Thursday, April 30, 2009

Sonny and Extreme Ironing

So this is our dog Sonny. He's an ex-con that we picked up at a homeless shelter. Long history of complete disregard for the laws of society but he's trying to get his life together. He still has one big vice that he refuses to give up on. He eats poop. Just loves the stuff. His preference is llama of which we have plenty of those tasty morsels laying around the place. Jeez.

Today's project is beginning on the fabrication of the ironwork for the Skeleton Gig. We have pretty much wrapped up construction of the body as of yesterday. Now we just need to figure out how to hold it in the chassis. The rear supports are a gracefully curved uprights starting at the rear frame and going up to the bottom of the seat.

We started with a piece of 1" diameter by 14 gauge steel tube. We bent the shape in our homebuilt large diameter bender. The trick is getting the right diameter on the bend to fit the body shape. I think we pulled that off and it looks proper. Now fabricating the end connections. The brace needs to fasten to a 2" wide rear frame support on the bottom and it just bolts under the seat which is a much simpler connection on the top.

That lower connection turned into a fairly complicated connection for a simple brace. Making sure the connection is strong enough to support the weight of the body and the passengers is of course pretty important. So we put a bolt coming down through the top and a back faceplate that will bolt through the back side of the frame cross brace. That will give us three 3/8" fasteners spread out over a 4" area. That will not be going anyplace anytime soon.

The toeboard supports and under body frame proved to be much easier projects. We liked the detail on the original Kimball vehicle that was the inspiration for much of this body design. It was 2" wide flat stock on the top side and another 2" wide support on the bottom. Of course on the Kimball the edges are well eased all around the perimeter of the metal brace. So quite a bit of time on our end spend grinding down the square top edges of the flat steel.

New subject tomorrow. We are midway through the construction of a new Marathon Carriage. I think we may just dig out a few photos of that project.

Have a great day!



Kim Bates said...

Who knew!?! Interesting- all the work that goes into a carriage. Will we see one of these at the Columbus Carriage Classic this year? And, the "extreme ironing" wasn't exactly what I thought it would be...I thought you'd have a picture of someone ironing in the carriage while it was being pulled...maybe we should have that as a new Division at the Carriage there's a thought!

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