Kirkham Motorsports University Bronze Coupe Fender
Hey Guys,
We had a customer who asked if we could make a Coupe from bronze. So, we started with a fender.
We have sold so many cars (and attic parts ) lately we had to hire 3 new people. My wife is also coming down to help as well. I lured her in with the new gym
With the new help around here I have been freed up to do some things I have long been wanting to do. Glenn Reynolds of www.instapundit.com (a site I think you guys would really like) and author of Army of Davids inspired us to start Kirkham University to show the world how we make things. We hope our metal forming and machining knowledge may be of interest and use to others. Many people freely gave of their time to us over the years to help us continually make better products. Now, we want to return the many favors we have received from so many kind people.
Here is some more Kirkham Motorsports University on YouTube--CNC Machining, Metal Forming, and Advanced Manufacturing Techniques.
- About how long does the process take to make the fender from start to finish?
- How are the sections joined together ... are they soldered together or welded?
Thanks.
- Tim
It takes about 8 man hours to make the fender and 8 hours to polish it. This doesn't include the time digitizing the car, machining the dies, or making the stretch form.
The sections are welded together, just like our aluminum cars. Silicon bronze, alloy 655, welds like a dream--but it is very hard so it is quite difficult to form.
Another great video! The level of skill and craftsmanship involved to produce a Kirkham is outstanding. Again, thanks for sharing. Darren.
Darren,
Your car is next up at Kirkham Motorsports University! I am really excited because we will show the entire process of figuring out where to cut the nose off your car, cutting it, building the sub-structure, and putting it all back together again. It should be a lot of fun.
Somebody told me somebody wanted a bronze piece to go with a copper one, but I didn't believe him.
So...comparing arruminum, copper and now the time you've had with bronze...what is each material like? Weight? Softness? Durability from skin rashes?
I swear...there are not many folks walking this planet who can repeatedly knock my socks off...amazing stuff.
Doubting Jamo,
Seeing is believing.
Aluminum is very light and quite soft. Aluminum is 1/3 the density of copper or bronze. (Copper is slightly denser than bronze as bronze is copper alloyed with something else, usually tin). In our case, the silicon bronze we are using is about 97% copper and 3% silicon. The silicon helps it to weld and gives it a beautiful golden color.
Copper is softer than bronze, but harder than aluminum. Silicon bronze has a yield strength of around 50,000 psi. The aluminum in the original AC Cobra had a yield of around 10,000 psi. So, you can see the bronze is a beast to form. We had to heat the bronze up to lift it off the die then slap it back down (while hot) to get it to lay down against the die. It was a real job. But, it really made a beautiful part when we were finished. So far, no skin rashes
As for knocking socks off--wait until next week. Sandwich is cooking up something really cool in the mill right now.
David,
Do you have the complete set of dies to do a complete car (coupe or cobra) or are those housed in Poland?
What type of file are you using to smooth the part? Is this the same process you would use to flatten the welds as in the body/chassis offered in the scratch and dent sale that was unfinished?
Is this polishing process the same process you use to polish the Aluminum cobras?
Wow, I'm worn out just watching the vid and thinking about the work involved! I won't be applying for a job anytime soon David.
Actually, several of my guys have told me it is the best job they could have ever imagined. People are generally happier when they work hard and have fun. Here at Kirkham, we take both to excess.
Kirkham Motorsports University Bronze Coupe Fender
) lately we had to hire 3 new people. My wife is also coming down to help as well. I lured her in with the new gym 
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