Assignment 2 | THE FUEL TANK

Yamaha IT250 
         Fuel Tank



Project Outline

Forming groups of 10 multidisciplinary students, a 1:1 scale model of the Yamaha IT250 fuel tank will be fabricated. As individual students, an aluminium skin will be created to adhere to the construction and detail of the model. 

Objectives

  • Model Construction  The creation of a 1:1 fuel tank template to assist with the fabrication process
  • Pattern Fabrication  Compose a pattern or template which will provide a method of construction and reference for the aluminium skin
  • Metal Shaping  Using the model and pattern as reference, shape and sculpt the aluminium to adhere closely to the construction of the fuel tank
  • Documentation  Record the process of fabricating the Yamaha IT250 fuel tank

1  Model Construction

The initial phase of constructing the model involved utilising Photogrammetry to digitally fabricate a 1:1 model. The required 3D model was created through Autodesk Recap, which compiled the range of photographs we collectively captured of the Yamaha IT250 fuel tank and composed the model. 
Thanks to a member of our group, Charlie McLeod, our model
was successfully created in Autodesk Recap after lots of photos

Our first Photogrammetry 
attempt was unsuccessful 














The next step involved transferring our created model into Autodesk Slicer. This program divided, or sliced, the model into components which could be used by a laser cutter, and as a group we opted for a tight grid which would enable us to fabricate a more cohesive and accurate model. Adobe Illustrator was then used to organise the templates created by Autodesk Slicer onto a sheet which would be compatible with the laser cutter. Once our files had been formatted correctly we could proceed to laser cutting.

The laser cut templates
were a perfect fit
Glue was needed to further
strengthen the bondage
Our Illustrator files translated
directly onto plywood sheets, 
which were then laser cut to
create our waffles
Our stack of laser cut
waffles

After our files had been laser cut, the next phase of model construction involved compiling the laser cut templates into the correct place to fabricate the model. Glue was used to further join the templates together to ensure structural integrity. Lastly, the
model was covered extensively with masking tape to smooth the exterior and provide a more cohesive finish to assist with the fabrication of the aluminium skin.


The finished product







               
The complete model
Masking tape provided
for a smoother finish















2  Pattern Fabrication

To assist with the construction of the aluminium skin, patterns of certain parts of the model were created from sheets of paper. Amity Yore, Emma La Coste and Thomas Surmon comprised my team, and as a group of four we divided the model into four correlating components which were:

TOP SIDE  AMITY
TOP  EMMA
SIDE  BEN






BACK  THOMAS

Following on from this, we began to draw out our paper templates of the described components of the model, which we then cut out using scissors and measured against the model to ensure accuracy. This was rather challenging, as drawing with the 2D nature of paper against our 3D model provided rather inaccurate depictions of the components which meant that multiple efforts to redraw the template was needed. Once we had successfully created our paper templates, we drew these with permanent marker onto our aluminium sheets which could then be ready for cutting.

Drawing the top was 
quite a challenge as a 
result of the many
dimensions
         
          Preparing to trace our pattern
          onto the aluminium skin
Using a combination of tin-snips, the guillotine and the cutting lever, the templates were cut out with precision and filed along the edges to eliminate undesired effects such as sharp protruding shards and uneven finishes. The result of this was a set of aluminium skins ready for shaping and sculpturing to our model.

Aluminium sheet ready 
for tracing
                
                Cutting the side template
                with the lever
             
             Thomas cutting his 
             template with tin-snips

 3  Metal Shaping

The third component of the project involved shaping our metal to match the construction of our Yamaha IT250 fuel tank model. 
Firstly, I started by analysing the shape of the sides by feeling for general characteristics such as bulges, depressions and curves. From this analysis I discovered that the main components forming the sides of the fuel tank were the following:
  • Large bulge towards the back plate
  • Depression leading away from this bulge toward the front of the model
  • Curves at the top of the side, running adjacent to Amity's section

My analysis of the sides
characteristics
Following on from this, I started the shaping of my templates by stretching the aluminium using the English Wheel to form the bulge. I repeated this method with my corresponding template for the other side of the model. This required patience and persistence, as I was constantly fitting my skin to the model to check how well it was adhering to the shape. 

Once the bulge was adhering well, I begun to work on fabricating the depression. This was challenging, as the inverse curve I was trying to create would disfigure the shape of the bulge. I discovered that soft and gentle strikes with a rubber mallet could achieve the depression without affecting the rest of the skin, so I begun to employ this tactic on both of my templates with great success. 

Lastly, I begun curving the edges of the skin to adhere correctly to the model, and I achieved this using both the shrinker and a dolly. The shrinker was used to provide a consistent curve along the edge of the skin, and then I used a dolly to exaggerate this curvilinear component. 






4  Documentation

My favourite part of the project - documenting both myself and my team's experience of creating the Yamaha IT250 fuel tank with aluminium skins. 

This was an enjoyable project which brought with it an array of challenges and rewarding learning curves. The shape of the fuel tank proved harder to manipulate with the aluminium skins than I first thought, however I am glad that we decided to undertake the challenge as I feel a sense of fulfilment with the finished project. 

See below for the finished product!
















5  Landscape Architecture

This project challenged me in terms of the complexity and the skill involved to achieve a cohesive and fitting aluminium skin. Another element this assignment delivered was the relation I could see between such a task and my field of study, Landscape Architecture. Often in any form of architecture, a lot of time is spent drawing and designing spaces, materials and elements, however often you are not involved in the fabrication process. This task was different - I thoroughly enjoyed being engaged in both aspects of the fuel tank; drawing/designing and then constructing. 

The knowledge I have gained through this task in regards to manufacturing and materiality I believe I can take with me with my studies. 

Comments

Post a Comment

Popular posts from this blog

Assignment 1 | THE BLISTER

Image
The last task of assignment one enabled us to learn how to fabricate an aluminium blister. Using a wooden template, a sheet of aluminium was positioned in place with screws and a set of clamps to ensure the sheet was as still as possible. Once all of these materials were in place, the manufacturing process could begin. Heeding advice from a fellow classmate, I slowly created an indentation in the aluminium using soft and gentle blows in order to avoid any cracking. I was able to best undertake this using a wooden hammer, as this absorbed more energy from the blows and had a softer surface. Once I found the depth of my blister to be satisfactory, I began to work on the circumference of the shape. Using a wooden shaft to allow me to access the narrow and awkward spaces, I slowly worked my way around the shape striking with gentle blows to create more depth along the rim. After removing the wooden template, I began softening out the wrinkles within the aluminium using a dolly and ha
Read more

Assignment 3 | A COMPREHENSIVE REFLECTION

Image
Overview Over the duration of the course, I have gained many new skills regarding both the digital and physical fabrication of materials - mainly wood and aluminium. A highly enjoyable course, BEIL0014 has provided me with a heightened understanding regarding the multi-level process which is digital making. Through a series of challenging and energising workshops, myself and others all produced a set of fabrications - ranging from the small and compact to the large and complex. Satisfied with my performance over the semester, I believe the materials I have fabricated are of good quality and I am happy upon reflection of my work to see how far I have progressed. Nevertheless, it is from this reflection that I believe my work could be further enhanced through one project - the tray.  The Tray One of the more challenging projects, I found the fabrication of the tray to be difficult as a result of the sharp and clean edges needed along all four sides in order to achieve an
Read more

Assignment 1 | THE TORUS

Image
Week 3 began with the introduction on how to construct the Torus, a fabrication which involved making a reverse curve. The reverse curve was surprisingly challenging to achieve. Once the sheet of aluminium was curved in one direction, shaping the middle of the sheet into a curve in the other direction was hard because the aluminium would begin to flatten out again.  I overcame this with persistence in striking the middle slowly and more delicately in order to achieve a curve whilst not flatting the entire sheet.  Overall, I found the Torus a fun and enjoyable construction, due to the challenges it provided me and the final finished product which I am satisfied with. 
Read more