https://www.harrystear.me/home daily 0.75 2024-02-16 https://images.squarespace-cdn.com/content/v1/6442ef4842b7395876978966/1682108240014-XDIUNHLV64UVCJ0VC29N/Sleek+Objects+1.jpg https://images.squarespace-cdn.com/content/v1/6442ef4842b7395876978966/1682108240120-TN08W1QGRYOPTVJ832W3/Light+Objects+1.jpg https://images.squarespace-cdn.com/content/v1/5ec321c2af33de48734cc929/2439f310-5041-44dd-a056-ad5bfa2b0b27/AroHa_02.jpg https://images.squarespace-cdn.com/content/v1/5ec321c2af33de48734cc929/5920f24a-7a42-4cc4-9994-db379cf87a73/20140301_Trade-151_0124-copy.jpg https://images.squarespace-cdn.com/content/v1/5ec321c2af33de48734cc929/189ef269-62dc-4d6f-8bc2-c40884b9bf08/Aro+Ha_0380.jpg https://images.squarespace-cdn.com/content/v1/5ec321c2af33de48734cc929/e8396263-41df-433a-8240-63023e19b710/image-asset+%282%29.jpeg https://images.squarespace-cdn.com/content/v1/5ec321c2af33de48734cc929/f8f59af1-6a74-490e-8097-27342fa0b6af/image-asset+%287%29.jpeg 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https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5c21d1cf-8487-48a9-b3fd-3b814648aa7f/DSC_1618.JPG Lathe Tool Holders The first student-completed lathe holder. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a44bbb2d-b54f-4faa-8868-04f6345f0f60/DSC_1620.JPG Lathe Tool Holders This block is within a +/- 0.1mm tolerance. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1f3f638c-a521-4a16-9f46-c1913ffb800c/DSC_1621.JPG Lathe Tool Holders There is nothing quite like a machined chamfer. Three meeting at a vertex like this looks very professional! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/efd70373-0eb1-4968-b5f4-cb3a1774f07c/DSC_1623.JPG Lathe Tool Holders The small relief step is noticeable in this shot. It's a small detail, but radically cuts down on friction while installing the tool. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7377af19-d2d3-4027-a8de-2613848a3356/DSC_1622.JPG Lathe Tool Holders This dovetail is quite tricky to measure, but after I made a go/no-go gauge, it became a lot easier! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0e409651-5d3a-440a-bdb7-918e5061ec80/DSC_1160.JPG Lathe Tool Holders A minor design change to the original design was required in order to hold this boring bar. I made a pair; one for each lathe. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8e73dcc8-39da-405d-a4ca-a1145820f3f3/DSC_1159.JPG Lathe Tool Holders The lay of the end mill is clearly visible in this image. Getting a really good surface finish on mild steel is fairly difficult, especially with a relatively light-weight milling machine. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ebd88482-6d0e-4859-8cbf-4c065ba59eb2/DSC_1161.JPG Lathe Tool Holders I've been very happy with how these have worked. Insert tools are expensive, but make so much sense in a school workshop because anybody can keep them sharp, simply by replacing tips. https://www.harrystear.me/welding-table daily 0.75 2025-08-15 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/981fe0b1-2697-4ee8-b5ce-6070a59a154a/Design+Drawing.jpg Welding Table The original design drawing, somewhat simpler than the final article. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/95beef4a-3a1b-4d5e-b893-835caefee44d/DSC_0238.JPG Welding Table Test fitting the frame for the shelf. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755264358434-E29485QMYV0Z94ZTN92O/DSC_0239.png Welding Table Gusseting the mounting points for the castors. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c5732dd4-0353-4e87-b3da-d61b8a09f198/DSC_0240.JPG Welding Table A close-up of an outside corner joint and two lap joints at the intersection of the leg and the benchtop support frame. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/043610d8-4398-43c4-b49c-8d8a9a33362f/DSC_0242.JPG Welding Table Standing on its castors for the first time, bench top trial-fitted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8341589b-82c2-4fc2-a209-55cbcf035124/DSC_0247.JPG Welding Table Adding gas bottle storage and retention to the side of the table. This comprises a strong base shelf, a pair of bent flat bar bottle dividers and a retention strap, also from bent flat bar, but this time bolted to the bench with machine screws, via tapped threads in the frame. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b1775809-7d94-42e5-a1d8-e2392141860b/DSC_0249.JPG Welding Table Please excuse the pile of tools and equipment on the bench. This is all equipment that needs to be housed on the bench in a more permanent location. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d40914ab-4bb1-47cb-bb75-b5d6d4aa4250/DSC_0615.JPG Welding Table Two bottles, side by side and securely held. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a0dad1d8-5e72-4890-a8cd-57d044c7416d/DSC_1400+-+Copy.JPG Welding Table Looking a little tidier now, complete with shelf for the welders, internal hooks for cables and storage for Tig filler rods. https://www.harrystear.me/grease daily 0.75 2025-08-16 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/569d4608-0402-4c92-a98f-3bbaeabb0c8e/Performance+Hero+Car+image.jpg Grease On stage during the first performance. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/738ccc1c-b935-4b7f-9a1e-f31d866a95df/IMG_20220630_180853.jpg Grease Grease Lightning, on stage under the lights, captured between shows. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a984d3df-1a6a-4107-8b96-87dad260783b/IMG_20220630_180858.jpg Grease Note the premature aging created by a combination of an off-white gelcoat pigment and a rust coloured metallic paint, with sand for texture. A little spray primer in a few locations and you would think this vehicle had been neglected for several decades! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/72cd4021-9e6c-4853-a78f-7ead42439d36/IMG_20220630_180909.jpg Grease The rather large dent in this wing was achieved by building out the female mould with plasticine/seam wax. It really adds to the abused aesthetic! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7e9f2a70-f611-4c04-936b-ac1cfd75ea89/IMG_20220706_155242.jpg Grease And what a change to the 'hero car' that the T-Birds dream of. Gloss white gelcoat, with silver vinyl lightning bolts and red vinyl tape outlines. Note also the 'chrome' hubcaps. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/15c3412b-05d7-4c0a-8181-a7282c4958d8/IMG_20220706_155251.jpg Grease Using real headlights and 'chrome' acrylic bezels, with real indicator lenses, the front view really glints. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e3314592-1d32-4d92-b386-40ab58a3fee3/IMG_20220706_155319.jpg Grease Note the unusually flat surfaces on the top of the wings and bonnet. These were designed to support being stood on. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ba4c6d82-dfc4-4557-9fe3-6075a6617aac/IMG_20220706_155332.jpg Grease This image gives the game away that the 'wheels' aren't real. Braked castors, weight-rated appropriately, were used to allow the car to be transferred easily to and from the wings. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ba43bb62-869e-4779-aecf-1267d5d27112/IMG_20220706_155944.jpg Grease This image shows some of the artwork done by one of the A-level art students to suggest the presence of an american V8 engine and radiator. You can also see the support structure for the wings, including the locating studs that enabled secure attachment of the wings and bonnet to the base structure, but also easy panel replacement during a scene change. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ec4b1b8f-5868-4582-963f-31ea19492557/IMG_20220706_160157.jpg Grease This shot demonstrates the additional fibreglass covered foam stiffening provided underneath the bonnet to enable it to be walked on. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/529aef55-edf2-46e3-a4a5-83bb87b2fc3c/IMG_20220706_160211.jpg Grease This image shows the 'accident damage' scar produced also using plasticine in the mould. You can also see more of the decorative artwork for the wheels. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9045cdea-e755-402d-811b-e8eae5ebf4b6/IMG_20220706_160303.jpg Grease All of the panels on the stage together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9550ac07-7062-4677-a623-27b48c7cb24d/IMG_20220405_163217.jpg Grease The first physical parts of the process, producing the bonnet plug. The dimensions were scaled from an image of a 1940 Ford Super Deluxe and converted into a SolidWorks model. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ead262d7-90e6-4545-b65a-c1056ebf9e5b/IMG_20220406_161805.jpg Grease Flexi-ply and polyurethane foam provided the curved surfaces. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/84dbe8eb-b2a8-44b0-a126-263a7196f1d2/IMG_20220426_152000.jpg Grease The wing plugs were formed in a similar fashion, this time using a laser-cut grid extracted directly from the Solidworks model. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/56420272-933e-45a0-8d35-e2470b22465b/IMG_20220510_171227.jpg Grease The wing plugs, of course needed to be handed. This image shows a bit more of the plug structure. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2398db24-f401-4d92-80eb-37437e3060b0/IMG_20220517_153615.jpg Grease Polyurethane foam infills enabled further shaping. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/80818cc4-75be-4a20-9551-4efe6afaf867/IMG_20220518_113505.jpg Grease A combination of rasps, surforms and coarse grit sandpaper on a longboard got the foam to follow the profile created by the laser-cut grid. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf1a1640-13cd-4f79-8109-3eb5a75ee65b/IMG_20220527_162605.jpg Grease Car body filler helped solidify the surface and produce a smooth even surface. Note the change of scenery: this is a covered shelter/open garage in the carpark. The volatile organic solvents in the polyester body filler (and the polyester resin used for the GRP) would be hazardous in an enclosed environment. Proper respirators for organic solvents were still required in the immediate vicinity. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1bd2ff97-7557-408d-b1cb-7fbf62c2de67/IMG_20220527_162613.jpg Grease Significant amounts of filling and sanding ensued to get a smooth fair surface. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ed9dcc83-bca4-49d6-a42a-ffa2aa1e05f9/IMG_20220528_182244.jpg Grease The outer surface was looking fairly smooth by now. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6cf58b4a-d124-4361-a1fa-6a0b3d21e1f4/IMG_20220608_122724.jpg Grease The inside edge of the wheel arches needed to be turned in, both for stiffness of the finished panel, but also to ensure that any sharp edges/fibreglass shards would be facing away from the actors. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ea82d98e-7741-4cda-9274-43ac55f8fd8d/IMG_20220608_122746.jpg Grease Several coats of a high build primer designed for GRP plugs, brought the finish to a super smooth pinhole free finish. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/de0864bf-06e1-422c-bb4b-18d68f39282e/IMG_20220609_160736.jpg Grease Wax and a lot of polishing brought the surface to a gloss finish, with a mould-release agent, ready to produce the female GRP moulds. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/62d4020c-1a5e-4c81-8bc2-973ee9721b96/IMG_20220609_191913.jpg Grease A parting surface made from MDF helped to produce a two-part mould. This MDF was painted with the same primer and release-agent combination as the plug. A seam sealing wax made the joint between it and the plug perfectly gap free. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/650afb87-074d-434e-89f9-8e85cb83ae96/IMG_20220612_113639.jpg Grease The first layer of mold gel-coat was applied. Note the plasticine mold locating points on the joint face. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/587950a3-7460-4e08-960f-23a4afd3b248/IMG_20220612_171240.jpg Grease The first layers of GRP. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6590a093-64db-4384-83bc-b2b7e75b1fbc/IMG_20220612_171318.jpg Grease The inside edges of the wheelarch were allowed to run over long. They were later cut back to a consistent flange length to enable mould release. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/957488f0-4b78-4f00-9e79-a24aed2cad6a/IMG_20220612_185159.jpg Grease A fully primed and waxed bonnet mould, also fitted with a flange along the rear edge. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cbc2807e-b38b-4825-83fc-b0620494eaf3/IMG_20220614_155536.jpg Grease Gelcoat now applied to the bonnet plug. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6764ea9c-6dfe-4e89-b3c9-565f88cc4584/IMG_20220614_205056.jpg Grease The first layers of GRP also applied to the bonnet plug. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb10e4e0-2a5a-4228-87ef-991a29f9615a/IMG_20220616_204510.jpg Grease The second half of the wing mould. By removing the MDF flange (along with the plasticine locating points) and applying mould release wax to the surface left behind, this part can then be perfectly realigned every time. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d8519f10-b765-42e4-8c1e-24ac706e8f33/IMG_20220616_204543.jpg Grease You can see the colour change as the resin cures. Cured on the right, uncured on the left. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/dfeb4e6b-d5e7-47be-a5d3-18ef649a7933/IMG_20220619_165500.jpg Grease The second half of this wing mould, now fully laminated. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/18fe8afb-9215-4de6-a89c-59d4f8f72c37/IMG_20220619_165515.jpg Grease Just some trimming now, plus a few assembly bolt holes to drill to complete the moulds. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/31ab179d-db63-4a22-9692-da637cd27f98/IMG_20220619_165545.jpg Grease The bonnet mould now sat on an early concept for the frame. Several tweaks were made before I was happy with the finished version. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8ebe0056-df89-48bc-a189-f674ee5be5d6/IMG_20220620_155237.jpg Grease Applying mould release wax to one of the wing moulds. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6f8c914c-ea61-4337-95e3-aad231414b09/IMG_20220620_180311.jpg Grease The bonnet mould also ready for mould release wax. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7c850427-7e95-4bce-90b2-eaef29ba9b1d/IMG_20220621_214045.jpg Grease The first actual panel, now in gelcoat. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ced35229-ab57-4ec6-93c7-826b2dcace54/IMG_20220623_120504.jpg Grease Finally, a complete (albeit untrimmed) panel, released from the mould. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b06495f9-ba0d-485f-ad5d-3e66314da3dc/IMG_20220623_120508.jpg Grease The yellow seam is the seam-sealing wax, showing the parting line of the two-piece mould. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/38e9050d-e497-4245-9f32-80bea447bfa6/IMG_20220623_120516.jpg Grease Pretty from every angle! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fa2b3a9c-d2d4-4b56-92c9-7bc43a756fdf/IMG_20220630_133220.jpg Grease Some last-minute grille-trim. Test fitting the foam base structure. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/76b1a064-8802-4d44-95af-87489a6c7f3b/IMG_20220630_133246.jpg Grease A little fairing enable a closer fit. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/97a035a7-1b5d-4ff5-9b9f-8093fc230f9d/IMG_20220706_155615.jpg Grease An up-close look at the artwork and panel locating pins. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/58fa078d-9485-4988-8bf1-e5a8d6dded8d/IMG_20220706_155622.jpg Grease The wheels were made from plywood, with grp coated foam tires and 6mm MDF wheel centres. The wheels were hung from a set of brackets that I fabricated to attach them to the main frame. They sat about 15-20mm above the stage floor. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb5c63d4-a49b-4c81-97be-64a98e54c0e4/IMG_20220706_155944.jpg Grease The bumper was also formed from a foam covered MDF structure. This was then faired with body filler before painting with a 'chrome' paint. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/638742a6-47a8-4590-8990-0b6bc53c5caa/IMG_20220706_160234.jpg Grease To convert the wheels for the hero-car, I blow-moulded these hubcaps from mirrored acrylic. They were attached using velcro dots. https://www.harrystear.me/mg-midget daily 0.75 2025-08-18 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/592fc5b8-7b00-4f37-8301-024aec65a499/DSC_1019.JPG MG Midget The trailer that has stored the MG Midget for nearly a decade. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755506642555-RJ4KDZJVNT87TF2S1EPG/DSC_1022.png MG Midget Opening for the first time in that period! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8cf8cef8-af33-440e-a4b7-171d6e16716c/DSC_1025.JPG MG Midget Tucked away... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cdc3b342-f732-49f5-a170-6e7fad2e236c/DSC_1026.JPG MG Midget Welding gas ready to go... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/67cdbc66-51fe-413d-a98e-9b410c231b3c/DSC_1027.JPG MG Midget The car has been stripped to a rolling shell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/598cae4c-a891-4a01-8918-467e41e8616b/DSC_1028.JPG MG Midget Boxes of parts packed around the car. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7b6ea4b3-6b24-4a4e-950f-39aa6e854446/IMG_20230724_104758.jpg MG Midget Not looking too bad, from a distance... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/eb18f684-da7b-419d-9aa1-40389050ebf0/IMG_20230724_104803.jpg MG Midget Somewhat worse up close. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d2354588-56b3-45ae-a9cb-1885c0d9b648/IMG_20230724_104828.jpg MG Midget Corrosion in the bottom of the B-pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0c74e38a-b93c-4875-9a43-a8ef184488a6/IMG_20230724_104835.jpg MG Midget And in the scuttle panel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/71290805-21d7-470a-89b9-1bf754e4e1cb/IMG_20230724_104839.jpg MG Midget Dodgy repairs to the offside footwell... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/069e4d81-29d8-46ff-a7a9-58f03ee66614/IMG_20230724_104848.jpg MG Midget Rust in the offside floor-pan. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cab78b85-d4af-4db4-97d5-8f6a4365ccce/IMG_20230724_104925.jpg MG Midget Including a hole through the floor. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a3624466-cb74-4d3b-89c9-b80cf2f6ec33/IMG_20230724_104937.jpg MG Midget Flaking paint in the footwell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/30ecd17e-910a-4842-8b2d-2493d668a0e0/IMG_20230724_105007.jpg MG Midget More dodgy repairs at the base of the A-pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/018eeb23-dcba-4772-939b-9148d31b8bce/IMG_20230724_105035.jpg MG Midget Lots of rust in the front clip, including more dodgy repairs. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5911b35d-cac6-4fd4-98bc-3949172b94a4/IMG_20230724_105108.jpg MG Midget The nearside looks marginally better. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/46ac045b-5c25-4e6e-b1e8-c38dbd8e272f/IMG_20230724_105123.jpg MG Midget Similar dodgy repairs to the nearside footwell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9c1b99b6-6737-4f23-aeb6-942312e89e3d/IMG_20230724_105131.jpg MG Midget Nearside inner wing attachment looking quite crusty. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b2e80809-119b-4c02-8f4c-d73dea67c150/IMG_20230724_105141.jpg MG Midget The outer sills look good at first glance... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a1d9be32-2ef5-4721-be5d-b82b7061144b/IMG_20230724_105149.jpg MG Midget But a closer inspection shows them to be barely attached to the car. A few blobs of weld on the top edge of the panel are all that is holding this outer sill to the inner sill. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a6a7d4ad-2093-4d99-909e-31f958337005/IMG_20230724_105422.jpg MG Midget Rust in the top of the offside B-pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c9863c2e-229c-4fbe-b180-48860872ff16/IMG_20230724_112226.jpg MG Midget And more rust where the pedal box mounts. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/406dd410-6c96-4dec-9d51-814aedf2555b/IMG_20230724_112232.jpg MG Midget Engine and gearbox are out and the chassis rails don't look too bad. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7bed9a4c-23d8-465c-a523-1995afcf71b1/IMG_20230724_112238.jpg MG Midget And the front crossmember is solid. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8ad16819-407a-4167-8c59-b86778ccbaab/IMG_20230724_142756.jpg MG Midget The first area to be attacked with the angle grinder. Outer wing removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f71ff2b0-eb7c-432c-907f-ce644659055d/IMG_20230724_165232.jpg MG Midget Revealing a rusty inner wheelarch lip. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e487ebb1-8a22-4c84-892a-d600ce79dfe9/IMG_20230724_165237.jpg MG Midget And very rusty boot floor extension. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/49ba3c94-d462-48c3-8744-2cb0eeba4b24/IMG_20230724_165240.jpg MG Midget Not much left of this section. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7fe21227-b311-48e6-aeb2-b8bf1d871e5c/IMG_20230725_125749.jpg MG Midget Removing the outer skin of the offside A-pillar reveals a lot of rust at the base. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755507081679-I21G5S4AMJRT010409BK/IMG_20230725_125800.jpg MG Midget Rust continues quite a long way up, but significantly better towards the top. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c5008ed6-716c-4e4d-a77d-8d19061a0e95/IMG_20230725_165741.jpg MG Midget Outer sill removed. It wasn't very well attached... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/096a87c6-8f51-4680-9c1c-944e3397fe02/IMG_20230725_165745.jpg MG Midget The inner sill looks like lace... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf67dd5d-9bd4-45f2-bd51-cedf64fb6a46/IMG_20230725_165749.jpg MG Midget Patches on the inside of the car hid the gravity of the situation. Removing the outer sill unveiled the reality. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9cbebc1f-2a15-416e-96a9-97bafcc434aa/IMG_20230726_114129.jpg MG Midget Floor and crossmember also removed. Steel box section welded in temporarily to retain rigidity. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0bccd281-0887-4578-92fc-ef8f8f36ff69/IMG_20230726_114139.jpg MG Midget Rear cross member doesn't look very good. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/aa42824f-c30a-442c-8843-b7b57141846d/IMG_20230726_114148.jpg MG Midget Reinforcing bracketry rusted completely away at the base. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/02c38217-81e3-440b-a617-35fbeb466eea/IMG_20230726_114201.jpg MG Midget Floor crossmember doesn't look too bad at the gearbox mount, but much thinner further from the centre of the car.The floor is in dire condition throughout. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5c7a2299-6bee-436a-bd73-4f9c613d4048/IMG_20230726_114208.jpg MG Midget Removing sections of the footwell. patch panels. More to follow... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1fbe0536-9828-4f22-b955-44ecd162ff0f/IMG_20230726_152559.jpg MG Midget Floor cut away up until the gearbox tunnel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e359840f-c8de-4f09-b74b-e5f63daeb557/IMG_20230726_152606.jpg MG Midget And as far as the front of the footwell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2ecf1d39-eb5e-4d40-b82a-bfdff8064185/IMG_20230727_172121.jpg MG Midget A slew of new repair panels. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a453a443-1bb7-43fa-b1c3-6846887c597f/IMG_20230728_121823.jpg MG Midget Removing sections of the rear bulkhead to access the corroded spring hanger. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d79eed22-7f09-4e7e-88a0-d6ec3816c3a3/IMG_20230728_121843.jpg MG Midget Rear shock absorber mounting bracket is very rusty and weakened. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/54562019-18db-4c86-afe5-5ea39df22c01/IMG_20230728_121831.jpg MG Midget Rusty section removed to show the underlying reinforcement bracket had also rusted through. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/56a1b396-a729-4921-8d1d-5aa96c9436fb/IMG_20230728_121837.jpg MG Midget Close-up shot shows yet more rust further down. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a24d7ae4-1b1d-453a-a806-85100e71f0db/IMG_20230728_184716.jpg MG Midget Cut out completely. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4bf337e4-ad06-4580-a5bf-d6faa0703306/IMG_20230728_184733.jpg MG Midget The offending article. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/afda5975-4056-4e75-bda3-11faee178f09/IMG_20230728_184743.jpg MG Midget These rust holes were hidden by underseal. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/427a157f-45dc-44ff-ae3f-60759acf9a70/IMG_20230728_184800.jpg MG Midget Floor cut back to solid metal. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4bd10ac9-1cb1-49f4-8074-f8458cadcc8b/IMG_20230730_132018.jpg MG Midget Repair patch made for the rear crossmember that the suspension bracket attaches to. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5c2934f5-1115-474f-9228-6d5d2a99dcea/IMG_20230730_132026.jpg MG Midget And the solid remaining section in situ in the car. Some minor repairs still required to the lower edge at this stage. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/88631a57-d366-44bc-909d-1e2874f9578b/IMG_20230730_173144.jpg MG Midget Floor sat back in and replacement spring hanger. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/edbd1e43-8da2-42bc-ab0e-ec67d2bc8305/IMG_20230730_173152.jpg MG Midget Temporarily clipped in place with mole grips for now! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ecb05abf-959a-431f-97d7-7964fb0057aa/IMG_20230731_142620.jpg MG Midget New inner sill mounted, along with brand new footwell side. All the old metal/rust/patches removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/734df545-c4da-470e-b560-a863ce529304/IMG_20230731_142634.jpg MG Midget Rusty scuttle panel section and entire A-pillar removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bc9ab50d-2619-4211-9458-07003f24df69/IMG_20230801_152701.jpg MG Midget Temporary structural bracing holding everything in position. New floor crossmember Tek-screwed in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/07860988-2885-4dcd-a9f4-d24adebc300f/IMG_20230801_152712.jpg MG Midget Weld preparation nearly complete. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/99755ba5-e888-4075-ad65-0d85e14e642a/IMG_20230801_152725.jpg MG Midget Yet more weld preparation. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fcab743f-1a7c-4c46-92fb-49b620aa9e44/IMG_20230801_152743.jpg MG Midget Looking good from the front wheel arch. (Should one be able to see the interior from the front wheelarch?!) https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d819075a-d695-42fc-b5e5-1d8e55bc3072/IMG_20230801_165527.jpg MG Midget New A-pillar and outer sill temporarily fitted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/af328aeb-01a7-4310-8712-73fc59141e99/IMG_20230801_165534.jpg MG Midget Jacking the floor panel to align with the sill. Tek-screws then fitted to attach them temporarily together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/dd909800-1ee6-4b63-840d-edefa6d570b5/IMG_20230802_102504.jpg MG Midget A pile of rust steel, now no longer part of the car. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f480842e-ac19-4054-b568-54293b1feb9f/IMG_20230802_145140.jpg MG Midget And the solid steel that replaced it. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/84c55f9f-eb73-43d3-ae15-b2c8fe8a5281/IMG_20230802_170843.jpg MG Midget Inner sill welded in properly. No spot welder available, so MIG plug-welds substituted. 8mm holes determined through experimentation to give the perfect plug weld. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/31cf341b-f554-4f50-a64b-0032154b6090/IMG_20230802_171020.jpg MG Midget New A-pillar installed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3d84121c-40bf-41b2-b0b6-defb0853fb7b/IMG_20230803_173456.jpg MG Midget Bracketry attached and weather shield fabricated. Original pressed shape was too complex to replicate with available tooling, so this boxy shape had to suffice. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fb031b60-d509-47c9-996d-7f86f6422126/IMG_20230803_173506.jpg MG Midget Welding in progress... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/51d03bab-2b8e-44b8-87d9-cbd8f0630632/IMG_20230804_164018.jpg MG Midget Boot floor patching also begun. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/88bed7c0-cd18-4b54-a85c-6aa4142ee109/IMG_20230804_164034.jpg MG Midget Replacement shock mount fabricated to allow forward progress instead of waiting for a delivery. Now solidly mounted in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/084f56c5-1fe4-4033-b883-d045ee2f5108/IMG_20230804_164048.jpg MG Midget More butt welded seams. Notice the gap near the gearbox tunnel... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c320ae71-8d03-4ddf-bf66-bee05fe36fcc/IMG_20230804_185638.jpg MG Midget Now filled in. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/68fb178e-4db5-4528-b1c5-360c6c73044f/IMG_20230805_185739.jpg MG Midget Inner wheelarch lip completely removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d41f536e-3384-4bc9-9772-fb2365fa1613/IMG_20230805_185744.jpg MG Midget Repairs to the lower edge of the inner arch https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f4326312-2130-4342-bd58-1f3695c272e9/IMG_20230805_185748.jpg MG Midget And repairs to the bottom of the wheelarch reinforcement. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/895e8f7d-bd0e-4ba7-8768-4eb79f632a9e/IMG_20230805_185759.jpg MG Midget Removed boot floor extension (behind the wheelarch), only to reveal that the corrosion travelled further. Boot floor then cut back until good steel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/93e3e97d-be8c-4889-91f2-4a3234ba33df/IMG_20230808_104432.jpg MG Midget Rear axle removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8b4ade4c-da72-44ea-8158-c6db9974fc73/IMG_20230808_131628.jpg MG Midget Rear axle tucked away for storage. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ee8b262b-7565-408a-8331-72de0d11d1e0/IMG_20230808_131618.jpg MG Midget Front clip removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e7b2ec27-57ca-47af-8f80-d4923c8f80d3/IMG_20230808_181926.jpg MG Midget Looking very tatty with significant corrosion present and many poor quality patches. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5c27c8a9-ec00-4e83-ab09-4f562f1ae40a/IMG_20230808_131637.jpg MG Midget Front bumper mounts and corroded away inner wing section. The intention is to remove these and run bumperless. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/10a59ff7-5db3-4f14-b99c-7ea590b5c886/IMG_20230808_131655.jpg MG Midget Paint stripping the engine bay. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6643e4d3-c9bc-4476-be31-8ef5ebc0925c/IMG_20230809_155638.jpg MG Midget Rear bulkhead fully repaired. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6ea448b1-549d-482c-928c-e71c4d3d2036/IMG_20230809_155658.jpg MG Midget A replacement bracket welded in to strengthen the bottom of the B-pillar. Primer applied to all bare metal. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8b30d7c2-a9be-4340-a9ae-b12d2088ce8c/IMG_20230809_155707.jpg MG Midget This whole corner looking a lot more solid now. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f4bf51ab-ee9a-458a-8c57-779b18c10c84/IMG_20230809_172402.jpg MG Midget New outer wing lower section in position. Note the repair to the lower B-pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/da5362c1-f926-4202-b585-8b12c7fabb01/IMG_20230809_172406.jpg MG Midget Shiny new inner arch lip also visible. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5e425387-edaf-41a3-99f2-694f9c87713b/IMG_20230809_182753.jpg MG Midget Front outer wing fitted to help with alignment of the outer sill. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b8cfdb7d-b6e1-42ee-9675-579c60134334/IMG_20230809_182758.jpg MG Midget This made for quite the psychological win. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6fa981ff-4904-4575-9b49-0eb69dc0d849/IMG_20230809_202246.jpg MG Midget Panel gaps looking at least as good as factory! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3050bed6-989b-4955-b381-a9a7e298cccd/IMG_20230810_191841.jpg MG Midget Stripping down the rear axle for inspection. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3f762372-26ea-45ba-acb2-372b73dee7f7/IMG_20230816_193722.jpg MG Midget Offside front inner wing removed and front footwell panel replaced. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ba9917c2-d71e-4bb7-9524-086cc15cd0e5/IMG_20230816_193734.jpg MG Midget New inner wing fabricated. The old one, it turned, out had 3 layers of patches, each overplating the corrosion of the previous. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bf54441d-5413-48b6-926e-0ec2a5d31baa/IMG_20230816_193742.jpg MG Midget Repairs to the bottom of the inner arch reinforcement bracket. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/677eb4a5-20a8-443f-89c7-17dd5cd77c8e/IMG_20230816_193758.jpg MG Midget Bumper mount cut back behind the plane of the grille and rust removed and repaired. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e8a17097-4ace-4e61-b23d-92c6a63f15b6/IMG_20230816_193805.jpg MG Midget Ready to join the two parts together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bed8d708-3c5f-47e7-93f3-a1c5c8e35414/IMG_20230819_135036.jpg MG Midget Inner wing welded back into the car. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/137bcdfc-31ad-4e5e-bb8b-efa4faaf139b/IMG_20230819_135042.jpg MG Midget Scuttle panel repair fabricated and Tek-screwed into position. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/db76acec-2669-4aa8-abf2-04b24f4412c0/IMG_20230819_135048.jpg MG Midget Joint alignment looking pretty good. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/24ad230e-9778-49ed-9d06-306c780aef51/IMG_20230819_135057.jpg MG Midget Clamps holding the A-pillar outer skin to the underlying structure while welding the two together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e4084618-a523-455b-a6d6-79dd12a401cb/IMG_20230819_151654.jpg MG Midget Rear outer wheelarch upper section fitted to the lower section repair panel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7e4393a5-3931-4793-be54-0f1e86a5fcf3/IMG_20230819_151703.jpg MG Midget This side now starting to look much more complete. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2b38aa04-cd68-4211-8d94-27d6b0f3cbc2/IMG_20230820_200044.jpg MG Midget Even more so with the front panels and the door rehung. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755507651933-T8U3D9J7W4I811EACY8G/IMG_20230820_200056.jpg MG Midget Panel gaps around the A-pillar looking good. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2b6c3273-a23d-4448-8b3d-ef6b7023729f/IMG_20230820_200115.jpg MG Midget Panel gaps at the B-pillar also looking good. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/87506514-499a-48c1-ac7f-4b7961bf0f6a/IMG_20230820_200127.jpg MG Midget Sill maybe doesn't look quite as good, but still no large gaps. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/92988020-f3d1-4e44-8225-da34674e7555/IMG_20230821_105105.jpg MG Midget New front clip section in situ temprarily. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5fff48ef-efed-4463-91b2-4971a56f5fd2/IMG_20230822_202843.jpg MG Midget https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/949539ca-f1e1-4565-abbe-ab399896d7df/IMG_20230822_202900.jpg MG Midget Rear off-side outer wing seam welded back together (butt welded) https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/509b1b9f-1d46-488f-890f-ae12e3b5fa4e/IMG_20230822_202909.jpg MG Midget Temporary stiffening braces finally removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/97c3eedf-1fed-4c85-aaf1-3842d15c8af8/IMG_20230822_202918.jpg MG Midget New angle plate welded into footwell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2d454f40-90ef-4a05-b161-db1a37fe0305/IMG_20230827_114300.jpg MG Midget All of the metal/rust removed from the off-side. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/43bf092a-8311-459c-b617-815aeefe124a/IMG_20230827_200849.jpg MG Midget Repairs to the nearside wheelarch lip. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4b73a933-8b88-4bfe-bd6a-6455742d326f/IMG_20230828_182646.jpg MG Midget Deja Vu? https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0e088b9a-e4ea-4995-b408-ba1a507faad7/IMG_20230828_182656.jpg MG Midget The reason for replacing both outer wings was to allow removal of the rear bumper, so these wings are to the pattern of the earlier chrome bumper variant. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ce3611e3-2b67-4d16-b4a7-f9a8c8447914/IMG_20230828_182708.jpg MG Midget The rear panel was replaced for the same reason. The rubber bumper cars do not have the protuberances underneath the tail-lights because the bumper sits directly below. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2881b29e-cfcf-451b-977c-884863f89bf4/IMG_20230829_155241.jpg MG Midget Looking very tidy. Replacing these panels also helped to deal with some rust in the lower edges. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/79888d66-a845-4483-9376-1c8651803826/IMG_20230902_190826.jpg MG Midget Trial fitting the front clip. Engine bay now primed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0159c0fb-fa3c-4763-a34a-e5eb202ce506/IMG_20231021_172854.jpg MG Midget Some repairs in progress to the nearside inner wing reinforcement bracket. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8ee61b99-06d7-436f-97f5-1d4971faa04d/IMG_20231021_172900.jpg MG Midget More visible here. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2fc9f8b1-bf0b-4955-a082-bd7aeda04b4f/IMG_20231021_173905.jpg MG Midget Repairs to the bottom flange of the gearbox tunnel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755507901985-VRI62KOB00VETOTWPKLM/IMG_20231021_181838.jpg MG Midget Repairs to this rear chassis member. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755507865906-1IG3ZB029YI7QOBUGG26/IMG_20231021_182232.jpg MG Midget Welding under the scuttle panel, reinstalling the windscreen mounting bracket. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9874cab0-cea9-4a91-92be-a9d95943408a/20240727_172229.jpg MG Midget Nearside footwell and inner wing before letting loose with the angle grinder. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6aebbca6-2371-44fe-a789-5860997a5c96/20240727_172234.jpg MG Midget Rust holes inside the inner wing. Lower footwell section removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/39da8efc-3139-4281-b41c-b2ec7bde0be8/20240727_172240.jpg MG Midget Patch removal at the footwell/inner-wing intersection. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/de1eb74f-e83f-4535-9d88-16b85c40bf4c/20240727_172254.jpg MG Midget Initial inner sill inspection doesn't look too bad... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/985480e5-5a6b-4f1d-9791-5a1ab6a0dc5f/20240727_172300.jpg MG Midget Front footwell also doesn't look too bad. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/55db92f7-4a10-4808-9f6f-27d0abf989a3/20240808_120542.jpg MG Midget Unfortunately removal of the outer sill tells a different story. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2542fc79-1172-49b1-bd77-dd140882a9b6/20240808_120547.jpg MG Midget I HATE over-plated patches. This section was continuing to rust away underneath the patch on the other side. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ad4dc29e-0c29-4842-be0d-217b43e5bd87/20240809_104140.jpg MG Midget Have I said how much I hate overplating?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/aa4ed4a4-7af8-4d80-ada8-c131d27fb38a/20240808_170212.jpg MG Midget Footwell floor looks solid... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1025071a-b4bb-4851-a531-c89431af7dbf/20240809_111742.jpg MG Midget But footwell side removal. Note also that the top of the inner wheelarch has been removed... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f538ce8e-de26-4323-8b25-9f41918251c7/20240809_111749.jpg MG Midget Shows it to be yet another example of overplating! There were three layers here... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/74eafc64-34ee-40d5-9029-07eb18c6ef50/20240809_111759.jpg MG Midget Inside the A-pillar. Removing panels is easier in stages. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1e4adc7c-607a-48d9-90e5-eb4f000e1806/20240809_111826.jpg MG Midget Now you see it... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6adac874-dd88-43f3-bf0e-db55ba08b294/20240809_161901.jpg MG Midget Now you don't! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7a9ad7f3-33f4-4002-a50f-28ffc304bcc2/20240809_161905.jpg MG Midget The removed front footwell section along with the inner arch stiffener. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e46b4aa6-0882-40d1-80f4-633c71e60d08/20240809_161928.jpg MG Midget Oh dear... Cracked wishbone mount. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ad36229b-73d4-4f5b-a21b-746797ae8fb3/20240809_161934.jpg MG Midget Front footwell. Some tidying up required... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/970c18fc-ca88-4717-bfa7-b106a2e31c8b/20240809_162014.jpg MG Midget https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7fc61dfc-9b5f-4fd2-921f-f828e9ca0922/20240810_171044.jpg MG Midget https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5cddc807-fc5a-4e5e-a0af-cc3d1e1150a7/20240810_171057.jpg MG Midget Peeling away the layers of footwell reveals a sorry looking A-pillar structure. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f625d351-f1dd-44e9-8595-d7f1835f039f/20240810_171103.jpg MG Midget Hinge mount and reinforcement box have disintegrated. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ec71af76-47d9-41de-8a17-427a10a90209/20240811_125344.jpg MG Midget Hinge box removed: Still looking crusty... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6cf6f57b-457d-4a2b-beef-0dd120855c75/20240811_125353.jpg MG Midget Not great from the outside either. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/50cf8894-d113-471e-b0e0-f12897ae0353/20240812_142041.jpg MG Midget Executive decision taken. A-pillar being replaced entirely! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e8f9bbbd-cd79-4d27-ba82-84df1e0665fa/20240812_142045.jpg MG Midget Footwell almost completely gone... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f737ee4c-7b53-4ed0-b076-6782f23fe09d/20240817_164958.jpg MG Midget And replaced with new panels. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/036591b2-01ef-4c95-b6a6-4591d2010194/20240817_165008.jpg MG Midget Angle plate. Notice how this forms yet another boxing/crossmember. Front footwell pre-drilled and prepared for plug welds. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0d9b4aa4-0a74-4856-ac31-79971a70c7d8/20240818_165745.jpg MG Midget New A-pillar attached. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ff935f7e-edcd-4548-b50f-d2be6e0357f8/20240818_165802.jpg MG Midget Lots of welding. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/91b742a4-95cc-4697-a40c-6453f1d9db5d/20240819_140931.jpg MG Midget Rear bulkhead removed. Reinforcement brackets also rusted away this side. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6570d32e-467b-4f18-8ae7-584efcf72426/20240819_140936.jpg MG Midget Similar B-pillar damage also. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8953fd41-86b5-4df0-92f9-0c5cb2a81505/20240819_141011.jpg MG Midget The rear bulkhead had clearly had repair patches fitted before, but they had not even been welded to these triangular reinforcing braces. The right hand ones are the spring mount... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8fffc1ed-0f81-4ed3-9c99-cd187f3a7c6d/20240819_160436.jpg MG Midget And now removed! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1bec8c0e-a527-4302-bd68-aef95a2be991/20240822_111827.jpg MG Midget Foam mats on the floor served as kneelers. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8f90ef1d-7cf6-4dc3-8d2e-db14b7ed9396/20240822_111852.jpg MG Midget Yet more rust cut out. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/eea80a33-44a4-4fd1-be91-7db538343a30/20240822_111906.jpg MG Midget And replacement patches made. These ones will be butt welded back to solid steel and will make these sections as good as new. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d91a962b-727f-4a3b-8b90-c4ca1532c4fc/20240823_172028.jpg MG Midget Welded in and good as new. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5d6f9eaa-6482-4c8d-a0f0-9d2f7a122815/20240823_172037.jpg MG Midget New floor and cross member laid in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3d72c99e-bfe0-457b-9ed1-794f137a09a9/20240823_172054.jpg MG Midget New inner sill trial fitted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9b58ef6e-cead-4693-a723-9439ee868500/20240824_183320.jpg MG Midget Looking a lot better! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1d57f5eb-4fc1-4c58-88e2-425ae2ae77b3/20240824_183329.jpg MG Midget https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/84e73894-701a-478d-967c-dc78ba6bf7eb/20240824_183338.jpg MG Midget Weld prep complete. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/811e150d-6020-4725-919a-5eb2140beedc/20240824_183352.jpg MG Midget New spring hanger in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c32248b5-96c4-4125-a35f-fa3df31737be/20240827_185541.jpg MG Midget Thanks Greg for getting the carbs serviced, new clutch kit fitted and gearbox mated back to the engine! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/13df6fe1-b199-468e-967c-e13b5d1c3ad7/20240827_190409.jpg MG Midget New inner wing panel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/11efc521-55ee-44a2-bde4-759ac1c89fb5/20240828_194923.jpg MG Midget Welding the new inner sill to the car. Photography by Greg, makeup by grinding disc, steel filings and rust! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a9b06a79-1e1c-4458-95db-b022a7bcd811/20240829_133738.jpg MG Midget New inner wing panel welded in, along with stiffener. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b1b0d374-d4f0-4dfd-aa3a-02c389f3629a/20240829_220939.jpg MG Midget Engine bay primer/undercoat applied. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3aca0353-abcb-468d-b589-65700a0188c4/20240830_120512.jpg MG Midget New British Racing Green topcoat! Doesn't the engine bay look good! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e5174d9f-c1b9-496c-b0e1-28f574bdf727/20240830_125231.jpg MG Midget Dashboard subassembly put back together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755508419304-QEVDD2X48JDWG32ZVTSW/20240830_130101.jpg MG Midget Greg reviewing the rear axle. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/92a35056-d9dc-45f6-92ed-72c354b2bcb4/20240831_101243.jpg MG Midget Greg with our engine lifting arrangement. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/61b961d6-ada1-4782-8c84-12400ef3cdba/20240831_101254.jpg MG Midget Engine and gearbox fitted back in the car. First time in a decade! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4df15d85-6abb-46f6-858e-54f3cd87fb9f/20240831_101843.jpg MG Midget Obligatory selfie... Me, Greg and my father. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7c9e1d07-181f-4912-b75c-77d51f289aa2/20240831_102708.jpg MG Midget She looks magnificent. Just excuse the missing inner wing section! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7a745b9a-9825-4a36-92e0-1c21d7c204ac/20240831_102713.jpg MG Midget All the angles! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/399df7a6-ae5c-48d7-90ba-1246c0a80c54/20241102_104037.jpg MG Midget New inner wheelarch section fitted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/81f7103a-3795-48c4-b774-88903364f077/20241102_104042.jpg MG Midget And welded in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/34031fca-34a6-402d-a32a-44b93cee8c38/20241102_104047.jpg MG Midget Outer sill fitted and welded in. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3dce00e6-cd14-4d82-8dd6-d55bc9f71eb9/20241102_104057.jpg MG Midget Rear bulkhead also repaired. This time properly attached to its triangulation! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/286a1004-1e18-498a-a9a8-d93485756008/20241102_104114.jpg MG Midget Repaired B-pillar too. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e834e7c2-bb51-43d7-9a34-4a831d1f55c0/20241102_104125.jpg MG Midget Sill and A-pillar properly attached. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9edb7d0f-2bbf-4d1a-965a-34b90c1d2b40/20241102_104201.jpg MG Midget Small boot floor repair patch fabricated using ballpein hammer and assorted wood blocks, channel iron etc.! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0e3bd194-2914-4304-934a-77f677bc1d12/20250220_133846.jpg MG Midget Front end panels rehung. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d1c90461-144e-44c2-9948-1d816d211c5c/20250220_133853.jpg MG Midget Newly repaired front clip. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/60cbe729-6350-454f-b429-0ddb74cece7f/20250220_133903.jpg MG Midget New offside grille surround fabricated from recycled steel (supplies were running low!) https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/75a68b05-7d7f-4978-84a1-fe227bf628a0/20250220_133909.jpg MG Midget And the nearside was also cobbled together from scraps. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b5a54cb3-85a6-42a5-82d1-c911da4c96d9/20250221_171005.jpg MG Midget Repair visible to the rear lower quarter of the outer wing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6d5b7537-56de-4e0f-b377-c9c9fe9cbb96/20250224_151244.jpg MG Midget And the same on the other side. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3cb0f1a1-e486-43fc-8b87-82f09663ab44/20250221_170403.jpg MG Midget Front end repair to this wing also visible. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7bab60cd-3bec-45d0-a838-747216eb991c/20250408_191255.jpg MG Midget Final repairs to the boot floor complete and a coat of primer/undercoat applied. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/90870cb5-754a-4dbc-9058-b510e9fc859d/20250419_132151.jpg MG Midget Rear axle and new fuel tank installed https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a8614f48-1a45-4a6b-964f-3a9bb63e0a45/20250224_151251.jpg MG Midget These rectangular openings for the indicators were the next thing to address. I am changing to Mini domed indicators, located directly under the headlights. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/93aede61-4511-43d4-869b-300b735aad51/20250419_132137.jpg MG Midget Front suspension bolted up. https://www.harrystear.me/kayak daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/08a48634-ae80-4bc4-b315-319a4cf9291b/IMG_20200328_181341_6.jpg Kayak Setting up the strongback. Each of these MDF forms were cut with a jigsaw from a full-size template that I spray glued to the MDF. The design drawings were purchased from Nick Schade at Guillemot Kayaks. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b776b526-c698-43a6-97cb-04e5f74f0b4c/IMG_20200328_181354_0.jpg Kayak Each MDF form was located on a 4" x 2" Aluminium rectangular hollow section. They were spaced using these plywood U-shaped spacers that slotted over the tube. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ae984324-9b5e-472e-b3a8-983668546ee8/IMG_20200328_181405_6.jpg Kayak The central spacer was split in two and plywood wedges were used to apply compression to the whole stack. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1e01cb1e-72ad-4929-9291-5e94659af7f9/IMG_20200328_181444_1.jpg Kayak Shaping the inner stem and stern pieces. These were roughed out with the jigsaw, before refining with a block plane and rasp. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/71bbed6b-c946-49c1-8552-1db8ce7516fa/IMG_20200328_181510_0.jpg Kayak This little brass block plane is a joy to work with. It nestles perfectly into my palm and cuts beautifully. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b6558d30-1496-4b1a-a3e6-8c17505f3116/IMG_20200329_141440_0.jpg Kayak Using a homemade fixture to laminate some 'boatshed' beams. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b280170a-4ed7-42ba-97c5-00433d6b5a64/IMG_20200329_141445_2%281%29.jpg Kayak Workshop setup... Outside with a jobsite table saw and a trestle or two! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2e622c9f-7526-42d3-827e-68b7489b672e/IMG_20200329_142839_6.jpg Kayak The 'boatshed' required several long beams. I glued up a few scarf joints, including for the ridge, a stop-splayed, undersquinted, tabled and wedged scarf joint. Why? Because I thought it would be fun to have a go at and I figured that it would also add strength! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8a82950a-51a8-405a-ae92-e4b71ac88d1a/IMG_20200402_181653_8.jpg Kayak Inner stem and stern attached to the bow and stern forms. Hot glue on masking tape. This fancy hot glue gun heats up in no time and was absolutely game-changing on this project. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c79f991b-ff67-46e6-9055-38ba5e6949fe/IMG_20200402_181730_3.jpg Kayak All of the edges of the forms were also taped to facilitate removal of the moulds from the finished kayak. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c1c4c82c-24d5-447d-b317-af18397d95d5/IMG_20200404_190542_6.jpg Kayak Setting up to cut strips. I had purchased my timber in 1" thick slabs from a single 6" x 4" piece of cedar. This enabled me to book match the strips. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/495cb2fa-9ce7-49b3-b72d-d02ecf1a68af/IMG_20200404_200203_3.jpg Kayak Feather board and outfeed guide wedge clamped in place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/218e6221-bd15-48d8-9a39-c1964d689508/IMG_20200407_124005_1.jpg Kayak All of the strips, in order, ready for bookmatching. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fcabcee4-92e9-403a-a8c3-8bac134aad08/IMG_20200407_130039_7.jpg Kayak They all looked beautiful. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a00da3b9-8b7f-4951-82fd-821538059964/IMG_20200407_155445_6.jpg Kayak First strip, hot glued to the forms, except at the stem and stern where wood glue was used to attach to the inner stem and stern pieces. This strip sat with its lower edge perfectly on the parting line of the hull and deck. It was crucial to take time to ensure a fair curve for this strip. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/516574cc-9c48-41e6-96ce-22a132765b1c/IMG_20200413_165428_5.jpg Kayak Gradually edge gluing planks together, while hot gluing them to the forms. The tool with the two doorknobs attached (sitting on the cedar on the left of the image) carries a small rebating plane to help produce the continuously changing bevel between each strip and ensure that each strip glues seamlessly to the previous one, while also conforming to the lines of the forms. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7eab3b96-8c53-4145-b5fa-799e1ac637f6/IMG_20200416_154418_3.jpg Kayak Hot glue and masking tape help hold each new strip in place while the wood glue cures. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/65e4d180-404b-4fa5-b39b-bb391e65cee9/IMG_20200416_154426_6.jpg Kayak Arthur, the Shih Tzu, coming out to say hello! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d2031211-ffc3-43b3-9b8b-d0163835956e/IMG_20200416_192851_8.jpg Kayak As I work up mostly on one side, the strips are allowed to run long. They will be cut back to the centre line in a later step. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/780322f5-ffd4-4b99-a604-261629ef38e0/IMG_20200416_192910_6.jpg Kayak The hull shape is really coming together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1a5c7151-b262-4658-b28e-58e1f9cc2143/IMG_20200423_180939_7.jpg Kayak The centreline cut was completed with a japanese pull saw. The second side of the hull is now ready for planking. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/539053d8-1dbb-48fd-82e8-9742fb818930/IMG_20200423_181028_2.jpg Kayak On the second side, each plank end had to be scarfed in to match the angle formed between the centreline and the previous strip. The other side then had to be completed before gradually planing small amounts from one end until the overall length was also perfect. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5f61fbbf-2ec7-4d3a-bf94-1581580e9976/IMG_20200424_131032_3.jpg Kayak Yet more tape and hot glue. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a7acb2fd-0860-44b4-b1b3-f5188c7ed26b/IMG_20200515_194525_0+-+Copy.jpg Kayak The same process was followed for the deck after flipping the form over. The parting line remains unglued. At this point I am gluing in a decorative unidirectional carbon fibre square rod along the centreline of the deck. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f0a991db-b082-403f-8548-aba9e28e34fd/IMG_20200516_202442_9+-+Copy.jpg Kayak You can see the rough outline of the cockpit coaming. The strips were left long to enable cutting the correct profile later. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/732b42f8-de86-42c9-9e2f-979dfedc44e0/IMG_20200516_202448_1+-+Copy.jpg Kayak Gluing in the last strips. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/577fad4f-f760-4bff-b1e7-748a75386b86/IMG_20200517_183544_8+-+Copy.jpg Kayak Keeping pressure to help bond the carbon fibre centre strip in place. This was glued to the deck with G-Flex epoxy. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8870c7c8-7b29-4798-891c-e3cf1b5cf893/IMG_20200518_105242_1+-+Copy.jpg Kayak Cockpit outline cut and epoxy curing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b4f0d549-a044-451e-acd6-313e965dd03a/IMG_20200519_112255_3+-+Copy.jpg Kayak Tape finally removed! Initial fairing has begun with a selection of card scrapers. The first task was to knock down the corners where each strip joined with the next. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2587db46-7f63-4a91-b1cd-d1b376819c58/IMG_20200519_185156_4+-+Copy.jpg Kayak After initial scraping, the shape was refined with sandpaper on a long board. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ef8411cf-5cf7-4713-8f25-3f8c70a1f1d4/IMG_20200520_210047_3+-+Copy.jpg Kayak Still more fairing. This tape was just to hold the deck and hull together while the boat was being regularly turned over to access different sections of the hull. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0dde88b4-cd5d-4ad1-943e-1bd26f0b68fa/IMG_20200522_123600_8+-+Copy.jpg Kayak Final fairing on this carbon strip was hard work, especially compared with the soft cedar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/67566e9f-dc4f-4ace-8468-bb20a8b9b951/IMG_20200610_153401_2+-+Copy.jpg Kayak The cockpit coaming was formed from lots of short edge glued pieces of cedar, all glued to the edge of the cockpit cut-out. A thickened epoxy fillet helped strengthen the joint and allowed fibreglass cloth to flow smoothly from the deck up the side of the coaming. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d2f7baed-0dc4-47b8-8a30-0abae5953741/IMG_20200610_153415_4+-+Copy.jpg Kayak Doesn't the boat look good with her first layers of fibreglass cloth?! A single layer of 300g woven cloth for the deck and two layers on the hull. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0ae69796-e73e-4848-893a-c59c73df8fc1/IMG_20200610_153437_3+-+Copy.jpg Kayak The epoxy resin really brings out the grain. Notice how there is an un-laminated strip along the deck-hull parting line. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8c53c596-179a-4aa4-9333-1d637b0c49d6/IMG_20200610_170339_0+-+Copy.jpg Kayak This unbonded parting line enables separation of the deck and hull to enable fairing the inside of the hull. Notice the small cedar alignment dogs, hot glued to the inside of both deck and hull. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d8d47ebf-da05-46fe-9208-4e83680f2f5a/IMG_20200610_170343_1+-+Copy.jpg Kayak Fairing the inside of the hull was even more time consuming and tricky than the outside. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a8b923fb-6bc3-4a65-bdfb-12dca86f89f7/IMG_20200614_100603_7+-+Copy.jpg Kayak But it was all worth it upon application of the carbon kevlar cloth. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/aa36071e-c1b5-4c62-ac5b-d3ccc74fbb0b/IMG_20200614_121624_9+-+Copy.jpg Kayak Doesn't the black carbon look great against the orange coloured cedar? https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1784a45e-c721-40ed-8bd9-ce675566e939/IMG_20200622_183826_9+-+Copy.jpg Kayak Forming the cockpit coaming. This was done with more cedar, carefully scribed and scarfed together to create a continuous ring. Loads of sanding and fairing later, the shape is looking good. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/93d26e5c-30a6-48ee-9624-33dd2f7a8700/IMG_20200622_183839_4+-+Copy.jpg Kayak Accumulated sawdust and scraps in the bottom of the hull. Notice that the rear hatch is now cut out. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7d64557d-66fb-459f-a3bb-bc77292a0f4a/IMG_20200624_135631_1+-+Copy.jpg Kayak Carbon lamination to the cockpit coaming and a continuous overlay of 300g woven glass ensure that the coaming is very strong and solidly attached to the deck structure. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8fa4a80d-4ebf-43b3-a47d-2d9c16df9a59/IMG_20200624_135646_7+-+Copy.jpg Kayak Shape looking good from either direction. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/76ef736e-eefd-4912-b07a-d7f886144cb8/IMG_20200626_121306_5+-+Copy.jpg Kayak The underside of the rear hatch, showing the carbon kevlar weave. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5a0cbb57-39f1-44ba-bc61-dfef14960987/IMG_20200626_121314_9+-+Copy.jpg Kayak Fairing the fibreglass deck-coaming joint. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ed20503c-c648-4541-acd1-2180db48765f/IMG_20200630_212225_9.jpg Kayak The sealing ring for the rear hatch. Laminated with carbon kevlar over a non-stick polymer form. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e61355d6-ebe0-4432-8a17-bf7c4043a1f4/IMG_20200708_173209_8.jpg Kayak Catches and hinges installed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ed010c98-e6ab-4aa1-a2b0-75a8b064c2e0/IMG_20200708_173418_4.jpg Kayak A gas strut holds the hatch open. Stainless hardware was chosen for corrosion resistance. Hinges were bonded to the hatch with epoxy to enable a strong, low profile joint. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4cec6abb-8597-4a1d-85c9-2736149d01ff/IMG_20200717_165905_0.jpg Kayak Rolling out the carbon tape that finally joins the deck and hull together on the inside. Long hair, epoxy and confined spaces... Not a great combination! A brush on a stick was used to help roll out and stipple down the tape, which had been pre-saturated outside on a prep-table. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c1f9686b-898e-4afb-b4f3-3809a3823f1f/IMG_20200718_163603_5.jpg Kayak A combination of tape and ratchet straps helped to hold the boat on its side and with proper deck-hull alignment while the interior joints were taped. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d3a1368a-c887-4f59-82dc-917d837e7eb0/IMG_20200719_120424_6.jpg Kayak Finally, one joined hull and deck, looking glorious in the sun! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf85632a-25df-435a-b59f-635342ea5df7/IMG_20200719_120444_2.jpg Kayak And from the stern! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/25e3a608-6ada-48c2-bf2e-10f35f1646cd/IMG_20200720_210047_1.jpg Kayak Templating the outer stem and stern pieces. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ad862298-0ce8-4353-82e5-a613fd58be20/IMG_20200721_111153_5.jpg Kayak The rear bulkhead, separating the main cockpit from the stern storage locker, was made from 5mm PU foam, laminated with carbon kevlar on either side. It was remarkably stiff and strong for such a thin piece. It was glued and tabbed in place with carbon kevlar and epoxy. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0384e007-80f1-4922-9799-f9709aa5ef72/IMG_20200721_111249_0.jpg Kayak At the far ends of the hull, a watertight bulkhead helped strengthen the stem and stern and create a sealed crash bulkhead. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0d96cff1-1651-42f7-a09b-25cbc712cbe2/IMG_20200726_160659_3.jpg Kayak Two part moulds for the carbon outer stem and stern pieces. Made from a sort of epoxy putty with glass strand reinforcement. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1a45be41-0a3c-4938-b604-26409d7c2d0f/IMG_20200730_145927_7.jpg Kayak Sanding the hull for the last time. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/55a96203-623e-4ef2-95c5-8bb9aacfa382/IMG_20200730_145946_0.jpg Kayak New carbon stem and stern pieces. These were moulded one side at a time, joined, then filled with epoxy foam. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/00f372fe-cdc1-4bf8-90ae-12c518be0f9e/IMG_20200730_161307_7.jpg Kayak Before being attached to the hull. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/586e922d-d62b-46c2-a885-293cdccd35cc/IMG_20200731_153146_4.jpg Kayak A final layer of glass over the hull, overlapping the deck-hull parting line, completed the connection and properly attached the stem and stern pieces. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6f0b07dc-c5db-4ed3-9e0b-ac5e279cc909/IMG_20200731_153157_9.jpg Kayak Looking stunning. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/07a6027b-caf9-4a4b-8bc3-7fdff91c6d1f/IMG_20200802_080740_8.jpg Kayak Mirror perfect! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8fc506f0-70bb-4c93-bcd2-f387985231e3/IMG_20200809_115823_8.jpg Kayak Christening the kayak! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e2e28b78-a824-431b-b749-df9705665826/IMG_20200809_115835_0.jpg Kayak First time in the water at the local canal! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f35b678a-5f6c-40c0-a02f-22628f4420f9/IMG_20200809_115942_8.jpg Kayak Getting in for the first time. As you can tell, this a tandem kayak. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e6d2ab9e-10da-43ec-90dd-ae234efb023c/IMG_20200809_115952_2.jpg Kayak This paddle was less than ideal, but I had not managed to build a proper set yet! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8b10e672-29de-4ad8-b62c-8cbfef7df656/IMG_20200809_130446_8.jpg Kayak Looking beautiful. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf4ca4f7-3113-4b33-ae3e-d018f596ce4a/IMG_20200818_200201_0.jpg Kayak First proper trip out, about to set out on the River Tweed. Note the canvas cockpit cover that I sewed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8a362f96-5305-4d2d-a892-d64adfd2ebf1/IMG_20200819_073826_0.jpg Kayak Plenty of space for kit. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bd20f2c5-2493-45cb-a388-665559c83250/IMG_20200819_082557_5+%281%29.jpg Kayak This is where she was meant to be! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7a7c30de-030a-4b23-a95b-2c170f71207e/IMG_20200819_083402_6.jpg Kayak Enjoying my paddle. This was also my first proper kayaking trip! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c691c6d6-d647-4e2a-81ab-9f58388b60f1/IMG_20200819_180311_9.jpg Kayak Camped up for the night on the banks of the Tweed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5df2267c-0412-421c-a0f5-6365ca43be7e/IMG_20200820_151012_4.jpg Kayak Disaster! I misjudged a set of rapids and got the boat lodged firmly on a rock. She is in frame, just with water flowing over every surface! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c2d1e7e2-7f38-4184-954d-67d660b5d0fa/IMG_20201030_153021_078.jpg Kayak Several weeks later, after a call from Berwick police. She had been found on the beach, having sailed herself, unaccompanied, 40 miles down river, through yet more sets of rapids, out to sea and then back in on the tide. I collected her from Berwick police station! https://www.harrystear.me/cnc-mill daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f24b0571-1e6a-41ff-a611-093f6e427a05/DSC_0653.JPG CNC Mill https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7f0bead9-8867-447b-89e6-7845eeec47d8/DSC_0654.JPG CNC Mill https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a7d3d40a-50eb-48ee-bb9c-65f1366b5417/DSC_0655.JPG CNC Mill https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2b7c2636-2f90-462b-a334-1ce286a850cd/DSC_0658.JPG CNC Mill https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7f1ae256-a709-4105-99a6-7e3a456f69eb/DSC_0659.JPG CNC Mill https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9af8d98d-eba4-4845-b4bf-571e81702869/DSC_0660.JPG CNC Mill 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about lathe tool geometry, I made this giant lathe tool from modelling foam. Each feature was then labelled. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/841d7a77-5eda-4e5b-8dd7-18d3bf075dcb/DSC_1262.JPG Teaching Aids Once a demonstration was given, explaining the reasons for each relief angle, the students were given their own piece of foam, albeit rather smaller than this one and tasked with shaping it using files and sandpaper to the correct geometry. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fd4a8da5-5731-4f80-9dd5-9d88dcf82006/DSC_1263.JPG Teaching Aids This really helped to visualise and fix this terminology, without becoming tedious rote learning. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755878171292-U1WMYWK91IUZSV83IKVE/20250626_200406.jpg Teaching Aids Given only one week's notice, I was asked by the Geography department if I could make some pieces for their upcoming 'Sustainable Cities' project. Geography: "Would it be possible to have a few laser cut acrylic solar panels and some 3D printed wind turbines?" Me: "Sure!" Geography (walking away): "And how about a hydroelectric dam?" Me: "Now you're talking!" https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755878191155-T9B7WIIWR3B59RJ0F02N/20250626_200412.jpg Teaching Aids I drew up this design, with a view to casting the dam in reinforced concrete, which though it may seem excessive to the casual observer, I decided was probably the easiest way to produce a water-tight tank and the other features required. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5204f1a9-7c10-4a07-9097-6f839f84f802/20250626_200424.jpg Teaching Aids I used a combination of hand cut and laser cut foam-board components, assembled with hot glue, to form a mould. The reservoir tank needed to be reinforced, so I used some weld mesh that was left over from a prior project. This was all mounted on a thick MDF base. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b8e959b7-446f-4a68-be4b-10a02444fa8f/20250629_090224.jpg Teaching Aids Some TIG rods provided reinforcement for the spillways and accompanying buttresses. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d7a904e1-2da2-40a8-ae9b-722c823c897c/20250629_123347.jpg Teaching Aids Concreting was done alongside helping a friend work on his car, so some trestles behind my car facilitated loading in and out. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7724377f-4d75-43a9-8004-a9f9f551629a/20250629_123350.jpg Teaching Aids An oscillating electric sander, minus its abrasive paper, was used to vibrate the concrete into the walls of the form, attempting to eliminate voids. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f3f664fc-0c24-493d-b372-1608cb213190/20250629_123354.jpg Teaching Aids This MDF grid structure slotted together inside the tank to support the foam board mould. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bc068da2-518d-4e9e-94de-f82e7a488c1b/20250629_123404.jpg Teaching Aids Concrete was mixed up using a mix of approximately 4:1 aggregate to cement with water added until the required slump was achieved. The aggregate was a mix of ballast and sharp sand, with the larger ballast gravel having to be picked out by hand, in order to fit around the weld mesh reinforcement. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2768c65a-32ad-4342-98e2-9c521150e340/20250629_123407.jpg Teaching Aids Wall thicknesses were only 30mm, held at thickness by these spacers at the top of each wall. In hindsight, extra bracing was required to the exterior walls as bowing occurred as the concrete level rose, and had to be contained with ratchet straps and wood blocks. I will blame it on the rushed schedule that I realised this for the interior faces, but forgot the exterior ones! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e5afd879-3ded-4b60-a98e-cfa3d0a169fe/20250630_143301.jpg Teaching Aids The casting, as removed from the mould. Not perfect. With hindsight, a mix with just sharp sand would have worked better and a slightly looser mix. Unavoidable was the scorching summer weekend that I poured this on, which did not give me as much working time as I would have preferred! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/44c1417b-04b8-426f-83ed-ab2216e97e2f/20250630_143323.jpg Teaching Aids Here you can see the cast-in-situ PVC pipe that formed the outflow for the turbine. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/80195d2e-8c8a-41cc-b5f8-c75733b70613/20250630_143337.jpg Teaching Aids These voids were repaired by filling with a sharp sand and cement mix. Some formwork was reattached to the interior and exterior faces before filling from a small hole at the outside top of the void. Copious vibration from the sander resulted in a properly repaired structure. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ffb269f1-509f-4a72-b581-a5704bcf7082/20250630_154958.jpg Teaching Aids Some additional formwork was built up to repair the top of the buttresses that formed the bridge deck supports. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2b8ba670-0f92-4bba-9ce5-b00014dad67e/20250701_173023.jpg Teaching Aids A couple of coats of masonry paint sealed the tank thoroughly, and a sharp sand and casting epoxy mix provided a "river bed" outfall. This was then plumbed into a catch bucket fitted with a sump pump to recirculate the water back to the reservoir tank. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755880781655-YDYZTK7ILQCSSKW7MODD/20250701_173012.jpg Teaching Aids This casting was to become the bridge deck. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a73604e6-f41f-4ec7-b7b5-a19b112fd131/IMAG0327.jpg Teaching Aids This lathe backdrop was an early project of mine. A place for every tool and every tool in its place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6961f795-c51d-4ad8-9ceb-0f0ed3cc89a2/IMAG0328.jpg Teaching Aids A combination of hooks, hardwood dovetails and blocks, line bent acrylic and folded aluminium ensured that all the components were safely held, then I drew around each tool and painted the enclosed area black, to ensure at a glance, that each tool could be accounted for. On either side of the board is a poster showing thread sizes and pitches and a metric/imperial conversion table. I repeated this for our second lathe, this ensured a consistent toolset for each lathe. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a462a0bc-8a4c-42f6-a215-fa740ca0b06b/IMG_20211123_175045.jpg Teaching Aids Some stage blocks built for (and with) Drama. I designed a kit of panels, including a router jig for the handle slots, to enable batch production of these boxes. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b966de16-7596-4232-b614-06eb8aaf70dd/IMG_20211123_175053.jpg Teaching Aids Drama students and teaching staff then spent a couple of after school sessions with me, firstly gluing and nailing each box together, before painting each block black. This saved the Drama department several hundred pounds versus buying pre-built blocks. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2fb49964-f11e-4620-90f1-963938e2b0de/IMG_20220617_165533.jpg Teaching Aids This tiered staging is a mock up for a 'bleachers' stage backdrop for 'Grease' the musical. We had the stage decks already and legs in two heights. I then determined the necessary lengths and quantity of additional legs required to achieve the desired stage layout. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/40d8244b-0a92-450e-bbdc-db8bbb923784/IMG_20220617_165545.jpg Teaching Aids I then ordered pre-cut aluminium scaffold tube and plastic plugs in the necessary numbers. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6cc65060-cba8-4fdf-85f0-38160d107cb1/IMG_20220916_180508.jpg Teaching Aids When Food Technology require knife blocks to store their chef knives, I realised upon a little research that there wasn't anywhere that sold a holder for 26 knives, each the same size! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/20ba897d-9b13-407d-a64d-ccd19b2c1fa8/IMG_20220916_180529.jpg Teaching Aids I designed this knife block from PETG for its food safe and easy clean features. The knife holes were laser cut, with the bend lines being engraved, then bent using a hot wire strip heater. The seam was at the bottom to enable any water on the knives to run out. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b16c25cd-1ff2-4a18-8353-bd3141b35273/IMG_20220916_180537.jpg Teaching Aids Oiled and waxed oak end-caps were later added to ensure that the blades could not be touched in transit. These were attached with wood screws to enable them to be removed for cleaning, but still requiring tools to do so. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5514d1bd-2100-405f-adfc-4d701c29002d/IMG_20230928_130843.jpg Teaching Aids A similar design yielded two smaller versions for these paring knives. These were likewise fitted with hardwood end-caps. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e01d9d47-2af6-40f1-9423-3653303be9ea/IMG_20230928_130847.jpg Teaching Aids Notice how the handles are canted to the outside, but the blades do not touch in the centre. This was achieved by modelling the knife geometry and testing in CAD assembly. These particular models were drawn in Onshape. https://www.harrystear.me/site-maintenance-fabrication daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/21f8e9b0-b454-423b-85d1-5b9d08ca631c/DSC_1392.JPG Site Maintenance Fabrication A nice, snug fitting grille that I built to protect this window vent. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9f203811-0050-44ae-90f0-113aed30d852/DSC_1393.JPG Site Maintenance Fabrication These windows were situated in a corridor space next to the lift. Students accumulated here at various points during the day and would kick these low level window vents. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9e7d62f1-10d9-489a-8f3c-8f31765bd9be/DSC_1394.JPG Site Maintenance Fabrication Site team had reattached the vents multiple times, but none of the fixing methods they tried stopped the students from repeatedly kicking out these vents. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f7caac52-66aa-4719-ae2a-fa67d2f363ec/DSC_1390.JPG Site Maintenance Fabrication I was asked to make a set of protective grilles to prevent this. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ef8d185a-d14e-4c01-8808-12af3f5d6fdf/DSC_1391.JPG Site Maintenance Fabrication Solidly affixed to the window frames, these grilles weren't going to go anywhere. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fe65a2be-c952-4ec5-9a7a-3ec6b2f02d9e/DSC_1395.JPG Site Maintenance Fabrication Which was a good job as when these ventilation panels were knocked out, they fell directly above an external door. A serious safety hazard. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9b598a17-3511-4fe5-adf0-5f20d7b19cf5/DSC_1396.JPG Site Maintenance Fabrication From the outside the grilles are nearly invisible. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/40504a68-4090-4959-91fb-8de42867b270/DSC_1397.JPG Site Maintenance Fabrication Though now, people entering or leaving the building are safe. https://www.harrystear.me/drawer-unit daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9a5a09bc-98e5-41a0-a50c-4766ad412cdc/DSC_0990.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/54749621-3a51-486c-b137-3c3c542dbfa6/DSC_0991.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f51d24c3-186d-4b52-bcbe-dd07d3558110/DSC_0992.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/77818133-7c19-4406-aa7e-6da24f0037b9/DSC_0993.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1278b28d-ce87-4329-98cb-30244750a0b2/DSC_0994.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c6d4aba1-dec9-4277-ae8a-e17b17bbcdc5/DSC_0995.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/545980f0-c8f0-41ca-bd1e-a1348ada0a77/DSC_0996.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/67c47008-74bb-4720-bb0a-e34973af3ab6/DSC_0997.JPG Drawer Unit https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ce66e014-a608-4d46-926d-1161269fa809/DSC_0998.JPG Drawer Unit https://www.harrystear.me/student-project-support daily 0.75 2025-08-18 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9bf035ad-f115-4ebd-8f90-175c352d82cc/IMG_20200305_170914_0.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c959b0db-d156-4118-9215-c103ad9cdff9/IMG_20200305_170917_3.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/eb73fbd9-a477-4e31-9536-8ae7652b5c40/IMG_20200305_170921_5.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ea2a39ae-7f71-4555-9374-fd5bb3dcce81/IMG_20200305_170928_8.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0dae5d08-f005-43a3-9ee0-b8deb02aeecd/IMG_20200305_171611_4.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d768cdda-eecd-4ff3-bc2e-63aa39650155/IMG_20200305_171626_2.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b6cc3acd-f86b-456f-ba20-789089ca5b52/IMG_20200305_171629_5.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9b9fc8e0-ea0f-4ea8-bdd8-409a35b745ac/IMG_20200305_172205_5.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d2e0ac94-d01d-4302-9678-e545c2c303ca/IMG_20200305_172209_3.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1514b3b1-f245-4729-8370-6d7fa88b5de7/IMG_20200305_172213_2.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1da0b2cc-649b-4832-b6d3-5914f5f1d0cb/IMG_20200305_172224_4.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/20772e35-05f9-4c54-93a9-d27b41fc36e9/IMG_20200305_172227_4.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f7b8ed96-26f8-41e0-b95f-6baf2bb02228/IMG_20200320_124922_1.jpg Student Project Support https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0f348922-bf00-4128-a9fc-0e50cfafeb37/IMG_20200320_125009_6.jpg Student Project Support https://www.harrystear.me/fly-cutter daily 0.75 2025-08-16 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2b7c48f1-b981-4d53-83f1-dd8faef09dc9/DSC_0632.JPG Fly Cutter A view of the drawing that I produced and worked to. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/10965df5-ee0e-4af5-8be5-c48bf47e8056/DSC_0633.JPG Fly Cutter After turning the diameters the milled features needed to be completed. This was done using a square collet block and angle blocks to create the angled features. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf127b74-7c65-47a8-9a42-1039c789fd74/DSC_0634.JPG Fly Cutter The design aimed to keep the cutting surface of the lathe tool running directly in line with the axis of rotation. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/79c86673-1de9-4a4a-b34f-a022fd5a4577/DSC_0635.JPG Fly Cutter The radius was produced using a ball end mill. This was after removing the bulk of the material using regular end mill. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/44c04dee-d5df-4039-ab70-34e8b16f8dc2/DSC_0636.JPG Fly Cutter Complete with its lathe tool cutting edge and grub screws. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/26200b54-893b-4bc3-acca-778e361547c8/DSC_0637.JPG Fly Cutter I was generally happy with the surface finishes on this part. https://www.harrystear.me/range-rover daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/17e397a9-725a-4a28-bf15-98d5185aa2bf/IMAG0306.jpg Range Rover This was how it looked when I first bought it. Not bad from a distance, eh?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/134d9cca-4ba7-453d-a317-ba704364819e/IMAG0312.jpg Range Rover It doesn't look too bad from here either, does it? https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/08df93a5-eebb-4da1-ba5d-5587cf0283f3/DSC_0733.JPG Range Rover But lift the carpets, and it was a different story! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3875654a-fa61-47df-98cf-5d59b450df99/DSC_0735.JPG Range Rover Hidden behind the front outer wing... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f31f42cf-b6a0-4d69-9d0a-ef5532e2464b/DSC_0736.JPG Range Rover Inside the front wheelarch! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5fb58413-91e9-479f-9de3-b02255181d0d/DSC_0737.JPG Range Rover This was the view from under the sills! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3684833f-4c27-4969-a5ca-afa818919739/DSC_0741.JPG Range Rover I'm not sure that there is supposed to be daylight showing here! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/92bbc709-63a9-452e-bc7e-063d7c4b74a1/DSC_0746.JPG Range Rover Not much left inside the rear doors either... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1f093136-c91b-4aa3-9e03-a41bd23dea10/DSC_0751.JPG Range Rover I got drastic with the angle grinder, but braced the door pillars first with some box-section. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/deb3d6eb-48d7-47bf-8978-9138da44530c/DSC_0762.JPG Range Rover Rear wheel arches didn't look great either... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3cde3392-fca1-4be5-b9df-0f319a39695d/DSC_0800.JPG Range Rover Looking through the engine bulkhead... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8de89b83-7944-40e0-a866-56a454677fe2/DSC_0806.JPG Range Rover It looks pretty crusty from the inside too. This jumble of wires was going to pose some issues too... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/724a2f6c-f102-484e-b701-30b3414c12e8/DSC_0819.JPG Range Rover Removing bits of inner wing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a050b229-1c9e-49d5-994d-4d56096f95fe/DSC_0824.JPG Range Rover And more bits... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c06734d6-d806-41aa-851c-bd20a03a40ba/DSC_0826.JPG Range Rover There isn't much left by this point... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/de1c8e24-ade5-47e2-b4b9-f53328dbd1ff/DSC_0833.JPG Range Rover The bottom of the door pillars weren't great either... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/533b4dfa-8327-4f38-b6d5-1f192af65296/DSC_0834.JPG Range Rover There was essentially nothing left of the front body mount. All that was holding the body on was gravity. I cut away what rust remained. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2ee1972a-727f-41e1-a826-d7ecc9259799/DSC_0836.JPG Range Rover I realised that I would need to remove the wiring harness... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/26e546f6-23ad-4da2-a9a1-a9ec52f0f3ac/DSC_0840.JPG Range Rover New metal! Just trial fit at this point... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3b127f8d-ece9-4b0f-8196-684cd86033d6/DSC_0842.JPG Range Rover ...and from another angle. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3a8c9f74-42cc-4367-9f6a-8430b7dbf9e9/DSC_0847.JPG Range Rover Repairs to the bottom of the door pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c4fd8398-47bc-4231-9bef-1b11a0c8346f/DSC_0848.JPG Range Rover The other side of the same pillar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/049cc5e5-1eb3-46ce-b1a5-7c29607e2c04/DSC_0852.JPG Range Rover Cardboard Aided Design. Extensive use was made... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/16e2e7a8-4a0e-4025-ae84-393594c9a8e1/DSC_0854.JPG Range Rover Sills welded in! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b862dd37-78e8-4d8b-958f-8050e9b57935/DSC_0858.JPG Range Rover Good penetration. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f6747655-596e-4d52-a7ba-e97dffda0d6d/DSC_0875.JPG Range Rover Even in this state, she still looks good... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b85d9eb8-e993-4d77-b278-090b1137a25c/DSC_0881.JPG Range Rover Shock absorber replacement. The old ones were both rusty and leaking. Surprise, surprise... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/37495b6e-8ff9-4bf2-a3fa-71dfeae6536c/DSC_0977.JPG Range Rover Repairs to the front bulkhead. There is drip channel at the base of the windscreen with a spot welded seam at the base... The sealant fails, then water gets into the joint and can't get out. Then the bulkhead rots out. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e952bb4f-809d-4ba0-b53a-2386eee748c0/DSC_0983.JPG Range Rover Look at the nice shiny new body mounts that I fabricated! Still sporting red Dykem. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0290600f-35bd-4261-b64b-a8ea80227744/DSC_0984.JPG Range Rover By this point, I was used to repair panels not being large enough... Just a few gaps still to fill! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/07d1e7a0-0000-4749-9b31-2abe8008e0ab/DSC_0999.JPG Range Rover New bulkhead plate fabricated... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/05868bae-a5fb-4dc3-b433-03510b526f57/DSC_1003.JPG Range Rover Then tacked in place... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6c0ebf40-e99e-436f-a011-c64e46d07585/DSC_1006.JPG Range Rover More repair panel extensions... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fff09929-1dc5-443b-a023-86f4c4f4b9e4/DSC_1008.JPG Range Rover Starting to fill in the gaps. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/23cf7fce-c5a0-4aeb-a2de-fe3a1b607af7/DSC_1013.JPG Range Rover Looks tidier now. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f741de23-b7c9-4efa-af66-320d919583cb/DSC_1015.JPG Range Rover Looking good from the outside too. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/afe9e558-51e6-488d-bc6d-30db61804e7e/DSC_1045.JPG Range Rover A brief interlude to machine a flat surface on the exhaust headers. Corrosion had really taken its toll and there was absolutely no way they were going to seal otherwise. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/18b60781-4fed-4e6a-854e-87633d14b358/DSC_1053.JPG Range Rover I enjoyed figuring out how to fixture these. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b193c967-d68e-4327-a298-50b6b87eb63d/DSC_1055.JPG Range Rover New repair metal going into the inner wings. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0400aa6c-1364-46f1-bb05-511b81f24bd9/DSC_1057.JPG Range Rover And its stiffener. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7cb5705d-23ec-46be-82fe-14687eb276b9/DSC_1063.JPG Range Rover One half down, another to go... At least you can see where I've been! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/871a3fa3-5615-4d64-a2ef-ff3ca7c38697/DSC_1080.JPG Range Rover The driver's side wasn't great either... This seat bracket had rusted clean through at the base... How did this car have an MOT?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8f4ebaf1-c700-4624-99a9-60a5f10ac399/DSC_1089.JPG Range Rover I took the opportunity to do the front swivels too, since they were leaking, hence the hub on this very rusty floor! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3b1b26d8-2447-4f16-9a32-700348dd42b1/DSC_1092.JPG Range Rover Yet more corrosion... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6426cbc2-f58f-4b03-8199-450e93d13f7d/DSC_1103.JPG Range Rover It doesn't matter which way you look... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/54c2e8ad-1fd1-4d00-b57b-df4d5048dd19/DSC_1104.JPG Range Rover It doesn't look great. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/edad603e-9b18-412b-862d-88dfc1730a59/DSC_1107.JPG Range Rover So much Iron Oxide... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/56562b5f-8241-4be5-9a53-a2f47613589f/DSC_1111.JPG Range Rover Similar issues in the footwell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/53c25dcf-d62c-4a28-8ada-8344b19e63b4/DSC_1117.JPG Range Rover The angle grinder made another appearance... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8c582fb2-5f2e-4ea3-a0d2-027fe936a02c/DSC_1120.JPG Range Rover And got a little carried away! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/536d0476-c5dd-48b2-b94d-5827e50eb4ad/DSC_1121.JPG Range Rover Not a lot left! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8e8de93a-4b31-491d-b870-3e338274983c/DSC_1125.JPG Range Rover The whole inner wing section removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4c1f4e4a-3c89-4a66-b602-c83e0146bb9a/DSC_1140.JPG Range Rover Much prettier! It should be more water-tight too! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/710d98cf-7c00-4638-8b2f-d083b9b50c50/DSC_1141.JPG Range Rover New sills... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3701ed4f-a66a-49c2-82d9-944b937654ba/DSC_1142.JPG Range Rover And door pillar repairs. Deja Vu?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0d0f2f56-5534-4128-98d5-d8f17ffccc02/DSC_1144.JPG Range Rover Clearly didn't get my CAD quite right! Never mind, my gap filling was pretty good by this point! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/103f5bef-8f79-472f-b0ab-e0697a10ea32/DSC_1145.JPG Range Rover The other angle... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/17059049-f93c-40e2-99c0-57b37464a65c/DSC_1150.JPG Range Rover Quite a complicated shape to achieve with a ball pein hammer and a piece of channel iron... There might have even been a block of wood involved at one point! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3a1172e3-ed00-4c72-accd-a084b05b4ca7/DSC_1151.JPG Range Rover Solid again. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/491df47c-3416-4e10-9f67-fc7762a2eb27/DSC_1157.JPG Range Rover Don't the new door pillar bottoms look much more solid?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/45800b94-590a-459d-aa4a-e8f891ffb5e3/DSC_1169.JPG Range Rover Good weld penetration on this side too! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6ae1856d-5f4e-444a-90b5-1c42637216a1/DSC_1170.JPG Range Rover Looking good! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fb711c89-f6fa-4b79-a89b-2be4efc366cf/DSC_1172.JPG Range Rover More body mount shots. This time with a mounting lip for the inner wing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/370faf8d-e7fc-44b1-9de9-cffe4b368583/DSC_1173.JPG Range Rover Just some of the rusty metal cut out of this project! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e410d695-d0b5-4ca2-83b6-c74c82b8fc17/DSC_1176.JPG Range Rover This drip tray had to be removed to facilitate repairing the bulkhead. It needed a few patches itself too. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/85bc7f09-2df2-4976-933a-e094c143904d/DSC_1179.JPG Range Rover Repairs to the seat mount. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6e6beea7-cd28-43a1-9fff-e430039378eb/DSC_1182.JPG Range Rover Looks a lot more solid now. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/40e9710b-b615-4c8a-964d-dc8e3ed031ef/DSC_1191.JPG Range Rover Seat bracket successfully welded back in. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2e08e200-cb40-49d9-8988-ef0ab2ef805e/DSC_1197.JPG Range Rover Rain gulley end cap successfully installed! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/df77e3bc-051b-4a94-8e62-fd4d0df867ce/DSC_1198.JPG Range Rover This wet look was part of the POR15 system. First a cleaner/degreaser, followed by a rust converter, then the paint itself. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/90c38350-24ab-48d0-a2e8-3f756ef06fb4/DSC_1201.JPG Range Rover So much new metal! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cf7e0efa-01be-4310-bc18-e2b404ca0985/DSC_1205.JPG Range Rover Getting the fancy angles! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/13236b37-d3ba-420a-81a7-5e82fde78a49/DSC_1215.JPG Range Rover Paint booth, courtesy of ebay! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b6823753-acd3-476c-80ac-41001c38cf11/DSC_1218.JPG Range Rover Shiny... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/764150ee-83b2-4302-a34f-7076efcbdb4f/DSC_1219.JPG Range Rover Doesn't that just look gorgeous?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/99e13089-c261-4fad-910c-e8aadd5dbdbb/DSC_1222.JPG Range Rover Rust, begone! And don't return! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d17f1771-cb43-49e9-bbf1-13c87a8ebd5f/DSC_1226.JPG Range Rover So good looking... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a1f37d68-36ab-44aa-9db1-762db0b2d6b9/DSC_1234.JPG Range Rover I suppose it's time to start reinstalling things?! Starting with the wiring loom... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/83076c95-a261-49af-a6ef-1107d6145d77/IMG_20200914_120913_3.jpg Range Rover The throttle position sensor didn't survive the storage. New ones of the correct type are unavailable. This one had the correct characteristics electrically, but was a little lacking in the mechanical department, so I made up an adapter. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5fb3baf8-fc31-4b0c-8c4d-1a214ac0ecd1/IMG_20200914_200522_3.jpg Range Rover Here, with the adapter affixed back to the throttle valve. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/76c074d3-bd79-4a0c-b731-f0dfe270582d/IMG_20200914_200907_0.jpg Range Rover And with the new TPS installed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2d1aa345-9771-4c2c-9508-28a81f1b434c/IMG_20210129_140917_8.jpg Range Rover The rear inner wings were also pretty rusty... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c2d044ca-88c8-4470-9b7c-436f0c3a7060/IMG_20210129_141001_7.jpg Range Rover I did say that the body was only held on by gravity, didn't I?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3dc1888e-2e74-40f0-8795-41e99837c707/IMG_20210129_141150_0.jpg Range Rover I was absolutely serious! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/613ce746-8ad3-4d84-bfb6-f0431622a483/IMG_20210209_150905_4.jpg Range Rover New rear body mount crossmember. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7cc7c754-221c-418b-a440-256dfd014749/IMG_20210208_165223_5.jpg Range Rover Repairs to the inner wheelarch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/de216984-42c5-4ef9-9905-6d5b0783a2f0/IMG_20210208_165236_6.jpg Range Rover Rust removal. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/94bb7bf5-d249-4eac-b21d-160b5591be35/IMG_20210208_165312_7.jpg Range Rover Extra ventilation... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/66154403-e7fd-4aec-8a7a-728664ae08da/IMG_20210208_165316_9.jpg Range Rover Is there something missing here?! I think that my tools might fall out... At least this spare wheel trough is looking a bit better! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/48045245-d883-4bcf-baa5-1f004d0eba61/IMG_20210208_165540_6.jpg Range Rover Looking from the inside. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4faeeb27-78dd-4058-9d04-c8341454c8e8/IMG_20210209_165347_6.jpg Range Rover And another angle. There is still some rust to remove at this point, but I thought that I ought to leave enough metal in place to keep the arch in place until this point! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/458712ef-ed40-4100-a9ef-f5b3227442e8/IMG_20210212_172930_1.jpg Range Rover Repairing some of the flanges that link the inner and outer arch panels. Range Rovers have mostly aluminium exterior panels, but hung from a steel inner shell. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f4a2e905-914c-435c-ba2f-b70965618773/IMG_20210219_171548_3.jpg Range Rover This inner wheel arch was too far gone to save. Several repairs to the inner wing were also required. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/beb7cf7e-cccf-4523-b8be-fde9ee595cbe/IMG_20210223_123148_7.jpg Range Rover The new floor panel was just a tad too short... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3872a2ec-c32d-4403-a777-ee942329dc89/IMG_20210223_124450_8.jpg Range Rover But supplied with an extra weld-in piece! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f76a5ac8-436f-4762-ba62-b2d8c8f9f900/IMG_20210224_153420_8.jpg Range Rover The obligatory fire extinguisher... I collected a fair few out of date CO2 extinguishers from school and they got plenty of use putting out minor underseal fires! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f8d7ee01-ec7a-42f2-893f-3bf8ae979b8e/IMG_20210225_175309_9.jpg Range Rover Shiny new boot floor supports. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/da834334-5db8-4703-9622-820dbe081c43/IMG_20210301_170912_3.jpg Range Rover Inner arches repaired and repainted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/22d0e205-5c21-449c-9ddb-724b4da4d3db/IMG_20210305_140752_6.jpg Range Rover Floor panel sealed in and more inner arch paint. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2d5035a4-4245-44d4-8809-cc5ba6dc15db/Barry+plate+edit.jpg Range Rover The first major trip after its new MOT. Visiting my yacht project in Barry. Yes. I do have too many projects! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/453a57b8-c26b-4e02-b75c-40886351b5c9/Cropredy+plate+edit.jpg Range Rover Looking majestic in the sunshine, shortly after its MOT. https://www.harrystear.me/bicycle-frame daily 0.75 2025-08-17 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/20dd8a07-ce84-4989-ade1-1b067619ca36/DSC_0709.JPG Bicycle Frame This project began with the production of a an adjustable fixture. The student had decided the dimensions and angles that he wanted to achieve in the final frame, so it was necessary to properly locate the head tube, bottom bracket and top of the seat tube. This was achieved using aluminium extrusion with different milled and/or turned locating blocks bolted to it. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6bfa0432-3991-4094-8a85-5889514186c7/DSC_0706.JPG Bicycle Frame This is the bottom bracket, tacked to the seat post. Note the milled slot in the seat post to enable mounting of a drinks bottle etc. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f5a694d9-7dca-449f-9275-d2ce48e8352e/DSC_0707.JPG Bicycle Frame These tacks were completed by the student. This was his first attempt at welding on the actual frame. We had practised on several pieces of scrap steel before he felt sufficiently confident to attempt this. Not bad for a first go though! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a9521663-41e8-4784-b7ca-cde42ebd56ba/DSC_0708.JPG Bicycle Frame Tacks to the other side also. Note the locating collars with grub screws that ensure correct lateral position of the bottom bracket. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e0e629f8-1938-4ff5-953a-1cdf3e5bef80/DSC_0713.JPG Bicycle Frame Now that the seat post is welded up fully where the down tube meets it, the downtube can be tacked on. The tubes were notched on a jig using a hole saw, before some tweaks to the profile with half-round and round files as required. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0c0c4c00-69c1-47bd-b116-ee6e0d2ad505/DSC_0711.JPG Bicycle Frame Now fully welded under where the downtube will be attaching. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/222c295b-d61b-4d9b-b303-94d0426a049c/DSC_0716.JPG Bicycle Frame Down tube tacked in underneath the bottom bracket. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e698db0e-df51-4d20-9b4d-fad368fae369/DSC_0717.JPG Bicycle Frame Tacking in the downtube at the head stock. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4f5e4b43-5533-45b0-8045-23101b63e1d9/DSC_0718.JPG Bicycle Frame A wider shot gives a better view of the process. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0f12da8f-7140-46ca-88d2-46815efdd01b/DSC_0719.JPG Bicycle Frame Positioning was tricky for these tacks on the side nearest the fixture. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7a70e981-00d6-4c42-a706-d5a374028924/DSC_0721.JPG Bicycle Frame Fully welded seat post and down tube. This was a tight joint to get into with the TIG torch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ff03b8cc-2fe4-4c79-b2dd-0c4a14775f9e/DSC_0723.JPG Bicycle Frame This is the top tube, attached to the seat post. The blob on the top of the joint is brass. We tried to do some TIG brazing to enable a smoothly blended brass fillet at each joint, however this didn't work particularly well for us and due to time constraints not facilitating a detailed testing regimen, the idea had to be abandoned. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/49037db8-e650-4a69-9296-f29c3ffd5c24/DSC_0725.JPG Bicycle Frame All of the front tubes tacked together. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8327475a-a7c1-4ac0-8fd6-f3360f55999d/DSC_0729.JPG Bicycle Frame The welding bench looking tidy with all the welding clamps attached to one end. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1be75ff6-ccb0-4cc0-9de4-3106030ba99f/DSC_0767.JPG Bicycle Frame The student, heating up a component to be bent using the gas torch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f8dc4164-6401-49f1-a7eb-5d69e272f26d/DSC_0769.JPG Bicycle Frame A small forge built from forge bricks helps concentrate the heat in a small space. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/997c5fd7-8ead-47fc-8ef8-00ae2cb145f2/DSC_0731+-+Copy.JPG Bicycle Frame The shelf and bench height were designed to enable the welders to sit on the shelf, and still be able to roll the bench over the casting furnace for more compact storage when the casting furnace was not in use. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ae7ac86f-f539-4bc4-a3c7-e3e35d7f0afa/DSC_0771.JPG Bicycle Frame The fully assembled frame. Looks great and functional too! Take a look at the CNC Milling project to find out how we made the chainstay bracket that attaches them to the bottom bracket. https://www.harrystear.me/flower-arch daily 0.75 2025-08-18 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d55f7b07-6c9c-400c-a693-4a19dd2989c6/IMG_20210320_104810_5.jpg Flower Arch The doorway and arch that the arrangement was to sit inside. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7576c937-5277-4382-bc2d-69207fbc0baa/IMG_20210320_105025_7.jpg Flower Arch The pillar detail, which was to provide the base for the arch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/905bb664-d03f-4832-ae77-e201253f5088/IMG_20210320_105106_6.jpg Flower Arch The arch detail that the jacking screws pressed against. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/949670cc-c739-4061-adc3-f83860c0d812/IMG_20210320_105213_3.jpg Flower Arch The top point of the arch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5997fb89-becc-43bb-bdfd-637ef6b1b0f6/IMG-20210620-WA0002+%281%29.jpg Flower Arch The final truss form. I made a jig to curve each arch section and then TIG welded each brace piece and jacking plate into place. The jack screws were hex head machine screws running through a tapped plate, welded to the frame, with a locking nut to eliminate any possibility of the screws backing out while in use. Steel plates at the top of the arch enabled the two halves of the arch to bolt together. Plates at the bottom ensured good load distribution across the stone plinth. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/568ac140-c86b-4488-8a5a-9b4a457e9539/IMG-20241115-WA0000+%281%29.jpg Flower Arch Complete with floral arrangement. https://www.harrystear.me/non-ferrous-casting daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5b052591-914a-4d67-962f-2c7078c3631f/DSC_0611.JPG Non-Ferrous Casting A new casting, as it appeared upon withdrawing the cope. Note the chalk on the parting face. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f99417c9-9558-41b1-8095-21a8e482a7de/DSC_0612.JPG Non-Ferrous Casting A close up shows the surface finish of the part. One can see details as fine as the layer lines on the 3D printed plug, due to the fine particle size of the bentomix sand used. Note also the charred layer immediately next to the part. This must be discarded while all sand remaining orange can be reused. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/34dbbdbb-1900-4f07-a8e3-83a9b229cf30/DSC_0616.JPG Non-Ferrous Casting A complete casting with the sand removed. Note the sprue and risers that will need to be removed for recycling before the part is ready for use. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/04ab59c8-960a-413b-9bf8-0b5bde344363/DSC_0618.JPG Non-Ferrous Casting And with the cope that it was extracted from. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6f2462e4-c7b6-48f1-ad4c-3c52b58f6358/DSC_0619.JPG Non-Ferrous Casting Preparing multiple components for casting in a single mould box. A runner/gate links each component to allow aluminium to flow to each part. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d0dd4209-840c-4816-8f39-d164b6ee0a15/DSC_0620.JPG Non-Ferrous Casting Up close, one can see that the runner/gate was cut by hand. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/32293695-9daf-40f8-9fa4-3cd7e76c50bf/DSC_0621.JPG Non-Ferrous Casting Risers at each corner ensure gases can escape and sufficient material exists for phase-change contraction at each corner. The sprues in the middle also help ensure that no voids exist in the finished castings. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7c0ef065-28b3-44fa-a5bf-48e969c37e64/DSC_0622.JPG Non-Ferrous Casting Here we see both cope and drag, with the 3D printed plugs removed. This just needs assembling, before casting can take place. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5173debe-ff05-4f03-bc2c-4b24039cc1f7/DSC_0623.JPG Non-Ferrous Casting A poured casting, next to a couple of mould boxes ready to go. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/78fecf4a-b946-4f57-ad8c-23803b58d9df/DSC_0624.JPG Non-Ferrous Casting Overflow on the top of the mould box. A deeper sand funnel may have helped prevent this. The yellow sand on the floor is there to prevent any splashing if spillages do occur when pouring. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b6b588c3-303b-4c36-be76-0514ab51e043/DSC_0625.JPG Non-Ferrous Casting The drag is placed upside down with the plug then coated in chalk parting powder. This powder enables extraction of the plug without disturbing the sand that will be packed around it. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8ef85dd0-02bb-4677-9c49-6e93d330a161/DSC_0626.JPG Non-Ferrous Casting The drag is packed with sand and then flipped back over, before more parting powder is applied and the cope installed. https://www.harrystear.me/forming-jig daily 0.75 2025-08-26 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cd4919c6-0b80-4def-aaf2-b981d4254822/DSC_1351.JPG Forming Jig Aluminium blank installed in Jig 1. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e315c56d-5afd-4b77-829f-31a891ab862f/DSC_1352.JPG Forming Jig Jig assembled. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/18d4ca1d-b3f4-406c-bcb3-ecbdd77638d8/DSC_1354.JPG Forming Jig Jig installed in vise. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/01dfd229-4ae9-48a3-b313-36095fe392ec/DSC_1355.JPG Forming Jig Radiused edges led to self alignment. Aluminium contacts ensured that surfaces would not be marred. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7849fa54-4586-4f0d-a342-8369cdd5d7e9/DSC_1356.JPG Forming Jig Partially compressed jig. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e763a8d4-7639-4d5f-900e-5379640758e2/DSC_1357.JPG Forming Jig Continued addition of pressure... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/099a7f9d-0b46-4aef-985a-88df8497e697/DSC_1358.JPG Forming Jig Until the steel bar forms a stop and confirms that the process is complete. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/37902aaa-e627-4686-beb2-aa2167b3b36a/DSC_1359.JPG Forming Jig Removed from vise. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7abc9289-d2fc-4f72-be3b-45cf372e01d1/DSC_1360.JPG Forming Jig Upper jig component retracted. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/918be60f-de2e-4808-8309-f3019658df9c/DSC_1361.JPG Forming Jig Component removed from the jig. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c99cd14d-4cdf-44e9-af5f-865e0a977292/DSC_1362.JPG Forming Jig Step one complete. This initial bend is properly centred, holds the correct radius and is a uniform shape and size. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/00df58eb-3285-4e2f-a61a-5dc0e654c041/DSC_1363.JPG Forming Jig The view from above shows perfect symmetry. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9037b4bb-c85e-482f-af08-b493e7a931f5/DSC_1364.JPG Forming Jig Jig 2. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/77b6e01a-0c07-44e6-8e0e-80d83529ea93/DSC_1365.JPG Forming Jig Inserting the stage 1 component. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/05b3137f-ab86-433a-9139-45e40ba6c5e9/DSC_1366.JPG Forming Jig Component properly located at the bottom of the jig. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fe3681fd-862f-4b39-b5d7-47c501756710/DSC_1367.JPG Forming Jig Some manual manipulation was required. There were several aspects to these jigs that with more testing could have been improved. Unfortunately, these jigs fell into the 'good enough' category of projects that never quite met their full potential! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cd3663f5-ceb6-4e96-8138-ec4373a7c11b/DSC_1368.JPG Forming Jig You can see from this angle, the way that this jig works. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5478a9ee-94ef-4c31-829f-3c497ab6e045/DSC_1370.JPG Forming Jig The lugs are squeezed toward the centre as the moving jaw is pushed toward the fixed jaw. They are then redirected by the central bar. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ee40889d-9a87-473e-baf7-bc2bc0701d81/DSC_1374.JPG Forming Jig The jig is securely held in a vise, before being compressed with a G-clamp. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6d5738b3-1aaf-4bbb-96fc-3e5d8f0473bd/DSC_1376.JPG Forming Jig The shape is starting to appear. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bfa0f5a6-2431-4aa1-949e-0f9568281d6c/DSC_1378.JPG Forming Jig This pushing block allows the lugs to protrude through the centre. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cfd58560-58b4-4335-bbeb-49ad32484d00/DSC_1379.JPG Forming Jig Forming complete. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7f57b540-85a0-4933-bfa1-da547e5d387b/DSC_1381.JPG Forming Jig G-clamp removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/74855656-192d-456c-a585-025030d14327/DSC_1382.JPG Forming Jig Jaws slid apart. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7c55b98d-51d5-4f1e-a220-d227fa95b77e/DSC_1383.JPG Forming Jig Complete component removed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4ec20264-5044-423b-b176-068460382f9e/DSC_1384.JPG Forming Jig The final component, ready to be fitted to a bicycle handlebar. https://www.harrystear.me/trepanning-tool daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b9c93535-d734-4352-a470-513e33b10f32/DSC_1477.JPG Trepanning Tool https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/244ed49f-c9b7-4df6-931e-e8a06f6dcbe9/DSC_1479.JPG Trepanning Tool https://www.harrystear.me/machinery-repairs daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cc7529a7-61db-449f-aca0-ddaaf32a13bd/DSC_1098.JPG Machinery Repairs After the emergency brake was pressed while the lathe was running, repairs were required in the gearbox. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4cc86403-57f4-4eb3-bc5a-973b0c9f57b5/DSC_1096.JPG Machinery Repairs It transpired that a couple of keys had sheared, in the process damaging the keyway in one of the gears. Some new keystock and a replacement gear later and the lathe was back up and running. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9198e23d-3722-43b1-86f0-3ea1dda32875/DSC_1099.JPG Machinery Repairs One of the removed gears. I inspected every gear to check for tooth damage or damage to keyways. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8e97cc81-1f4a-4be0-9933-f54356ec2c51/DSC_1101.JPG Machinery Repairs A view of the motor, emergency brake drum and change gears. I was the first person ever to utilise the change gears. This became apparent to me when I realised that ALL the spare change gears were still wrapped in their original waxed brown paper and cosmoline! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d51b3480-86ff-427d-9c39-c0ba2da9c21a/DSC_0231.JPG Machinery Repairs After noticing that the milling machine was producing significant noise under higher cutting loads, I endeavoured to track down the root cause. I began by draining the headstock oil. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ba638286-b44f-49d2-9faa-3b83a5a5ded6/DSC_0229.JPG Machinery Repairs These gears are part of the spindle gearing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb46c61b-f083-4341-8500-0bf60a10c66a/DSC_0230.JPG Machinery Repairs This is part of the Z-axis/Quill gearing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b609eb3d-7cbc-4f02-bfc4-dc69ce3ccea6/DSC_0233.JPG Machinery Repairs The gearbox oil had clearly not been changed in a while. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ab13ce90-25ff-4877-abaa-06a2b66bf027/DSC_0234.JPG Machinery Repairs After inspecting all the gears and bearings, looking for excess backlash etc. I could not track down a specific issue. Given more time and resource, more could probably have been done to get a proper resolution, but I chose instead to clean, reassemble and limit cutting loads accordingly. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6bad43d3-7ecc-4667-a4f2-e47544da9a86/IMG_20220202_103045.jpg Machinery Repairs This hot wire strip heater was condemned at the annual machinery inspection due to the High/Low temperature toggle switch plastic actuator having been broken by a student. The recommendation by the external company that did the inspection was to replace the machine (about £400). https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/55df5dc1-bdf5-4dc8-8c2a-4bc79f516a2d/IMG_20220930_120824.jpg Machinery Repairs I instead found an identical toggle switch from RS Tools, for £1.50 and replaced it, keeping the machine working for years after. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8752605f-a99b-4677-88f5-48d7eebb5f18/IMG_20220929_102331.jpg Machinery Repairs I have had to make several repairs to these scroll saws over the years. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cee15a19-b511-41f0-972b-116d0cfff2c9/L1689332585258_IMG_20230714_120305.jpg Machinery Repairs These switches tend to break fairly often. The on button ceases to latch properly. I had to find a supplier of suitable replacement parts as neither the manufacturer, nor the reseller offer spare parts. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb7d1e40-f155-44c0-8acd-1c61dc8f8488/IMG_20230714_120324.jpg Machinery Repairs These potentiometers also tend to get broken. Often the failure is a mechanical one, where the input shaft is sheared off due to rough handling of the control knob. I sourced suitable replacements with equivalent resistance values and voltage/current ratings. https://www.harrystear.me/3d-printing daily 0.75 2025-08-26 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4f1b4236-c888-49a9-8a15-b43f977dd0ea/DSC_0651.JPG 3D Printing Prototype components for the bicycle frame build. Designed in SolidWorks and printed in PLA on the Cubicon Single. This helped figure out fixturing for the CNC and allowed us to test and tweak the shapes alongside the partially built frame. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ea2acb08-06b0-4ac8-aa4e-4d9440d9482c/IMG_20220112_092449.jpg 3D Printing Printing a housing for an LCD display. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6f9afb25-7fb8-43d5-8aef-a87909b73535/IMG_20220112_092513.jpg 3D Printing This image gives a good idea of the shape of this component. The unsupported horizontal span has the potential to be problematic... https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e3fca9cf-ec2a-424b-bd56-21dba931e305/IMG_20220112_092520.jpg 3D Printing However, these central 'columns' are support material, which enables the span to be printed without sagging. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/828eb30f-b805-4312-ae9f-b31b2a2dd260/IMG_20220112_092528.jpg 3D Printing From underneath, you can see the grid structure of the support material. This will then be removed by pulling it away from the finished structure using fingers, plyers, or anything else that works! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f740a77c-d063-4b92-834e-8e8a4c88ddab/IMG_20230116_175815.jpg 3D Printing Turning on the new RGB LEDs in the newly built RatRig Vcore3. Have you really build a 3D printer if you didn't install RGB LEDs?! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/83c457fe-1b11-4f3e-bdce-a752455d5fb4/IMG_20230116_175817.jpg 3D Printing We wanted the CAD/CAM corner to stand out as a cool place to hang out. The earlier you can catch students' attention and the more you can encourage a playful approach to learning, the more successful your teaching will be. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0f97a162-97fe-4fb1-af2e-6ad855d7cf44/IMG_20230116_175843.jpg 3D Printing It turns out that building a 3D printer takes a lot of wiring, fiddly connectors and other small components. While in build, the workspace got a little untidy. Now, however, a set of benches with drawers and cupboards help ensure that the area stays clean and tidy. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1ce5007c-a6e1-4f60-a0bb-0bcfe49316e6/IMG_20230124_090425.jpg 3D Printing This interesting design was a reduced scale prototype for a slideshow camera. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/492775a9-8401-40cd-896a-2536ca35c8ca/IMG_20230124_090649.jpg 3D Printing A flat spiral spring inside, attached to a drum, enabled a scroll of images to be withdrawn from the body of the 'camera' before retracting upon release. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/4a4e8564-ac62-42f3-82ba-45cc9ec62c11/IMG_20230124_090654.jpg 3D Printing While this version was a prototype, a large part of the finished design was also 3D printed, with the idea being that this would be a good analogue for a production item that would most likely be injection moulded. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f788f5fe-06f0-4a40-8b3c-bf389a542ec4/IMG_20230314_135830.jpg 3D Printing Beginning the printing for the finished camera body. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/be51e551-fd3c-4223-a468-7c726acd16d4/IMG_20230314_135834.jpg 3D Printing A cinematic low-angle photo... This printer was quite hard to observe in operation at certain points of motion, due to the full enclosure and the only light being on the front of the print head. This was one of the driving decisions for fitting more LEDs in the RatRig build. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a8e279c1-8b19-419a-81d8-a0623799f263/IMG_20230314_140444.jpg 3D Printing Moving beyond the base layers, the internal details and sides are now starting to be built up. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/329f691f-fb57-443c-bb3b-f2041b50ae93/20250430_162825.jpg 3D Printing Testing out the new Flashforge AD5X. This set of print-in-place assemblies proved that the machine printed dimensionally accurately, and also demonstrated the print speed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5105993e-f75a-40a3-ab7c-cc5ed98f8756/20250430_162828.jpg 3D Printing Each of these designs, downloaded from online 3D printing websites, has separate articulating components and complex mechanisms, all printed in one. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/29753aee-99c2-4715-a93f-2a146ca34779/20250430_164127.jpg 3D Printing We used these prototypes to showcase to students the wide range of possibilities associated with 3D printing and to encourage them to stretch their imagination with their design ideas. https://www.harrystear.me/workbench-build daily 0.75 2025-09-10 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9c007587-6ad2-458d-840e-1d82b8fa438f/DSC_1341.JPG Workbench Build Laminating the bench tops from 4"x2" construction timber. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb51b03d-81bc-4c75-865d-5107b3bd7a37/DSC_1342.JPG Workbench Build The apron was formed from 2"x6"s and 2"x8"s https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7e302c22-f3b7-48ed-92cb-3e00b7ca761e/DSC_1337.JPG Workbench Build Temporarily fitted leg frames. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0015c719-dc2e-4165-a129-5834c911c02a/DSC_1338.JPG Workbench Build Leg posts from 6"x6"s with cross braces mortise and tenon jointed into the legs. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e1c78883-16fe-4118-af7a-84abdba62aac/DSC_1339.JPG Workbench Build At the top of the leg frame, a jointed cross brace, with a spacer (gap for an end vice) followed by a top beam. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/eeb78d31-a8d0-4ec8-9247-4d5d636d9524/DSC_1340.JPG Workbench Build Notice the tapered slot cut into the apron. This is where the wedge fits to secure the leg frame. The bench top is split into two sections, connected with a tool well. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c76d8056-3e77-4e38-b817-88c3905ddcf4/DSC_1343.JPG Workbench Build Installed in the shed, with a face vice fitted. Now that my parents have moved house, it has pride of place in my father's barn workshop. You may notice that I did, in fact add some coach bolts through the aprons, purely to allow the bench top to break down into smaller sections for transportation (Two apron/benchtop sections and the gap insert). https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2abe56c8-7d5a-420d-880c-d98d6a8a3dcc/DSC_1344.JPG Workbench Build The tool well in the centre allows tools to be put down without rolling/being knocked off. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6db23df1-f9cd-44e0-b5c1-eace45e55139/DSC_1345.JPG Workbench Build The box on the bench contains a 6" metalworking vice. This was later mounted to a corner of the bench. https://www.harrystear.me/textiles-projects daily 0.75 2025-08-20 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/d55f7b07-6c9c-400c-a693-4a19dd2989c6/IMG_20210320_104810_5.jpg Textiles Projects The doorway and arch that the arrangement was to sit inside. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/7576c937-5277-4382-bc2d-69207fbc0baa/IMG_20210320_105025_7.jpg Textiles Projects The pillar detail, which was to provide the base for the arch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/905bb664-d03f-4832-ae77-e201253f5088/IMG_20210320_105106_6.jpg Textiles Projects The arch detail that the jacking screws pressed against. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/949670cc-c739-4061-adc3-f83860c0d812/IMG_20210320_105213_3.jpg Textiles Projects The top point of the arch. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5997fb89-becc-43bb-bdfd-637ef6b1b0f6/IMG-20210620-WA0002+%281%29.jpg Textiles Projects The final truss form. I made a jig to curve each arch section and then TIG welded each brace piece and jacking plate into place. The jack screws were hex head machine screws running through a tapped plate, welded to the frame, with a locking nut to eliminate any possibility of the screws backing out while in use. Steel plates at the top of the arch enabled the two halves of the arch to bolt together. Plates at the bottom ensured good load distribution across the stone plinth. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/568ac140-c86b-4488-8a5a-9b4a457e9539/IMG-20241115-WA0000+%281%29.jpg Textiles Projects Complete with floral arrangement. https://www.harrystear.me/laser-cutting daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2ccba991-ca1b-423c-a5e8-2e2dba85b980/IMG_20220202_101733.jpg Laser Cutting The laser cutter itself. Capable of cutting a range of organic materials to a depth of up to 9mm or more and engraving in even more materials including stone and glass. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e36e3ff4-68f5-47c8-954c-4e0d033c3749/DSC_0907.JPG Laser Cutting Components of a handheld fan project, cut from acrylic. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/96609ae6-e7dc-46a2-a476-ffce28f3df20/DSC_0909.JPG Laser Cutting Assembled into kits. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/cd101fd6-90b5-4218-9094-a21d99334820/DSC_0911.JPG Laser Cutting This project did not tesselate particularly well. In later years I got exceedingly good at minimising material wastage with quality tessellation. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a49defc8-9649-479e-be09-8d8118c833ed/IMG-20231205-WA0000.jpg Laser Cutting This corridor in my parents' house required a radiator cover. I designed a 3 panel cover, pictured here on the left, with 3 custom panels picking up on the floor tile design. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/898bbc11-faed-466b-9571-e2c27d710342/IMG-20231206-WA0002.jpeg Laser Cutting Cutting in process. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e06066bf-6faa-45d0-8934-c80b9aecfd96/IMG-20231206-WA0005.jpeg Laser Cutting A complete panel. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c0df3f0b-655b-4f2f-9245-ac5bf6e2cc3a/IMG_20200312_125744_5.jpg Laser Cutting In aid of a textiles project, I cut these flowers from cotton cloth for the student to applique to her design. This was the leftover cloth, showing considerably less wastage than would have occurred with hand cutting. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/33852ce5-a600-4743-a526-da39fa3095e2/IMG_20200312_125753_2.jpg Laser Cutting The process was also considerably faster than cutting by hand. The added advantage in that the heat helps to fix the edges of the cut, minimising the fraying while attaching the pieces. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8518e34c-b9f6-4f42-a9fa-ad672c84598c/IMG_20200305_170917_3.jpg Laser Cutting This jig was constructed to enable cutting slot profiles, at 5 equally spaced angles around this acrylic tube. See 'Student Project Support' for more info. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e412ae2a-a1d8-4f2b-88ed-c58c0bb3e86c/IMG_20200305_172213_2.jpg Laser Cutting This project was designed as a table decoration that hung wine glasses. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8a105c3a-92bd-4cbf-b512-78cf6bdc7ce3/20241217_163628.jpg Laser Cutting Holly gift tags, laser engraved and cut. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8caf374f-4f73-4b42-b1e2-d9018b17b2fb/IMG_20211216_172305.jpg Laser Cutting Christmas tree gift tags cut on behalf of Food Technology. See 'Gifts and Trophies' for more info. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f5be6a51-14b8-4e2f-828a-ea3fbfd79fcf/IMG_20210722_130103.jpg Laser Cutting Parts of a Harley Davidson 3D model that I designed as a leaving gift for our headmaster. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/dbe8a1ae-0d10-489b-8ed2-a1e7571e9ba1/IMG_20210802_135702.jpg Laser Cutting The assembled model. See 'Gifts and Trophies' for more info. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/78dec6d6-1d9f-438b-b7ec-ab3d61062541/IMG_20230628_141829.jpg Laser Cutting A cookbook stand that I designed to be used for gifts for visiting some speakers to the Food Technology department. I manufactured several of these. See 'Gifts and Trophies' for more info. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a9000715-157d-484e-9eb3-3565c92aaeb9/IMG-20200915-WA0019.jpg Laser Cutting A laser engraved acrylic panel, which I then edge lit, created this birthday card/gift for our Food Technology teacher. See 'Gifts and Trophies' for more info. https://www.harrystear.me/display-boards daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3394bf56-2c91-4b5a-bd59-1f062d5867e1/IMG_20201014_172406_8.jpg Display Boards This corner used to be particularly dull with dated displays. We decided to turn the area into a CAD/CAM corner, with 3D printing and laser cutting, with a vinyl printer/cutter to be added later. I designed and produced these two display boards, showcasing and informing about these techniques. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/2e639c8b-581a-4388-82ae-e8ddbcf29284/IMG_20201014_172422_0.jpg Display Boards This CAM board featured an LED lit sign, laser cut from acrylic. A large aluminium heatsink kept the temperatures down from these super bright LEDs and a mains power supply/transformer was used to power them. Each CAM process features images and interesting information about the use of CAM techniques in industry. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0e172eb2-ac1c-4c33-b484-8f92f3ec3298/IMG_20201014_172432_2.jpg Display Boards The CAD board displayed some different CAD designed letters forming the title. Different CAD packages that were in use at the department at that particular point in time were then detailed below. This has been updated as required as the CAD packages in use have changed. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9e7ad7d2-6935-41a8-bb9c-5529813002d6/IMG_20210326_155134_6.jpg Display Boards Asked to produce a display showing different materials used in Design & Technology, I made a centrepiece title that used a whole range of different material examples. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e42af403-4d81-4340-9dbc-f1e29aeb1394/IMG_20210330_094119_8.jpg Display Boards The top three letters represent Wood: manufactured boards represented by oriented strand board (OSB), hardwoods, represented with Walnut and softwood, represented by pine. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a711ead1-66a0-4edd-b6db-63cb6ffef92a/IMG_20210419_180133_4.jpg Display Boards The middle three letters represent metals: non-ferrous metals represented by copper, ferrous metals represented by stainless steel and alloys, represented by brass.. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3e374ff3-4044-4aa6-82f9-53e30ada1530/IMG_20210419_180139_8.jpg Display Boards The lower three letters represent plastics: thermoset polymers and composites represented by carbon fibre reinforced polymer, thermoplastic synthetic polymers represented by High Density Polystyrene (HDPS) and natural polymers, represented by natural rubber. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1194a55d-d53e-428b-8815-86069271ff82/IMG_20210419_180150_2.jpg Display Boards I also used numerous processes and finishing techniques, including staining, waxing and varnishing, copper beating, engine turning and TIG welding, polishing and solid rivetting, composite hand layup, vacuum forming and hand engraving. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755782090449-BVXDMMJYDDVXWESYRKPM/IMG_20210419_180122_0.jpg Display Boards This title formed the centrepiece of the display, here pictured mounted before the supporting information was added. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/461c33e7-5bbf-42b2-9dae-6e8ecc9e7a15/IMG_20210422_170909_7.jpg Display Boards Gradually adding information outlining different materials, their properties and uses, all grouped by category. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/441b0ea2-710e-4348-b9f3-6b42d54bf42a/IMG_20210422_170931_6.jpg Display Boards Woods and metals are shown to the left of the title. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f7bfb15d-2f50-462d-bf66-be5fcaf7dd0f/IMG_20210422_173239_0.jpg Display Boards Polymers and composites are to the right of the title. https://www.harrystear.me/cad-drawing daily 0.75 2025-08-25 https://www.harrystear.me/scheme-of-work-development daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755793970987-9AZQT2HRUVPJQHSDE20F/IMG_20211119_143733.jpg Scheme of Work Development Spatula Handle: Skills include reading orthographic drawings, marking out, cutting, filing, drilling, tapping, and bending https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a4c86576-c61b-45ac-88da-e1e4fc451983/IMG_20211119_171640.jpg Scheme of Work Development The finished spatula demonstrates a number of materials and processes and practices a series of skills required for GCSE level engineering qualifications. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/49f75c58-3ac7-4e6b-9eb6-05af28ab0826/IMG_20211119_171756.jpg Scheme of Work Development This project was designed to be completed in pairs, with similar processes involved in both the manufacture of the handle and the blade. Assembly is then a joint task, using countersunk machine screws to attach the blade to the tapped threads in the handle. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9c6253a3-aaeb-4465-bae4-d53ce63939b7/IMG_20211119_174617.jpg Scheme of Work Development Wooden grips were designed to be produced using jigs and fixtures both for drilling and belt sanding of the final shape. The grips were then designed to be rivetted to the handle, however testing indicated that even using Oak grips and annealed aluminium rivets, the wood compressed before the head of the solid rivet could be completed properly. A redesign would use solid rivets to attach the blade to the handle and machine screws to attach the two grips. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/840f5bc2-dbac-483f-82fe-6e2a97a5c97d/Spatula+Scheme+of+Work.jpg Scheme of Work Development Click the image to download a copy of the specification for the Y9 Engineering Spatula Project. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755795251370-6BGJO1EPP411NJQBDCE1/Introduction%2Bto%2BEngineering%2BSpatula.jpg Scheme of Work Development Click the image to view the presentation accompanying the Spatula Project scheme of work. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755794074295-N8FX326GG0RFS1XXLTS9/Process%2BFigure.jpg Scheme of Work Development An earlier project for Y9 involved the manufacture of this metal figure, using a range of processes. Drawings for each component taught effective reading of orthographic drawings. An assembly drawing introduced that concept. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/fa69292b-25e3-4497-a060-00fee75a7215/DSC_0228.JPG Scheme of Work Development The body was gravity die cast in Pewter, using student made MDF moulds, before being drilled and tapped. The head was turned from mild steel on the lathe, before a thread was die cut into the neck. The hat was drilled, cut, and filed from flat bar and MIG welded, with a couple of tack welds, to the head. The legs were made from Aluminium, cut to length and holes drilled, before annealing and bending, mounting to the body was by machine screws. The feet were mild steel, drilled and countersunk for a solid rivet, before case hardening. The arms were cut to length and chamfers filed, before inserting into the body and drilling for a roll pin. https://www.harrystear.me/gifts-and-trophies daily 0.75 2025-08-21 https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/3895b73d-a0a8-4c6b-ba1c-d41675a9439b/20240722_135248.jpg Gifts and Trophies A leaving gift for a science technician. Made from a broken bunsen burner mounted to a sapele base. The brass plaque was spray painted black, then the blank space engraved clean using the laser cutter, before a final clearcoat was applied. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/51f388ee-b090-4ba8-9f31-ba2e73481151/20240722_135251.jpg Gifts and Trophies The bunsen burner was sanded and painted as the well used original was looking its age. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755783749953-IWCK35LVNJGHFZMP2EOU/20241217_163628.jpg Gifts and Trophies A custom gift tag, drawn and laser engraved for the Food Tech department. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8d98a40e-44a3-4b8a-b1c1-08fde0f16915/IMG_20200125_163813_1.jpg Gifts and Trophies A coat hanger and entrance hall shelf, built from oak for my mother. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/021e6de4-d9d3-4a06-b0c6-be6edabe0830/IMG_20200125_163828_5.jpg Gifts and Trophies This simple design matched the oak staircase and flooring in this entrance room. It was assembled using dowel joints, and mounted using stainless steel screws. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c76d5a19-ffd6-4b7f-9cfc-17c4d72562e4/IMG_20200125_163840_2.jpg Gifts and Trophies 5 equally spaced hooks and the shelf above provided plenty of storage for coats and other belongings. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/5d6fb5ab-7f4c-448e-81e9-55d31901337b/IMG_20201216_135255_9.jpg Gifts and Trophies I made this gingerbread wreath for a secret santa gift for a colleague https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f85868ba-630e-4200-a544-601a3e423eb0/IMG_20201216_135303_4.jpg Gifts and Trophies Laser cut birch ply snowflakes helped to decorate the wrapping. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/c2140a1c-57be-46cc-8b79-18134680566e/IMG_20210730_135711.jpg Gifts and Trophies When our headmaster announced that he was leaving to take up another position, I designed this motorcycle 3D model, due to his love of Harley Davidson. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/269aa441-3950-49db-a198-2b8a056e40b2/IMG_20210722_130100.jpg Gifts and Trophies Each laser cut component was designed in SolidWorks using a series of planes and hand drawn splines. I imported a background image and used it as a guide to create the outlines of each shape. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/6bca64b8-45bb-44e5-ad80-f4ccab774518/IMG_20210730_135717.jpg Gifts and Trophies I tested the design and assembly process in MDF before the final article was cut from 3mm birch plywood. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0f0234d6-ad14-4f20-ad29-446722a90d2f/IMG_20210730_135723.jpg Gifts and Trophies Each component slotted together and the finished design self supported using the centre stand. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/bb359062-38ee-4824-885b-2d313099ccd9/IMG_20210802_135635.jpg Gifts and Trophies A series of interlocking components in orthogonal planes led to a design that self supported without the use of glue. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f379bd99-0451-4f26-9a8f-e34b818be936/IMG_20210802_135645.jpg Gifts and Trophies I was very happy with the finished product. It really captures the desired look. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b49bf0dd-cbff-4383-a2e1-ef0a8ad29203/IMG_20210802_135654.jpg Gifts and Trophies The headmaster was very touched by the gift which, to my understanding, now takes pride of place on his mantelpiece. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/297f64e3-b69c-4623-a9cd-ec3cf413d44a/IMG_20210802_135659.jpg Gifts and Trophies The SolidWorks to complete this project was particularly complicated and I learnt that splines are best avoided due to the complexity involved in fully defining them. This led to a number of issues when it came to adjusting lines later in the project. a small change to one spline could wreak havoc on other components. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e57d5710-8e96-4bd1-bf29-57dd76dcca73/IMG_20210802_135712.jpg Gifts and Trophies Looking magnificent on the top of the laser cutter, shortly before being presented to the headmaster. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/978cf0ff-c871-4f75-8915-a49677bb1855/IMG_20211216_172305.jpg Gifts and Trophies Another gift tag for the Food Technology department. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/0bc61e37-bfa8-4699-ba56-025c3158413a/IMG_20221220_165910.jpg Gifts and Trophies A gingerbread house made with my god-daughter and her sister for christmas. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ebe192bc-1d0c-4f0d-81cb-f5de3366b1e8/IMG_20221220_165917.jpg Gifts and Trophies And some gingerbread people to go with it! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/04970873-d294-411c-aae8-ad6141f66da0/IMG_20221221_162326.jpg Gifts and Trophies A selection of laser cut christmas decorations made for numerous colleagues, friends and family. Note the snowflakes and the laser cut bauble. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/afebb792-ebca-4e28-a8d1-39027636a778/IMG_20221221_162340.jpg Gifts and Trophies This bauble was made of three layers. A fabric centre was laminated to two laser cut bauble shapes with detailed cut outs. The birch ply was sprayed with a glitter clearcoat that really caught the light. A red ribbon was then threaded through to hang the bauble. I made a set of 12 of these baubles in a laser cut gift/storage box for the quizmistress at the pub quiz that I and some of my colleagues attended. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/ed4ca7fb-63ee-41ca-96ba-d2bfc46d1906/IMG_20230628_141829.jpg Gifts and Trophies A recipe stand designed and manufactured for gifts for some visiting speakers to the Food Technology department. With the school's name and logo engraved in the front, this will be a reminder of their visit every time they cook. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/69c0acd3-f95a-40d8-9d09-c78189ba2fca/IMG_20230628_141839.jpg Gifts and Trophies The side profile shows the return that helps hold the book on the stand, while keeping the book open at the desired page. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/e1187eb1-fe62-4a85-b124-f7fe076f6ddd/IMG_20230628_141850.jpg Gifts and Trophies The reverse side. Each birch ply piece was laser cut, using box joints to connect them. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/860487ac-1552-4ee1-a94b-b3f2addab839/IMG_20230628_163155.jpg Gifts and Trophies As the photo shows, the design worked well. A food safe wax finish protects the wood from stains and helps ensure that the stand remains hygienic. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b252d0e1-45e6-4f7c-a970-47bdb9ef8c39/IMG_20230628_163209.jpg Gifts and Trophies The base was made from Sapele and features a routed ogee radius and mortise and tenon connection to the birch ply stand. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/95d5115b-d4d4-4c98-bf6d-4a7d92ddc6b3/IMG-20200915-WA0010.jpg Gifts and Trophies A laser engraved acrylic birthday card/gift, edge-lit from below provided a unique celebration for a colleague. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/8753ca56-945e-4f63-904d-009f4bfaf37a/IMG-20200915-WA0019.jpg Gifts and Trophies The batteries, LED and resistor were buried in the live edge piece of wood forming the base, with a switch inset to turn the light on and off. A cover plate screwed on from below gives access to the batteries when they need changing. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/b6479866-57ce-43f2-ab66-27c1b37431a7/IMG-20200915-WA0020.jpg Gifts and Trophies Edge-lighting really helped make this pop. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1755787070682-7GPZNJDZLC1501SQVD5P/IMG-20200916-WA0000.jpg Gifts and Trophies My colleague was very pleased with her gift. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/378ef6be-584b-46f3-a813-baff32b9e4b0/IMG_20201019_142830_2.jpg Gifts and Trophies When my colleague had her first child, I made a set of beech stacking blocks, laser-engraved with the letters of the alphabet and numbers 0-9. Each block also had the school's logo and a teddy bear. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f6aafa4b-4f74-4bae-acf7-5661fc434fda/IMG_20201019_142843_3.jpg Gifts and Trophies I made a sanding jig to get consistent chamfers on each corner and had previously used a jig to ensure proper alignment for laser engraving. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/19356b28-8bae-4365-94b4-e7931abd18ad/IMG-20230301-WA0002.jpg Gifts and Trophies The blocks were still in use a few years later with her second child. The large chamfers have ensured that the blocks handle rough treatment well and are as safe as can be when thrown across the floor! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/080cfe8e-65f9-42a7-839e-e3b0bb514962/IMG-20230301-WA0004.jpg Gifts and Trophies I made the blocks using beech due to its non-toxic, tough, splinter resistant grain and finished each block with a food grade hypo-allergenic beeswax. These blocks are quite capable of handling teething children safely! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/afd19fce-424c-42f8-b9a9-2b7e2cc7eed2/IMG_20201216_230349_4.jpg Gifts and Trophies For the grand-daughter of another colleague, I produced a puzzle in the shape of her name. Each piece was in laser-cut birch ply and the background was stained before the whole puzzle was finished with beeswax. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/da57e3c6-5de9-4f64-a065-a9c86a5b9257/IMG_20201216_230430_0.jpg Gifts and Trophies Each letter had dowels to give good hand holds for small fingers. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/a49d81bb-40d3-44a6-9bbb-5f076d7107ad/DSC_1530.JPG Gifts and Trophies For our head of department's maternity party, I designed and laser cut this rocking crib (at 3/4 scale to fit each piece onto the laser bed) from 6mm MDF. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/98c7d369-5edb-48a9-9b0d-2f65559c03b5/DSC_1529.JPG Gifts and Trophies My colleagues and I filled the crib with gifts essential to an expecting/new mother. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/1bc6f412-0350-491f-b35b-f66f89e528f7/DSC_1541.JPG Gifts and Trophies Note the miniature quilt covering the crib. I made this in the textiles department from assorted scraps of fabric. The whole effect was really cute. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/31a81d89-0b9d-4280-a437-ad8d7ed1b769/DSC_1433.JPG Gifts and Trophies As a Mother's day gift, I decided to make an end-grain cutting board. I used a combination of Oak, Beech and Black Walnut to create the board, which spelled out 'Mother'. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/16bd48f6-11d4-4e68-a6e8-2f0700ce40e8/DSC_1435.JPG Gifts and Trophies With hindsight, my glue-up strategy could have been improved. Nevertheless, the finished article turned out well, albeit with rather more stress than I would have liked! https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/f74ea395-b913-4777-8e34-2ef0aaee5b7b/IMG_20210617_181638.jpg Gifts and Trophies I designed and manufactured this giant pegboard at the request of a colleague, who was in charge of organising the Y11 Prom. She requested a 'Donut Wall' to be displayed in the prom marquee. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/be433b61-3921-4576-bdc9-454a9a2f5b04/IMG_20210617_182325.jpg Gifts and Trophies I designed a system based around two heavy MDF plinths, which would ensure stability, combined with a pine frame, enclosing 3 vertical panels. Each pine vertical was rabbetted to accept a stack of laser-cut peg boards, plus a title space. The top of each vertical was then dowelled together with a top rail. All components were able to be disassembled for transportation in a standard car. https://images.squarespace-cdn.com/content/v1/655fa375df998a39f485de79/9b5ec584-f964-45a7-9a40-616a05529b14/IMG_20210618_101544.jpg Gifts and Trophies Testing the board with the first donuts. The whole board had capacity for 360 donuts! In case of any doubt, gluing 360 dowels into 360 holes is incredibly tedious. Thankfully the holes themselves could be laser cut, rather than needing to be individually drilled!