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A German Factory Pressed This in Seconds. It Took Daz Two Days

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A German factory would have pressed this toolbox lid in seconds. It takes Daz about two days. Work continues on our captured WWI German howitzer. Jess is flexing his metalworking skills on the towing eye and spade, while Daz takes on the gun trail toolbox. The top had almost completely rusted away, but what’s left gives enough clues to recreate it: a double bend to form a waterproof lip, extended tails folded around the corners, rough welds (that’s what the grinder is for), and a careful grind that leaves a few imperfections, because on a hundred year old gun they blend in better than perfect steel. The top cover gets the same treatment, with scored and hand-bent edges because we don’t have a press brake with a segmented blade, and strips of matching steel formed around pipe for the corner seals. Never going to be seen, never going out in the weather, but if someone lifts the lid, they’ll see it was done right. Then the hinges. The lid was missing, but two original bottom hinges survive. They’re ground off, the rivets knocked out, a fatigue tear welded up, and the twist pressed flat. The top hinge has to be made from scratch to sit off-centre, working from the one photo we have. And finally, our first go at hot riveting. Hand riveting with homemade bucking tools came out passable but pushed to one side, so we try the press with dies made on the milling machine. Nobody here has done this before, and there’s no formula for how much rivet to allow. Trial and error. Mostly error, for now. Got a better way to bend thin sheet or set rivets? Daz asked for hints, so post them. šŸ“ŗ Part 1, saving this gun from collapse: https://youtu.be/00hgaHEQCYI šŸ“ŗ Rebuilding the recoil housing: https://youtu.be/zdWzMX6uZUM šŸŽŸļø AusArmourfest 2027 tickets are LIVE! Get yours HERE ā© https://bit.ly/AusArmourfest2027 TIMESTAMPS: 00:00 - Jess on the Towing Eye and Spade 00:17 - The Most Riveting Episode Ever 00:25 - What’s Left of the Toolbox 00:38 - A Double Bend for a Waterproof Lip 01:06 - Filling the Cuts 01:35 - Grinding Back 03:31 - Imperfections on a 100 Year Old Gun 04:09 - A Crimp From the Press 04:23 - The Top Cover 04:41 - Never Seen, Done Right Anyway 05:07 - Duckbill Pliers Bend Too Round 05:30 - If You’ve Got Hints, Post Them 06:11 - Bending by Hand 07:04 - A Nice Tight Corner 08:36 - Corner Seals From Pipe 10:17 - Does the Lid Fit? 13:12 - Welding It Off Slowly 14:03 - Hinges: One Original Left 14:38 - Finding Where the Hinge Sat 15:19 - Knocking Out the Old Pin 18:00 - A Fatigue Tear 19:13 - Pressing the Twist Out 20:16 - Two Original Bottom Hinges 20:32 - Making the Top Hinge 21:47 - Homemade Dies 21:57 - Hinges Off-Centre, Like the Original 22:20 - Our First Riveting Attempts 22:36 - Trial and Error on the Press šŸŽ„ Videography and editing by Ella from AusArmour The Australian Armour & Artillery Museum is home to the largest collection of armoured vehicles and artillery in the Southern Hemisphere, located in Cairns, North Queensland. We are dedicated to the collection, preservation, restoration and display of military vehicles from the 1800s to present day. Our collection includes over 220 armoured vehicles and artillery pieces from 15 countries. šŸ”§ Visit us: https://www.ausarmour.com šŸ“± Facebook: https://www.facebook.com/ausarmour #WorkshopWednesday #WWI #Howitzer #ArtilleryRestoration #Riveting #Fabrication #MilitaryHistory

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