Reverse Engineering-New Tech for Old School Rides

We're building a model of a tranny tunnel to pull a fiberglass mold from.
Here is a mock up of the tunnel that has been prepped for 3-D scanning.
http://www.clubhotrod.com/photopost/...dium/a_039.jpg

The blue covering is painters tape, we used it to reduce reflections and make it easier to remove the reflective reference dots after scanning.
A 3 head 3-D portable laser scanner was used for scanning.
The dots are placed (semi randomly) on the surface to be scanned. The 3-D laser scanning camera uses these dots to create a "World" by recording the position of the dots. A "Point Cloud " can then be achieved by triangulating the recorded positons using proprietary scanning software..

From there the point cloud can be reformulated for solid modeling via RapidForm software.
http://www.clubhotrod.com/photopost/.../medium/16.jpg

Also design changes can be incorporated at this point.
You can see where two steel rods were afixed to the top of the tunnel.
The designer wanted to raise the top surface of the tunnel to the level of the steel rods.
http://www.clubhotrod.com/photopost/...tunnel_007.jpg

Here are the completed changes.
http://www.clubhotrod.com/photopost/..._rev2_side.jpg
http://www.clubhotrod.com/photopost/..._rev2_iso1.jpg

Once the model meets the design criteria, the RapidForm file is exported to a CAM package, In our case either MasterCam or Cimatron where toolpaths will be formulated and written into G-Code then downloaded to a CNC Mill.
The part is then cut.
http://www.clubhotrod.com/photopost/...tunnel_003.jpg

We used 1.5" thick home insulating foam cut into 24"X 56" rectangles laminated together to give us the proper size blank.
http://www.clubhotrod.com/photopost/...tunnel_013.jpg

A 1.25" Ball Nosed carbide indexable cutter was used for "whittlin".
http://www.clubhotrod.com/photopost/...unnel_0171.jpg

Here is the final outcome of the machining process.
http://www.clubhotrod.com/photopost/...tunnel_021.jpg

I love to watch stuff like this. Have some good friends who are currently reverse engineering a 427 sideoiler and will be producing it in billet aluminum instead of cast aluminum like the current Shelby and DOVE offerings...........Only difference is they did their whittling out of wood instead of styrofoam....

http://www.kirkhammotorsports.com/mfg/block_index.html


Bill S.

Very cool. Thanks for sharing with us.:D

Once the model meets the design criteria, the RapidForm file is exported to a CAM package, In our case either MasterCam or Cimatron where toolpaths will be formulated and written into G-Code then downloaded to a CNC Mill.
The part is then cut...Quote Supa Roosta



Oh yeah, I have one of those MasterCam thingies sitting in my garage, and I could have used it to make my tunnel, but I used an electric carving knife instead.:rolleyes: :LOL: :LOL: Make sure you don't let the resin touch the styrofoam!! :eek: :LOL:


That is very neat Tom. I got your email with these pictures in it, and found it very interesting. Machinery like this has got to be so much fun to play with. Keep the pictures coming as you guys progress on this project.

Don

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Originally Posted by Itoldyouso

Oh yeah, I used an electric carving knife instead.:rolleyes: :LOL: :LOL: Make sure you don't let the resin touch the styrofoam!! :eek: :LOL:



Don

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ROFLMAO

Hey, It's not the destination that's crucial, it's the journey!
I just forgot to warn you of the speed traps along the route.....:eek: :p :LOL:

Thanks guys.
I am in a very lucky situation, I get to learn and play.
Not only do we have some nice equipment, I'm lead by one of the Best minds in the field. A true genius, my professor Gary Walters.
Gary leads, I follow

I also have Don to keep me humble and on my toes, what more can a guy ask for???:toocool:

way cool.

I'd have just made a wire form from welding rod and laid the fiberglass on that.

But then, I assume you are making this for mass production?

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Originally Posted by firebird77clone

way cool.


But then, I assume you are making this for mass production?

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I asked the "Designer" He said, "They'll be making a bunch of them, but he doubts they'll be doing it in Church!":eek: :3dSMILE:


:p a little manufacturing humor,,,,, reeeeal little....;)

Thanks, I'll post more projects as they come.

Quote:

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Originally Posted by firebird77clone

way cool.

I'd have just made a wire form from welding rod and laid the fiberglass on that.

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That is how they made the original mock up with the inclusion of some chicken wire.