Hayes HD Dump Truck - Take II

[ihbuilder]

Originally Posted by RCP57

A tiny bit of progress after hours of work.lol There is a reason people that build and sell wheels have CNC machinery. I would say that I am about halfway on these wheels after two full days. Next up will be machining the beads(not the kind Mario uses) and then I will do some more work on the hubs to make them look more realistic. I have started making my own axle housings(Rockwell 4640) for this but I am unsure at this point if i will use them. Once I decide what I am doing with that I will either cross drill the hubs for a set screw and a blind axle hole or machine a hex into the back for the stock axles, drilling right through and using a cap on the hub.






Thanks for looking!

Look great Reg . Yes , the CNC is necessary for wheel production otherwise you go crazy

[RCP57]

Originally Posted by Jakyat

Simply AMAZING!!! Money will buy all the tools needed for a project like this, but the skill and talent you have is priceless!!! Definitly be watching these builds.

Thanks very much. Yes, you need to have a little of both to build these kind of things. Hopefully I can keep the build interesting!

Originally Posted by ihbuilder

Look great Reg . Yes , the CNC is necessary for wheel production otherwise you go crazy

I would say you know that better than anyone else Steve! Even with stamping the centers this isn't a quick job. Especially when you factor in making hubs for all three axles. It took me 3 1/2 days to make the wheel assemblies for the first HD. I thought I could do it faster this time but it is going to be about the same. I guess one guy can only make parts so fast when each part requires several different setups and processes. Hopefully it looks ok in the end and then it will all be worth while.

[kerst]

Great work! The wheels look great.

Kerst

[up9018]

Those are some great looking wheels. This is going to be a great truck, I always liked the old Hayes, they were pure work trucks.

Nice Job,
Chris

[Exclusive RC]

Beautiful job, i wouldn't expect anything less

[tc1cat]

I have to agree, "WONDERFUL JOB". 1 question for you, What is the wall thickness of the rim at the grooves? Would really like to see these in person They do look amazing. Are my eyes playing tricks on me or do the centers have an angle on the main body?

[RCP57]

Thanks guys. I'm not sure what the wall thickness is. I know the grooves are 2mm deep so I am guessing it's around 1mm thick. Yes the hubs are tapered a little.

[tc1cat]

Thanks for the quick answers! Another ?? for you- Why didn't you turn the grooves in the wheels instead of milling them? I know, I know, lots of silly ?'s but this is the way you learn things

[RCP57]

Originally Posted by tc1cat

Thanks for the quick answers! Another ?? for you- Why didn't you turn the grooves in the wheels instead of milling them? I know, I know, lots of silly ?'s but this is the way you learn things

I find it to be faster than turning them in the lathe. I don't know if it is my setup/tooling or what but I can never cut the grooves in the lathe without galling issues unless I turn the stuff really slow. Even then I have ruined a couple of wheels when they were almost finished. In the mill I use a 1/8 cutter with the mill screaming. I use the drill to turn the rotary table and my right hand can steadily feed the Z axis down(slowly) with only the occasional squirt of alcohol needed for coolant. The wrong way to do it but it works well for me.

[D8R]

That's an intresting way to make wheels. Read the tread twice but could not find how you made those oval holes. How did you fasten the discs to the tubing??
Didn't realy follow why it was not possible to turning them in lahte. The grooves could be done before pressing the disc inside, that way you will not ruin the hole wheel, just a thought
Dan

[RCP57]

Originally Posted by tc1cat

Your way of machining the grooves is not wrong. Just another way of doing it. I normally use WD40 or a cutting/tapping fluid for coolant. Never thought about using alcohol. Would not be as messy!!

Yes, the alcohol works very well. The mess evaporates and so it doesn't leave a residue that effects paint or powder coat. I owe my father in-law for that bit of knowledge...

Originally Posted by D8R

That's an intresting way to make wheels. Read the tread twice but could not find how you made those oval holes. How did you fasten the discs to the tubing??
Didn't realy follow why it was not possible to turning them in lahte. The grooves could be done before pressing the disc inside, that way you will not ruin the hole wheel, just a thought
Dan

The oval holes are made with a custom ground two flute end mill. Nothing fancy. The centers are pressed in tight and the lip I leave on them holds them straight. With the rear duals being one piece they are very strong just the way they are but once powder coating has been applied they should stay put for sure. Like I said before, I think it is my tooling or setup in the lathe that just doesn't work well causing it to gall and make a mess. I used a couple of different parting tools to do the job and they did work but you have to go very slow. I made the grooves in the wheels for my KW on the lathe and it took forever. I also destroyed one when it galled up and collapsed it in the chuck. I learned the hard way that it is better to press in the centers first before you machine the grooves. The centers are quite hard to press in and you run the risk of ruining the outer bead on the rim.

[RCP57]

Got the new kicks for this one the other day. I guess I had better get going on the axles!

[RCP57]

I haven't worked on this truck for months which is not good. Since the weekend was my "B-day weekend" but I still needed to work on customer stuff I decided to work on this. I bought a used foot shear a couple of weeks ago so I have been eager to use it and get the hang of it. I started out by shearing some strips and then bending them into frame rails. I mounted up stock front suspension and chucked in some plastic cross members to get the overall width right. I then started to make my own cross members. I will likely be making my own suspension for both ends of this truck so that it looks more like the 1:1. I also built the front bumper for the truck although the front part of the frame is not cut to length yet.








Thanks for looking

[doodlebug]

Way to go Reg! Soon you will be making everything!
Cheers, Neil.

[Mikem]

I'm amazed thanks mike

[Rvjimd]

Reg,

Very cool! Any tricks to making the matching dies? Do you just turn the second one to match the dimensions of the first, less the amount of allowance for the stock to be stamped?

And, would you mind posting a picture of the modified end mill you use to make the oval holes? I'm not sure I understand how you are doing that.

Thanks for all the info!

Jim

[Wiskybilt]

Reg

You might try a little cutting lube or cool mist to keep the heat down on your tooling. Sometimes just step in and out also. The heat and friction is causing the gaulding. The truck is looking great. Did you press stamp the center part of the wheel or spin form it?

[RCP57]

Originally Posted by doodlebug

Way to go Reg! Soon you will be making everything!
Cheers, Neil.

Thanks Neil. I think I am nearly at that point or at least I was with my 850KW. Sometimes it just isn't worth the time to build all your own parts and other times it is. I guess that is determined by the time available and the uniqueness of the parts needed.

Originally Posted by Mikem

I'm amazed thanks mike

Thanks Mike!

Originally Posted by Rvjimd

Reg,

Very cool! Any tricks to making the matching dies? Do you just turn the second one to match the dimensions of the first, less the amount of allowance for the stock to be stamped?

And, would you mind posting a picture of the modified end mill you use to make the oval holes? I'm not sure I understand how you are doing that.

Thanks for all the info!

Jim

Hey Jim, I just machined the dies to be close by eye. I squished out a couple of test pieces and then made some mods. Tried it again and it was good enough I thought. I will post a picture of the endmill later. I just rounded the corners on a regular cutter. Nothing special at all just some trial and error to get the right cut for the oval hole.

Originally Posted by Wiskybilt

Reg

You might try a little cutting lube or cool mist to keep the heat down on your tooling. Sometimes just step in and out also. The heat and friction is causing the gaulding. The truck is looking great. Did you press stamp the center part of the wheel or spin form it?

I use alcohol now and it works very well. No mess as it evaporates quickly and leaves no residue... It also makes me feel like I'm doing a better job when I'm half cut.lol Just kidding.

[RCP57]

It's been months since I've worked on this and I need to get moving on it so this afternoon I made some parts for the front end of the frame. I am going to add more detail to this truck than I did on my own. I want the frame to look less Tamiya and more mini Hayes HD so I have a lot of machining to do yet just to mount the front axle.

[up9018]

Nice metal work, looks really good. By your You-Tube videos, you have plenty of work for this truck to do.

Chris