Assignment 2 : 1:1 Fuel Tank

Preparation material: Original fuel tank, Laser cutting templates, Aluminum sheet,

Fuel tank model : Harley 883 Iron

Preparation 

Step 1: Taking photos as much as different angles photos 

Original fuel tank photos for photogrammetry

(This process requires an amount of different angles photos to get an exact shape.)

Step 2: Using photogrammetry (Autodesk recap) to generate 3D model 

Once we got Photos for photogrammetry (recap), we used recap to create the 3D model of fuel tank. We give dimensions of physical model and remove unnecessary part.

Step 3: Using Slicer to get assembled templates for laser printing. 

We input to Slicer to get assembled templates and we decide to make 30 pieces (15 vertical & 15 Horizontal). 

Step 4: Using laser cutting machine to get assembled templates & Assembled together. 

Laser cutting plywood

Process 

Finished templates model 

Step 5: Wrapping the model 

Wrapping the whole surfaces to get smooth and enclosed faces. 

Dividing the model into 3 pieces

Step 1: Pattern making

We used paper to get approximately shape of fuel tank and also we divide as 3 pieces of a fuel tank (1 model for 3 people).

Step 2: Cutting shapes into 3 pieces

After cutting paper templates, we draw shapes into aluminum sheet.

Making a fuel tank

This is individual work. Once I got selected part, I need to do make a fuel tank with my knowledge from previous work. 

Step 1: Hammering from inside to outside. 

I hammered curving part (outer and centre) to ready to using an English Wheel. 

Step 2: Using an English wheel to get an exact shape with smooth surface.

Step 3: Repeating step 1 & 2 process to fit on assembled model.

Semi-finished model

Step 4: Assembled 3 parts into templates model to cut unnecessary parts

 Step 5: Finished model (Polishing the surface.)