Cosmo Mod: FLYINGA2 Style

[BigDK]

Red and Black. I was also going to have a clear loop but I think red and black will be the nicest.

I look forward to seeing those tubes filled up

Good choice of colours

[Elusid]

That's so sick! I love the reservoirs =) I always like builds that come up with interesting ways to show off the reservoir systems.

[CyberDruid]

Don't get excited...I'm not making a "Special" Mother's Day gift for the wife...I decided to cap the cylinder reservoirs with 1/2 spheres...and drill and tap them for plugs...such fun.


A simple fixture.


I'll adhere the spheres to the squares of ply.



Blue tape..gotta have it.


Bit for boring a flat to seat the Oring.


Some lovely 3M tape for doing this sort of mad work.


Sphere adhered...


I followed the Forstner bit with an 11.8 drill bit and then tapped it with a BSPP 1/4. I took a few tries as the material did not tap well.


They will go here.


Too much fun...


Taped a pair of tubes together to get an exact bevel (10 degrees in this case) on the mitre saw.


After trimming the center tube to the appropriate angle I laid out marks for the ports. They would have to be very close together...


I made sure I got them all drilled and tapped and counterbored for Oring fittings before I bothered with the final sanding and edging...suprisingly the 1/2" material tapped well...


The threads came out nice.



I did some sanding with the spindle sander to make the back plate follow the bend of the rails better and get it locked in to the receding angle.



The only way I could really check all three angles to see if they closed up was bay applying some clamping force...and the only way I could do that effectively was with a Spanish Windlass type contraption using some wire and blocks.

I gotta tell you I made it hard on myself my adding the jaunty angle and the canted center cylinder...getting the three tubes to line up to the front rack and the backplate took about 3 hours...and endless fiddling with the clamp set up...


Once I was satisfied that the three tubes would line up and needed to make some dividers to keep the return from cavitating the supply. I probably should have made them out of clear to be less obtrusive but on a whim I went with flourescent red-orange for the reservoirs with black fluid and black for the reservoir with red fluid.


Here's another place I made it hard...by having a bevel the tube will only align in one position on the backplate...the divider needs to run horizontal and split the ports...this required a lot more testing and fitting and some tiny marks to get right...


After much annoyance and several attempts I got the three cylinders adhered to the back plate. The water thin solvent I usually use was not doing the job...and I had to start over and re sand everything and use Weldon 26...a thick-bodied methylacrylate adhesive/solvent...not nearly as pretty and ALWAYS drips on something...so I protected the rig as I did the work.


Once the backplate had stopped screwing with me I was able to adjust the front rack and glue that to the tubes. This will stabilize the entire assembly.


Got the nose cones glued on easily..that was one of the few easy parts...I just set the unit vertical and plopped them on.

I did a sort of destruction test with a spare piece of tube and mistapped nosecone I had glued up with the water thin solvent..it would not seperate even after a severe beating on the bench...(on video lol).


So it needs to sit up for 24 hours and then I am going to pressure test it and see if it leaks.


There are some things I need to dial in a bit... the glue got out of hand and made some smudges on the backplate...nothing I can't do away with...but I want to make sure the res is functional before I doll it up any further.


Looks pretty good to me...

[TedShred]

That's insane.

Unbelievable work

[CyberDruid]

It has been like pulling teeth to find the span of time I knew this would take. Between playing Mister GreenJeans with the yardwork and minding the kids and doing some special projects for Mother's Day...it's been an uphill climb. But today I got about 10 hours in without interruption and that was awesome...

[TedShred]

I can see how a nice long stretch could really help for something that ambitious.

That's a whack of work to pack into even 10 hours tho. Very impressive stuff, man.

[biftek.]

Don't get excited...I'm not making a "Special" Mother's Day gift for the wife...

nice work though I like the red acrylic in there. those turned out great

[CyberDruid]

Well it's a start...sometimes I find a day away gives me a chance to see all the hideous flaws so much better...but I do like the concept...I think I would have to simplify it to right angles if I ever do it again...the bevels add too much uncertainty in the glue up..twist them a 1/16" one way or the other and they don't line up or seal...so they have to be glued in place...what a mess. 90 degree cut and I could easily have set them onto the base plate on the bench and glued them up without all the conniptions...

[disruptfam]

cd i'm really impressed mate those res's are great...

your modding skills never cease to amaze me.

[CyberDruid]

Well considering that this build is about 5 weeks off schedule I can only hope that the results will offset the wait.

[CyberDruid]

http://www.youtube.com/watch?v=YP-ksXUNELw

[smee]

Hahaha, Bam... bam bam bam bam bam bam bam... *pause*..... BAM.... bam bam bam bam bam bam bam bam bam bam bam bam bam *pause*.....


Good work so far CD!!!! Looks amazing!

[CyberDruid]

lol

[[XC] NetburstXE]

Amazing!

[BigDK]

Top class work there, I admire the skills it takes to produce work like that

[CyberDruid]

Well I did not like how the res looked in the cold light of day...so I fired up the Krups.

When in doubt Brew Up is a motto I can live with.

I took the whole thing apart and totally reworked it...sometimes you just gotta do what you gotta do...

I worked my butt off and got the resrevoir completed and it's much tidier...

[-Evo-]

Looks great so far. Just a odd question, what is supporting the support for the tubes? From the looks of the pictures they are just resting on the bars. Are you going to permanently attach them or is the plan for them to just rest on the top?

[TedShred]

Love how the tube reservoirs work with the long shape of the rails, especially from the front angle views. This is fun to watch!

[fart_plume]

Hey Cyber do you have a knee mill?

[CyberDruid]

Looks great so far. Just a odd question, what is supporting the support for the tubes? From the looks of the pictures they are just resting on the bars. Are you going to permanently attach them or is the plan for them to just rest on the top?

I have an idea about that...basically a small thin (flexible) lexan tab on the bottom held in place with a screw. But I might come up with something else.

Hell I might remake it a third time...the slash cut tubes are a real PITA to get a good bond with...and I am not too crazy about trying that a third time...so if for some reason I end up making this again it will be with perpendicular cuts.

[biftek.]

Love the fogged acrylic, you should do it to the tubes too. That'd be super fresh

[fart_plume]

Anyway the reason i was asking is if you do you could set the head to the right angle you needed and counter bore your mount instead of sanding the tubes. If you have the cash flow you can find an old bridgeport at machine shop auctions or Ebay pretty cheap like $1500 and up..........

[CyberDruid]

Hey Cyber do you have a knee mill?

Hmmm...well it sure as hell wouldn't hurt to have one. My Drillpress is absolute junk...there's a ton of play in the head. Trying to do anything with a router bolted to the underside of the table is really only good for simple parts.

[CyberDruid]

Love the fogged acrylic, you should do it to the tubes too. That'd be super fresh

I was thinking about masking them off and blasting them with the Cosmos logo but at this point I just want to make some progress.

I also did some more work on the trim piece that goes over the top radiator. I re-did the cut out...the circle just looked dorky. So I followed the profile of the inset in that trim piece and will be making a piece of mesh for it tomorrow...I'll get to beat the living hell out of something...which is a great way to start the day.

[fart_plume]

if you get a mill with the two head angle adjustments you can even do compound angles.............and counter boring for your tubes is a lot easier than sanding. plus you can do multiple parts with one setup if your doing a production run.