Tutorial - Ferrari Front Bumper Step 1: Mapping out the Shape from 3D Model or File Using the high resolution 3D Print (see Assignment 2) and direct measurements from the buck (using the middle piece as a centrepoint) map out the 5 shapes of the front bumper onto a piece of Aluminium sized to suit the flattened pattern of the bumper. Using a pencil draw on the aluminium 2 horizontal guidelines to match the upper and lower limits of the bumper. Step 2: Creating the Reliefs using Guides Guide Block: Using a piece of timber cut out a circle and square hole to match the drawings on the aluminium. [to make a square hole, drill out the 4 corners with a small drill and then use a chisel to gouge out the middle, the depth doesn't matter]. Clamp the aluminium to the guide block and place a blank block on either side of the intended relief area to avoid warping. Using a dowel and a square piece of timber (you may have to make these is if you cannot find...
Starting with the roller I then used the foot powered squeezer. This caused some cracking and splitting which was not ideal! It was very difficult to make an even spreading to cause the reverse curve. Moving onto the wooden mould the shape was made symmetrical and the curve enhanced. Using the metal curved dolly I pulled the side curves down to make it look neat and pretty. Here is a timelapse of me making the side curves. Finishing off the edge curve and making it even and symmetrical (and of course beautiful!).
We started our tray with 4 peices of identical timber templates. Using these to then cut a 1cm border around the Aluminium we created two trays that were almost perfectly identical (we got them confused many times). Removing the aluminium from the mould. Like two aluminium peas in workshop.
Love it!!!!
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