Making Heavy Metal Cones
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- čas přidán 21. 07. 2024
- This video shows how to make cones from 1/8-inch (3.2mm) steel, using simple shop-made equipment.
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I am a machinist at the Green Bank Observatory and we make parts for radio telescopes. We have to make MASSIVE cones that end up connecting together to be often 6ft tall that starts at 4-5 ft diameter and ends at 5 inches or so!! We do it COMPLETELY out of either billet stainless steel or aluminum. It would be amazing to be able to save so much material by doing it this way!
My hat is off to you for making such large and precise parts. You must fill up multiple dumpsters with chips!
@Nathaniel Langston - I just met someone randomly yesterday while doing some volunteer work and we got to talking about all kinds of things and he mentioned visiting the observatory and how close it is to us in Ohio. I had never heard of it before and here you are. Pretty wild the small world experiences sometimes. Are these components structural or for wave guide?
Rich - I hope Nathaniel Langston sees your comment, and replies. I don't know how this works - I can certainly see all comments on my videos, and the comments on the comments, but I don't know what the commenters see when someone comments on their comment. If YOU know - let ME know.
@@RonCovell I added the @Nathaniel Langston just in case, but he still should have gotten a notification. Sometimes it is added automatically but other times not. I stopped getting new video reminders from all of the channels I'm subscribed to years ago and have never figured out why. Some things just remain a mystery.
Yes, Google and CZcams work in mysterious ways!
You are the Bob Ross of metal forming, so relaxing and enjoyable to watch!
As a CAD guy that took some manual drafting classes, the contructions and template making are so interesting. Thanks for sharing Ron!
I'm so glad you enjoy my videos!
In the 60s Jr high schools had a thing called metal shop classes. Kids would layout and make this wonderful thing called a funnel.
I guess nowadays well paid youtube geniuses like this guy have to reinvent the basics that are now long gone.
Gonna put some happy little cones right over here...
So many CZcams channels claim to be "Experts" yet the average people can see their flaws. This channel is THE metal forming expert.
Thanks for the kind words!
I will never grow tired of your minimalist approach to no need of fancy expensive tools videos :D
Thanks. I learned a couple of years ago that people enjoy seeing how to do work with the simplest of tools.
I roll cones all the time up to 1/2" for mines and industrial applications. This is absolutely awesome, especially for branch and takeoffs in the field. Thank Ron!
Your a badd ass I've looked to your work for many years especially when I was starting to shape metal. It's been about 20years now &hundred or so cars and motorcycle competed. I love that your still teaching me new things. Thank you for your commitment and love for this industry. It wouldn't be where it is today without you an your great teachings and knowledge nor would I... thanks Ron!!!!!
Wow - it takes a lot of doing to complete 100 cars and motorcycles. My hat is off to you for becoming a lifetime professional, and I'm glad I could teach you a few tricks along the way!
Ron you have done it again, you have blown my mind. Making seemingly impossible shapes by using simple but ingenious tools and techniques. Amazing! Thank you so much for sharing this with all of us. It is truly a pleasure to watch a master at work.
Greetings from the Netherlands, Mark
Wow, thanks, Mark. I do appreciate your continued interest in my videos.
As always. Amazing series. Thanks for being around and sharing your knowledge.
I appreciate that!
Great stuff. As a blacksmith, I've had to forge a lot of cones over the years for various projects, and it's always a bugger. I'm starting to learn a lot about sheet metal thanks to this channel and can see me doing more with it. Anything that doesn't involve tons of heat scorching me is a good thing in my book!
Well, certainly sometimes you need heat to make metal do what it doesn't 'want' to do - but with the right tools and techniques you can do a lot at room temperature.
Ron, As always, you do nothing but impress! I have a project coming up that I was bouncing around in my head as to the best way to get a good form on 1/8" material. Needless to say I now have a very simple and elegant answer.
Keep up the videos if you can they are always very interesting and useful to the less experienced and not so widely exposed of us.
Thanks again for this.
Mark.
Hey, I'm very glad you found this video interesting, and that it might actually help on a future project. I've been consistently uploading new videos every two weeks, and I'm trying hard to keep on that schedule.
I love watching these videos. Consistently, I realize a huge part of your success with these builds is the easily overlooked preparation and tool building aspect of a project.
Yeah, carefully thinking through a project and doing adequate preparation pay huge dividends!
I so appreciate your videos, Ron. The quality of your work is amazing. And your demeanor is a joy to experience. I absolutely love learning the processes you demonstrate for us. Thank you for passing on your vast knowledge of fabrication!
Wow, thank you!
Calmly creating fixtures and anything is possible. 👍👍😎👍👍. Thank you Ron for another tutorial on how to form metal. The art pieces were really cool.
Glad you liked the furniture pieces, as well as the car parts.
Another beautiful job Ron. It’s amazing what a little flat plate in threaded rod will help us with. I can’t express the amount of knowledge I learned from this video as always. Make On man.
Wow, thank you!
I am a retired Sheet Metal Worker,I still get a buzz watching a craftsman at work.
Wow Ron! You make these cones look so easy to make! Brilliant, as an earlier comment stated! Thanks for all your time and sharing all of your great technics! 👍😎
I'm so glad you liked this video!
Calm, confident and very clear voiced instruction. You are surely a master teacher! Bending my ear and making me cone-sistant will make me a better teacher!
Wow, thank you!
Ron, I get so excited whenever I see you have posted a new video! I always learn from you! Thank you for sharing your knowledge!
So nice of you!
You have such talent and wisdom. I greatly appreciate you sharing all that you have. I also use your videos to prove to my friend that fit up and layout are as important as the finished part!
Whoo, boy are fit up and layout important!
this is brilliant.
Thanks!
Ron, if you explain an do it, it seems and looks so easy!
Every time when I am watching your videos, I am also impressed what you are able to realize with such easy tools!
Glad you are enjoying my videos!
years ago I had a small business custom making motorcycle mufflers in stainless steel,, cones cones and more cone, intersecting cones and perfect polishes,, I dont miss it I make knives and swords now , but this vid did bring back some memories,, I was one of the last old school sheet metal workers, industrial manufacturing is so different now a days, I dont miss working in the big stainless fabrication shops, I have my small workshop and still have the rollers I made,, Nicely done on the video , good explanations and I like the jigs you used, some good ideas there,,
Hugo - thanks for chiming in. I'd be interested to know how you rolled those cones from thin stainless. It's not easy to do!
yesterday i used your rolation technique for the first time. Worked great. Thanks a lot for sharing your knowledge
Hey, I'm delighted that it worked well for you!
I remeber trying to make a cone out of coke can tin back when I was a teen. I just saw you overcome every problem I had from that experience. I am so thankful I found you on CZcams.
That's very good news!
Wonderful work Ron. You make it a pleasure to watch & learn with clear video work without loud music. 5 star. Machinist.
Thank you so much for the kind words!
That is an absolutely beautiful finished product!! Fantastic explanation as always!!!
Thank you so much 😊
Ron, your instruction is incredible. Thank you and cheers from New Zealand!
You are very welcome! I hope to return to New Zealand - I've taught many workshops there, and toured quite a bit on both islands. It's a wonderful place!
Holy smokes, Ron. This is super cool. Thanks for sharing your extensive knowledge - it's really enjoyable watching your videos.
My pleasure!
Ron, you are a true Master. Your work has amazed me for years. Thank You!
Wow, thank you!
Thank you, Ron, for sharing your technique! That will undoubtedly come in handy someday.
I hope so!
I am feeling my creative juices salivating having watched just these few shaping videos...Thanks very much Ron
Glad you like them!
This is absolute top notch how to! Thank you, Sir
This Old Tony brought me here.
Awesome, thank you!
The Covell standard…excellent video production/discussion/demonstration/build….thank you for sharing/mentoring
Thank you kindly!
What a great explanation and fantastic results. Thank you for your videos Ron!
Thanks for watching!
Once again, I am reminded that preparation and being patient enough to build the tool or jig rather than trying to take shortcuts are key.
You got it!
@@RonCovell and to always use the KISS principle (keep it simple S) many over complicate things. Regards Dennis
Thank you for sharing this beautiful technique for making such beautiful cones. The video was a great delight and joy for me to watch, such mastery over such a complicated and beautifully symmetric shape.
You are so welcome!
Well done again ,I love projects like this, watched this video already three times , I am truly amazed at how your mind works in finding simple/practical solution to different problems.
Thank you very much!
Ron, I am excited to learn from you at the Metal Bash. See you in a couple weeks.
I'm sure we'll have a fantastic weekend!
Fantastic presentation and clearly the author has a lot of knowledge and experience.
Holy crap! Ron, every time I watch your videos, my mind is blown. I did not think it was possible to roll a cone out of 1/8" plate with that tight of a diameter.
I wasn't sure I could do it until I tried!
I love all the approaches you have to various problems, gives me so many ideas
Great - I hope they will be useful someday soon!
I always fund myself fascinated by your level of skill, Ron 😊. Well done!
Cheers!
What a great video Ron, I'm going to use this method to make some cones for my smithing.
Go for it!
Hi Ron..my first visit to your channel and you had me.Beautiful , clear, precise, on topic, presentation.I'm a subscriber from now on.Great work!
Awesome, thank you!
Thank you for keeping on going.
Lots more videos on the way, including one on making a LOOOONG cone!
After watching this video, I'm just amazed. You are a true master of engineering. You use the K.I.S.S. concepts. You make things look so easy but I know it's not. Keep up the great video!
Wow, thanks! I do work hard to keep things as simple as I can!
WoW!! so much work for such a simple shape (ostensibly) thanks for a great video.
Glad you liked it!
your fixturing is genius, will probably never make something like this but will use the idea for other projects for sure, Thank You!!
I certainly hope this idea comes in handy for you.
another weapon in my frabracation arsenal , I've been looking for a way to roll cone's Thanks Ron
Hey, this could be just the ticket!
What a master! Innovative, imaginative and practical.
Wow - thanks for the high praise!
Always a pleasure watching you work.
Thank you, sir!
You have done it quite nicely and made it look like very simple and easy too. Great Brain
Thanks a lot 😊
Tremendous work as always. Thanks for making this video!
I'm very glad you enjoyed the video.
You are the Bob Ross of metal work! Great presentation.
Wow, thanks!
I just stumbled across this video randomly. Great technique 👌 subbed
Awesome! Thank you! Be sure to check out some of my other videos - I have around 80 available on CZcams.
Another truly inspiring demonstration.
Thank you! Cheers!
Oh. That weld job. Pro job, if there ever was one. It was a treat to watch. Thanks.
Thanks!
I have just finished a project at work making near identical parts. I formed the cones by making up a tool for the press brake. Basically it was a 20mm bar between two pieces of tooling . Which I used to press the steel in creases into a piece of 15mm hard rubber which was sat on a flat solid bottom tool. This produced the cone with nice gentle radius creases. My Aluminium mandrel had a large diameter straight section which I used to lock into my bench vice which has Aluminium jaws with a central vee machined into them. This locks everything in super snug. I then used a nylon dead blow hammer to smooth out the creases. After welding and cleaning I used the mandrel in the lathe to mount the cones and spun it up to polish the final parts. They came out lovely and the customer was delighted with them. Nice to watch you use a different technique to achieve them same result Ron.
Your technique sounds great! I wish I had a press brake - but since I don't, it forces me to be creative sometimes.
@@RonCovell Ron you certainly are creative. It's a pleasure to watch you work. Best regards from the UK
As usual, thank you very much Mr. Covell!
You're very welcome!
Fantastic video. I was so relieved when you welded the bending bar on, I was thinking there's no way I could bend that round........
It does take a lot of force. I tried holding the first bar into place with clamps alone, but it slipped off when the going got tough. Just a couple of small tack welds solved the problem with ease.
Nice work, you are a master craftsman. Innovative methods and great results. Thanks for sharing.
My pleasure!
Hi Ron, thanks a lot for sharing your impressive knowledge with so many people around the world! It's always great to watch your videos and learn. even if I might not need to shape a thick wall cone it's very helpful to see the kind of finding a solution for a unique issue. Best regards, TOBi 👋😉👍
Hey, you just never know when you might need thick-walled cone!
@Ron Covell 👍😄👍 #WordsOfWisdom
Another method to make a cone like this is to cut a disc, put a hole in the center, then draw it through a cylinder. The "coin ring" crowd has been doing this for a long time. They make a cone first, then draw it out into a ring and roll the edges.
I had never heard of that technique, but I quickly researched it on CZcams. That's a pretty cool technique, and I would not have learned about it without your suggestion. Thanks a million!
Awesome video! So glad youtube algorithm suggested this!
Hey, nobody is more delighted than I am!
excellent tutorial - keep on keepin on Ron
More to come!
Clever fixture, Ron. Beautiful results!
Many thanks!
I never get tired of seeing this master doing his amazing job
Thanks so much!
another thoughtful piece of work! stellar
Thanks so much!
Stunning craftmanship.
Thank you!
THIS GUY NEVER CEASES TO AMAZE ME - IT'S ALL SO EFFORTLESS FOR HIM , HE'S LIKE A GENIUS , I WOULD THINK HE WAS SOME KIND OF ASTRO PHYSICIST OR MATH GENIUS OR SOMETHIN - GREAT TEACHER
Thanks so much for the kind words! I'm glad you liked the video.
GREAT VIDEO RON, WOULD LOVE TO SEE MORE OF THIS HEAVY GAUGE METAL SHAPPING
You might enjoy this article I wrote:
www.motortrend.com/how-to/making-stainless-windshield-posts/
@@RonCovell THANKS RON
These builds are great to watch so much to learn from these videos
Glad you like them! More on the way.
You, sir, are a wizard! Beautiful work!
Thank you kindly!
Wow! This is genius, truly it is Ron! Thank you
Glad you like it!
Beautiful techniques, wish the video was out earlier, I had rolled a 500 mm copper cone using lumber mandrel, was a real pain
Well, at least you'll be better prepared the next time!
Great work Ron, very informative.
Glad you enjoyed it!
thanks! I've been wondering how to make cones for various applications. Very useful for me!
Glad it was helpful!
Amazing ingenuity. Thanks Ron!
Thanks for watching!
such precision work you do using this sheet metal techniques amazing skills and problem solving.
Thank you very much!
Ron... That was an Amazing Video!!!
I'm so glad you enjoyed it.
That is a great way to do it. I own a fab shop and will make that part in 2 sections and use a press brake and bump brake the half's to shape then sand the creases out. Faster my way but your way is cleaner. Another point is bump brake long cones is possible as is thickness. It is up to how big is the brake press.
Yes, I have seen huge cones made from VERY thick material made by bumping with a press brake. I don't own a press brake, so I can only dream!
That was very interesting. A well thought out execution.
Glad you liked it!
Hell yeah heavy metal 🤘
Lmao
Oh yeah ImI
This is why I stopped watching TV and am madly in love with CZcams. You sir are a metal working god!
Matthew - I'm so glad you enjoy my videos! For what it's worth, I have not watched much TV for the last 30 years, but I love the vast selection of content available on CZcams.
Wonderful Job ! I would only change one thing. Machine the come from steel, but make it 3/4 longer, and that 3/4 longer would be on the big end, and a machined hex shape, for a wrench to turn it instead of welding on an arm.
That sounds like a great idea!
Pure magic. Amazing handywork!
We aim to please!
clever stuff Ron
Thanks - glad you liked it!
THAT was extremely COOL! Thank you for that!
Glad you liked it!
Interesting and informative as always,I would love to see how you would go about making a bullet shape like the dagmars on a 1950’s caddy.
I make a large bullet shape in this video:
czcams.com/video/ES2g7OR9bic/video.html
Awesome job, thanks for sharing your knowledge with us.
My pleasure!
This video is the ultimate youtube content in my opinion.
If the landing page of youtube contained content like this the world would be a better place.
Thanks for the very nice compliment!
Metal that thick really doesn't want to be formed, outstanding job!
Thank you! Since most of my work has been with automotive-grade sheetmetal, 1/8-inch (3.2mm) material seems heavy to me. But some people work with metal 20 times that thick every day, and form some fabulous things with it!
you are a metal wizard, just amazing
Thanks for the kind words!
Nice job, that is a very ingenious way to form them. I have done small cones from 5/8 stainless by bump forming on a brake but those were a much shallower angle.
Well, bump forming is certainly a viable technique. Unless you have a HUGE window die, you'd almost have to make s cone in two halves.
@@RonCovell most of the big ones,i.e. 2"thick aluminum with a 15' dia, I did were in two pieces. The smaller ones were one piece. I worked off the end of the die.
You know, I don't own a press brake, and it didn't occur to me that you can work off the end of the die. I can see lots of great possibilities with that setup!
Thank you for approach!
Glad it was helpful!
Amazing. It is just what I am looking for for the manufacture of rockets nozzles. Thank you very much, a cordial greeting from Bolivia 🇧🇴🚀
Wow - that's a specialized application. I presume the metal must be Monel, or some other high-nickel alloy?
Excellent job..! :)
I've never seen it done like that before. Never too old to learn something new. :)
Thank you very much!
Finally I can make a legit "The Cones of Dunshire" set!
Being serious, this is a very cool method. Thank you for sharing.
Glad it was helpful!
Simply amazing yet again. Such clever thinking.
Thank you very much!
Ron sir you the best in fabrication. Genius man.
Thank you so much for the kind words!
WOW, awesome talent Ron,
Thank you kindly!