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Flanging Dies

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zenith-list(at)steensland
Guest

Posted: Thu Oct 23, 2008 4:07 pm Post subject: Flanging Dies

Fellow builders,



I am trying to get a little ahead on the wings and have my dad build the 

ribs for my 601xl.  However, I have been looking around and flanging 

dies are hard to come by unless you want to make them out of wood (which 

is completely doable).  I had a local machine shop quote me for all 4 

and they want $2300+ for the set! After I got done laughing, I starting 

thinking of alternatives.  There are about 10k+ ways to skin this cat, 

but I figured I'd see if anyone had a set for loan?

-- 

Lee Steensland

601XL/Corvair (7637L reserved) Kit/Scratch builder 0.1% complete!

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psm(at)att.net
Guest

Posted: Thu Oct 23, 2008 4:19 pm Post subject: Flanging Dies

Hi Lee,



A slotted stick works really well for bending the flanges on 

lightening holes.  I made one out of very fancy Russian 1/2" Russian 

plywood.  I don't know my actual cost but it was probably something 

around a nickel.



Flanging dies are very nice if you are running a kit building factory 

and don't really care how close the results are to the finished 

needs.  After bending the flanges with a die you still need to use 

the slotted stick to adjust the final bend to get a truly flat rib 

web.  In the kit case this final step is left to the final kit builder.



The problem is there is spring-back of the metal after being stamped 

with the flanging dies.  This causes the rib web to spring back as 

well and you get warped webs around the hole.  This is easy to 

relieve with the slotted stick by bending the flange a little further 

than the position it comes out of the die.  You just work your way 

around the hole bending a little bit while watching the flatness of 

the web against your work bench.  You will probably want to perform a 

similar bending operation on the outside flange of each rib for the 

same reasons.



For scratch builders, you can do the same operation after cutting the 

hole with the slotted stick and just skip the flanging die 

altogether.  This will take an extra minute or so for each lightening hole.



Good luck,



Paul

XL getting close

At 05:06 PM 10/23/2008, you wrote:

 	  Quote: 	
		  Fellow builders,



I am trying to get a little ahead on the wings and have my dad build 

the ribs for my 601xl.  However, I have been looking around and 

flanging dies are hard to come by unless you want to make them out 

of wood (which is completely doable).  I had a local machine shop 

quote me for all 4 and they want $2300+ for the set! After I got 

done laughing, I starting thinking of alternatives.  There are about 

10k+ ways to skin this cat, but I figured I'd see if anyone had a set for loan?

--

Lee Steensland

601XL/Corvair (7637L reserved) Kit/Scratch builder 0.1% complete!

- The Matronics Zenith601-List Email Forum -

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naumuk(at)alltel.net
Guest

Posted: Thu Oct 23, 2008 4:31 pm Post subject: Flanging Dies

Lee-

    I believe Gary Boothe posted instructions on how to make them out of 

wood that should be in the archives.

                                                    Bill

---

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carlossa52(at)gmail.com
Guest

Posted: Thu Oct 23, 2008 6:01 pm Post subject: Flanging Dies

Recently (a few weeks ago?) someone had a set available for loan.

I don't remember on which of the Z lists, you would have to search the archives...



Good luck



Carlos

CH601-HD, plans



 2008/10/23 Lee Steensland <zenith-list(at)steensland.net (zenith-list(at)steensland.net)>

[quote] --> Zenith601-List message posted by: Lee Steensland <zenith-list(at)steensland.net (zenith-list(at)steensland.net)>

 

 Fellow builders,

 

 I am trying to get a little ahead on the wings and have my dad build the ribs for my 601xl.  However, I have been looking around and flanging dies are hard to come by unless you want to make them out of wood (which is completely doable).  I had a local machine shop quote me for all 4 and they want $2300+ for the set! After I got done laughing, I starting thinking of alternatives.  There are about 10k+ ways to skin this cat, but I figured I'd see if anyone had a set for loan?

  

 

 -- 

 Lee Steensland[b]

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n4546v(at)mindspring.com
Guest

Posted: Thu Oct 23, 2008 6:51 pm Post subject: Flanging Dies

Do not archive

  

 Are there now four flanging die sizes needed for  the 601?  There used to be three; 65, 95, 115.  What's  new?

  

 Regards,

  

 Randy, Las Vegas

  

  

  

  

 [quote]    I had a local machine shop quote me for    all 4 and they want $2300+



[b]

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sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Thu Oct 23, 2008 7:20 pm Post subject: Flanging Dies

Hey Lee,



Just for another perspective, I'll throw in my two cents. Making the dies out of locally available oak (like at Home Depot) is really not too hard, although it does require a lathe. I bet you could get a high school shop class to turn yours for less than $2300. (LOL - I was floored by that - sounds like you were too.) If you check my Kitlog site, there are some pretty good pictures that detail how I glued mine up and turned them. I'm including the link below. 



I must not have been doing something right with the "slotted stick" method. I've read plenty of guys who had luck with it, but mine always ended up looking like hell. BTW, my dies are in use or you could use them - still can if you want to wait a little while.



I have noticed that some people mention an "oil-canning" or bowing of the webs that I never experienced. I've come to suspect that most people who got that result did one of two things...



1.) Either their dies never included, or had an ill-formed "shelf" portion at the top of the die - the part that actually straightens the web back out to 90-degrees after flanging the hole. I've seen people make the beveled part of the die with a router bit and never include the flat "shelf." An early experiment of mine didn't have the flat part, and they bowed the webs like crazy. The little flat part at the top is very important.



2.) Their dies included the flat shelf, but they never hauled-off and whacked the die as hard as you need to to straighten it out properly.



I've said it before, I'm no expert - just offering another opinion. Good luck, and I hope this helps!



Debo Cox

Nags Head, NC

Scratchbuilt XL/Corvair

Airframe 85% complete

www.mykitlog.com/debo

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TxDave

Joined: 22 Jul 2006
Posts: 168
Location: Temple, TX

Posted: Thu Oct 23, 2008 10:01 pm Post subject: Re: Flanging Dies

There are plans for dies on the ch601.org web site. I was fortunate enough to have Debo's dies. 



Dave Clay

Temple, TX

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