12th January 2017, 19:09
Bronze, Titanium and Carbon Fibre. A 'Case' Study ;) (Photo heavy)
I've got to a scratch head, think about it stage with my Porsche Engine - Specifically how to get it back out of the garage when its fully assembled.
Because of this I have allowed myself a diversion.
Some of you will remember the Lumaholic watch http://forum.tz-uk.com/showthread.ph...m-a-Lumeaholic.
In that thread I said it was an idea for a case, and the plastic one was a prototype.
Well, I was happy with how it turned out, with a few minor alterations.
As a result I made the small changes and printed a pattern.
I then sent these off to a guy I know who does lost wax bronze castings for a living.
I've wanted to make a Carbon Fibre dial for a while, and so I dug out some thin CF sheet that I have.
Marked a circle and made with the Saw. Carbon Fibre is horrible to cut,and thin Carbon Fibre is really yuck. A lot of little itchy bits.
Still, a blank for the dial, a blank for the case, and a piece of Ti for the back.
Looks like a start :)
A blank dial would be beautiful - I'll polish the carbon to really show it off, but I need to practice applied indices.
So I grabbed another piece of Ti, and some files.
Made a Trapizoid, and filed the pins into it:
A 12 marker:
The casting needs a little work.
I thought Id see how it would polish up on the case edges.
Quite nicely it turns out:
The back will be a snap on, made from Titanium.
first make the square round:
Thats about the right size:
I have a soft jaw chuck, which is great for holding thin things. First you load the jaw, and then bore a shallow hole to hold the part.
Then you can grip the part for turning
If you look carefully you can see the 'snap' angle on the back piece. there is a matching bevel inside the case
It needs the outside profiling, another soft jaw job
Of course I need a crystal as well.
I started with some crystal plate:
And I bored the Case on my Unimat.
Cut a blank for the Crystal:
Profiled the outside to a nice bevel:
and cut the inside
I beveled a chapter ring into the case. Its going to look nice:
More to come at some point - I stil have to fit the movement to the dial, make a few more markers, some hands, and drill the case for the stem.
Then I probably need to make a stem and soem incidental bits and bobs.
Of course I also have to get the Porsche engine done and back in the car...
12th January 2017, 19:21
Love that! It's great you've got the tools and materials to hand. Is the carbon bare? If you lacquer it with a few coats you can really polish it up to a high finish. A friend of mine who's in the bodywork trade has made some really nice carbon skinned car parts, both for interior and exterior.
Have you cut the profile into the crystal or was it bought like that? What plans do you have for a strap?
Can't wait to see the next instalments.
12th January 2017, 19:22
Looking forward to more info/pics of the next steps
12th January 2017, 20:28
Yes the Carbon needs lacquer and polish.
The Crystal was cut from the sheet and profiled / turned / finished to the shape it is now.
Strap - I'm not sure, brown leather I think - I've got 2/3rds of a skin in a light brown almost orange colour.
Leatherwork will be a new thing to learn...
12th January 2017, 21:30
That is really impressive, I look forward to the updates!
13th January 2017, 19:13
Originally Posted by .olli.
+1, great stuff!
16th January 2017, 01:25
I'm glad you're back with an update, I enjoyed your earlier work.
It's obvious, to me, that you are a man of precision, technology, and good taste... you use .177 Air Rifle pellets, not .22 (2 slow) slugs like the knuckle draggers do ;-)
16th January 2017, 13:40
.177 is for the 10 meter target pistol.
I also have 22 for making bigger holes.
Much like I have 3 different sized lathes :)
16th January 2017, 22:57
17th January 2017, 20:22
Roughly cut the hands out and laid them on the dial:
There is more polishing work to do on the dial.
But as a watch its going to look nice:
There is a lot of filing and polishing to do. The hand blanks are rather thick, but at least I'll be able to give then a nice 3d shape.
17th January 2017, 21:05
17th January 2017, 21:41
Keep it going mate, Faster faster
17th January 2017, 22:16
Wonderful job, keep up the good work!
19th January 2017, 09:11
19th January 2017, 20:50
Thanks for the update, more great work there! What's the state of play with the engine?
19th January 2017, 22:02
The Porsche engine has got to the "its assembled, how do I get it back off the engine stand and out of the workshop?" stage...
I did a pretty dodgy lifting manoeuvre involving a ladder, a block and tackle and some climbing knots to get it on there.
I don't fancy doing the reverse now its all shiny, so I need to figure out how to reverse it with no damage or risk of hurting myself.
Typically Im alone in the workshop, and I cant afford to get injured...
Anyway that means I have to figure it out, and in the mean time I *have* to be making something, so bronze it is.
I have 6 of these castings, so there might even be a couple for sale at some point.
They'll have Chinese movements, but I intend to make a movement based on the Chinese one as the 'next big thing' I do.
The Titanium watch is at a stage where I need to decide on the case shape, so another pause point, where as this is a simpler thing to do.
Anyway, that aside tonight a little hour hand work:
Starting with a rough cut Hour hand blank
bit of filing to sort the edges and the blank is ready to shape in more detail
So glue it to a stanley knife blade
and start with the faceting
Its important to keep the two sides even, or a wonky hand will result
Then the back facets
thin it down, just like the minute hand
Both of them now need polishing to (hopefully) black perfection. Then they can patina nicely as the watch ages.
19th January 2017, 22:10
23rd January 2017, 22:52
Did a bit of polishing of the hands tonight.
I need to make a jig to get better results for the facets, but there are a couple of photos up on my Twitter feed : @SolutionsByDave
26th January 2017, 22:52
30th March 2017, 21:43
Bit of an update. I've been doing a little bit on the Porsche engine, a little on this.
I polished the hour hand as well, then it was time to make some inroads on the case.
Spring bar holes, drilled lugs as I like the simplicity for changing straps.
Then drill a hole for the stem to go through.
And make the case back snap on. I've still got to bevel the edge of the back.
Before making the crown and cutting the stem to the correct length I made delrin movement spacer, to hold the movement in position.
Then it was time to make a start on the crown. Bronze of course :)
I took this photo because the swarf is tiny, but looks just like 'real' swarf.
The drill is 0.5mm for scale.
Thats about the right size, this is a hand winder after all:
Then a rough clean up with some files on the case. You can start to see the beautiful curve / facet thing coming out.
After finishing the crown, tapping it and fitting to the case I remembered that the case side is actually bevelled... So a crown recess is in order.
Bosh the case in the mill, and make one :)
My vision for this case is a nice combo of curves and King Seiko Hi Beatesk flats.
To make the facets as flat and reglar as Seiko manage will be a feat, but I'm going to try :)
First I need a jig to use. After a dose of thinking about I put a hunk of brass in the big lathe and turned a plug thats a nice tight fit in the inside of the case.
I initially planned to use a large Ball bearing to run the files and stones on to give me the angle of the facet.
However this was far too wobbly, and required a great deal of concentration to keep the facet flat and not bowed.
Its not very obvious in the photo, it is only slight,
Even a slight bow is really a fail in this, so I hacked up JigMk2 (tm).
I really should make a proper one, and maybe I will once I can get to the welder and the surface grinder (which would of course make making flat flats a piece of cake...)
There now follows a long period of carefully rubbing up and down and the facets appear:
There is still a way to go, but its getting there, a bit like the Porsche engine...
More frequent (mostly live) updates occur on Twitter @solutionsbydave
20th April 2017, 21:29
21st April 2017, 01:24
Excellent result, truly unique! Such skill and patience. I presume you'll wear the watch as you drive the Porsche with it's newly fitted engine? ;-)
21st April 2017, 07:29
You're one hell of a talented guy, Dave. Awesome skills and creativity.
I can just about change a plug - so envious.
21st April 2017, 18:52
Yeah, I'll wear it in the Porsche.
I'm running out of distractions / excuses for not getting on with that...
The head is on, camshafts and valve timing next...