ASSIGNMENT 2: FUEL TANK

Fuel Tank of Harley 883 Iron

Step 1: Form a group of nine and our group chose to do the fuel tank of Harley 883 Iron.

My groupmates include:

Li Chen

Moonjin Kim

Eu Gene Hyun

Louis Yu Tak Cheung

Lverson Chun Yat Chiu

Yixuan Zhang

Yihui Wang

Alex Sostres-Roberts

Step 2: Building the 3D model by photogrammetry. In this process, we need to take many photos from different angles. Then, put these photos into the software Recap. After the 3D model created, we need to measure the dimension from the fuel tank and put the dimension into the 3D model. For this time, we have measured that the highest point of the fuel tank was 209mm, the top length was 396mm, the bottom length was 392mm and the width was around 230mm.

Step 3: Using the Slicer tool for Fusion 360 to create the laser cut template. Then, export the file and put it into the UNSW Illustrator template for laser cutting. This time we have used the 6mm plywood for our wood template.

Step 4: After printing out the laser cut template, we need to assemble the template into 3D model.

Step 5: Wrapping around the model by cling wrap to create a smooth surface.

Step 6: Three groupmates form a small group. My group members are Yixuan Zhang and Yihui Wang. Using paper to wrap around the model. Then, divided the 3D model into several parts and cut the paper out. At this time, our group has separated the model into four parts which are left, right, front middle and back middle.

Step 7: Put the paper on a metal sheet and use marker to draw along the paper edge.

Step 8: Use Hand Lever Shear to cut the metal sheet. Besides, I was assigned to do the middle part.

Step 9: Use the English Wheel to create a general curve for the metal sheet. For the edge, shrinking the metal sheet by a mallet on the metal curved dolly or using the Shrinker/Stretcher Tool to create a deeper curve. After that, put the metal sheet on the 3D model and match. Keep shrinking the metal sheet until it closely adhere to the contours of the template.