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Old 06-01-2016, 10:01 AM   #110
knc1
99.44/100% On Holiday
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Posts: 17,206
Karma: 18210797
Join Date: Feb 2012
Location: Central Texas
Device: No K1, PW2, KV, KOA
I am back on the job.
I admit it - I took a couple of days off for holiday weekend activities.

= = = =

Last week, the tool to make the tooling:

Pic 1:
A waxed, wooden positioning jig, each of the three surfaces at right-angles to the others.
The photo perspective might make it hard to see that each of the three sides are indeed square with the other two.

Shown below the jig, a piece of Aluminum channel.

The various molding, modeling, and casting compounds will not stick to the waxed surfaces.
They will stick to the Aluminum channel.

Pic 2:
The positioning jig has a recess in the back and bottom surfaces to hold a "slip-in" piece of the channel.

When in-place, the bottom surface is even the top edge of the channel and the back surface is even with the rear, inside, surface of the channel.

= = = =

The positioning jig is intended to be re-usable.
The slip-in "mold carrier" will be a permanent part of the mold or casting that is made.

The "fit" is close enough that the mold or casting (in its aluminum channel carrier) can be removed and returned to the same position relative to all three surfaces.

This tool is needed because the "connector bulge" on the top will not be an exact copy of that on the bottom (nor in the same position).

So the process will be to cast a mold of a long edge and of the bottom edge -
Take the two molds in their channel carriers and cut them into slices -
Slices that when re-assembled in a different order, will make a model of the bulge to be made in the top edge.
Attached Thumbnails
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Name:	corner-jig.jpg
Views:	111
Size:	1.31 MB
ID:	149095  

Last edited by knc1; 06-01-2016 at 11:16 AM.
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