Student project TM Metalworking Workshop Kent White

    Making progress

    This shows what the lower half looks like after it has been formed, joined, and planished.

  • Student project TM Metalworking Workshop Kent White

    Painted and installed on the airplane

    "Kent, I attended your workshop in San Antonio a year ago. I wanted you to see the final product; people are amazed that it was beat out of a flat sheet! Thanks again for sharing your incredible knowledge and skill that allowed me to complete the project. The workshop was a milestone event in my metal forming journey. Warm Regards, Rod Johannsen."

  • Student project TM Metalworking Workshop Kent White

    Al’s project: Aluminum baseball hat

    Paper patterns show the size and relation of the parts and the division of the sections.

  • Student project TM Metalworking Workshop Kent White

    Welding

    Al begins welding the shaped sections together.

  • Student project TM Metalworking Workshop Kent White

    Planishing

    Next, he used the TM Air Power Hammer to planish his welds and smooth his piece.

  • Student project TM Metalworking Workshop Kent White

    Adjusting

    Little adjustments are done to the fit.

  • Student project TM Metalworking Workshop Kent White

    Final fit

    Profile view of the nearly finished piece.