Week 4 (02-14-18) - Preparations for Welding

This week's tasks including preparations for welding and practice for Angelo and Kevin on the welder with Dan's supervision. In addition to the welding experience, I took part in videotaping Dan (from Full-Scale Bogey) while he was demonstrating the necessary steps and safety warnings that were associated with TIG welding. I am hoping to create a document that shows a summary of what he has shown us, that way this information could be passed onto multiple generations of welders who want to utilize the welding equipment we have in-house. In addition to the welding introductions, the rest of the team is starting to set up a regular schedule of coming in two extra times a week in order to complete the mountain of work we have ahead of us. I know we can complete this project on time and be ready for Maker Faire if we keep up with this schedule.

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Week 13 (04-25-18): Cleaning up Welded Track Attachments

This week, I focused my efforts on cleaning up some of the welded sections that I worked on last week. Within the square tubing, there is a slight rise that follows along the length of the tubing. This makes it impossible for these parts to slide into the support sleeves that we have already made. In order to finish up these components, I filed them down with a combination of using a Dremel tool with a diamond bit tip and Spartan Superway's file. The first image shows the excess metal that protrudes out of the inside of the square tubing. The next image shows that same protrusion grinded down with the use of the Dremel tool and shop file.

Week 12 (04-18-18): Welding For Last Support Components

On Monday, the team met up and needed to address some of the issues that we had with the welder. Kevin was in constant communication with administration and Dan (from full-scale bogey) to ensure we were taking the correct course of action. Kevin and I took a trip to Praxair to retrieve a new tank of Argon for the remaining welds. After coming back and setting up the welder, I started and finished the welds necessary for the support structures. I encountered some issues during this process as I never found the correct way to properly weld these two components together due to the differences in thickness of the square tubing and the sheet metal. If I utilize too high of a current, the sheet metal would have a hole burnt through. However, if the current was too low, there would be no penetration of the square tubing. Even after completing 80 welds, this process was not mastered and still need to be cleaned up through other methods that will be looked into.

Week 14 (05-02-18): Finishing up the Supports & Putting the Track Together

Last week, I ground down the welded support parts that attach to the track. I finished 20 of these parts and it required a lot of patience since grinding down steel requires some time. I even had a collet for the Dremel tool break on me since the diamond tip Dremel-bit pushed the collet to open up throughout the duration of the grinding process. By trying to close up the collet to secure the bit, one of the collet's prongs broke. After these parts were completed, I started drilling holes into them to ensure that they would fit into the whole track assembly smoothly. I used the drill press and some of the brackets that Kevin finished printing. The end result of these components looks like the following image: After the support structures were put together, we assembled the track fully for the first time. Although it was a small assembly that reduced the length of the track, due to removing several straights, it allowed for the other subteams to test the bogey and controls....

Bryan Oyan - 1/12th Scale Track Design + Manufacturing

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