I am a machinist at the Green Bank Observatory and we make parts for radio telescopes. We have to make MASSIVE cones that end up connecting together to be often 6ft tall that starts at 4-5 ft diameter and ends at 5 inches or so!! We do it COMPLETELY out of either billet stainless steel or aluminum. It would be amazing to be able to save so much material by doing it this way!
@Nathaniel Langston - I just met someone randomly yesterday while doing some volunteer work and we got to talking about all kinds of things and he mentioned visiting the observatory and how close it is to us in Ohio. I had never heard of it before and here you are. Pretty wild the small world experiences sometimes. Are these components structural or for wave guide?
Rich - I hope Nathaniel Langston sees your comment, and replies. I don't know how this works - I can certainly see all comments on my videos, and the comments on the comments, but I don't know what the commenters see when someone comments on their comment. If YOU know - let ME know.
@@RonCovell I added the @Nathaniel Langston just in case, but he still should have gotten a notification. Sometimes it is added automatically but other times not. I stopped getting new video reminders from all of the channels I'm subscribed to years ago and have never figured out why. Some things just remain a mystery.
You are the Bob Ross of metal forming, so relaxing and enjoyable to watch! As a CAD guy that took some manual drafting classes, the contructions and template making are so interesting. Thanks for sharing Ron!
In the 60s Jr high schools had a thing called metal shop classes. Kids would layout and make this wonderful thing called a funnel. I guess nowadays well paid youtube geniuses like this guy have to reinvent the basics that are now long gone.
I love watching these videos. Consistently, I realize a huge part of your success with these builds is the easily overlooked preparation and tool building aspect of a project.
I roll cones all the time up to 1/2" for mines and industrial applications. This is absolutely awesome, especially for branch and takeoffs in the field. Thank Ron!
Your a badd ass I've looked to your work for many years especially when I was starting to shape metal. It's been about 20years now &hundred or so cars and motorcycle competed. I love that your still teaching me new things. Thank you for your commitment and love for this industry. It wouldn't be where it is today without you an your great teachings and knowledge nor would I... thanks Ron!!!!!
Wow - it takes a lot of doing to complete 100 cars and motorcycles. My hat is off to you for becoming a lifetime professional, and I'm glad I could teach you a few tricks along the way!
Another beautiful job Ron. It’s amazing what a little flat plate in threaded rod will help us with. I can’t express the amount of knowledge I learned from this video as always. Make On man.
Great stuff. As a blacksmith, I've had to forge a lot of cones over the years for various projects, and it's always a bugger. I'm starting to learn a lot about sheet metal thanks to this channel and can see me doing more with it. Anything that doesn't involve tons of heat scorching me is a good thing in my book!
Well, certainly sometimes you need heat to make metal do what it doesn't 'want' to do - but with the right tools and techniques you can do a lot at room temperature.
Ron you have done it again, you have blown my mind. Making seemingly impossible shapes by using simple but ingenious tools and techniques. Amazing! Thank you so much for sharing this with all of us. It is truly a pleasure to watch a master at work. Greetings from the Netherlands, Mark
Ron, if you explain an do it, it seems and looks so easy! Every time when I am watching your videos, I am also impressed what you are able to realize with such easy tools!
You have such talent and wisdom. I greatly appreciate you sharing all that you have. I also use your videos to prove to my friend that fit up and layout are as important as the finished part!
Calm, confident and very clear voiced instruction. You are surely a master teacher! Bending my ear and making me cone-sistant will make me a better teacher!
Ron, As always, you do nothing but impress! I have a project coming up that I was bouncing around in my head as to the best way to get a good form on 1/8" material. Needless to say I now have a very simple and elegant answer. Keep up the videos if you can they are always very interesting and useful to the less experienced and not so widely exposed of us. Thanks again for this. Mark.
Hey, I'm very glad you found this video interesting, and that it might actually help on a future project. I've been consistently uploading new videos every two weeks, and I'm trying hard to keep on that schedule.
I so appreciate your videos, Ron. The quality of your work is amazing. And your demeanor is a joy to experience. I absolutely love learning the processes you demonstrate for us. Thank you for passing on your vast knowledge of fabrication!
years ago I had a small business custom making motorcycle mufflers in stainless steel,, cones cones and more cone, intersecting cones and perfect polishes,, I dont miss it I make knives and swords now , but this vid did bring back some memories,, I was one of the last old school sheet metal workers, industrial manufacturing is so different now a days, I dont miss working in the big stainless fabrication shops, I have my small workshop and still have the rollers I made,, Nicely done on the video , good explanations and I like the jigs you used, some good ideas there,,
I have just finished a project at work making near identical parts. I formed the cones by making up a tool for the press brake. Basically it was a 20mm bar between two pieces of tooling . Which I used to press the steel in creases into a piece of 15mm hard rubber which was sat on a flat solid bottom tool. This produced the cone with nice gentle radius creases. My Aluminium mandrel had a large diameter straight section which I used to lock into my bench vice which has Aluminium jaws with a central vee machined into them. This locks everything in super snug. I then used a nylon dead blow hammer to smooth out the creases. After welding and cleaning I used the mandrel in the lathe to mount the cones and spun it up to polish the final parts. They came out lovely and the customer was delighted with them. Nice to watch you use a different technique to achieve them same result Ron.
This video is the ultimate youtube content in my opinion. If the landing page of youtube contained content like this the world would be a better place.
You are very welcome! I hope to return to New Zealand - I've taught many workshops there, and toured quite a bit on both islands. It's a wonderful place!
It does take a lot of force. I tried holding the first bar into place with clamps alone, but it slipped off when the going got tough. Just a couple of small tack welds solved the problem with ease.
Wonderful Job ! I would only change one thing. Machine the come from steel, but make it 3/4 longer, and that 3/4 longer would be on the big end, and a machined hex shape, for a wrench to turn it instead of welding on an arm.
Holy crap! Ron, every time I watch your videos, my mind is blown. I did not think it was possible to roll a cone out of 1/8" plate with that tight of a diameter.
THIS GUY NEVER CEASES TO AMAZE ME - IT'S ALL SO EFFORTLESS FOR HIM , HE'S LIKE A GENIUS , I WOULD THINK HE WAS SOME KIND OF ASTRO PHYSICIST OR MATH GENIUS OR SOMETHIN - GREAT TEACHER
Another method to make a cone like this is to cut a disc, put a hole in the center, then draw it through a cylinder. The "coin ring" crowd has been doing this for a long time. They make a cone first, then draw it out into a ring and roll the edges.
I had never heard of that technique, but I quickly researched it on TH-cam. That's a pretty cool technique, and I would not have learned about it without your suggestion. Thanks a million!
I remeber trying to make a cone out of coke can tin back when I was a teen. I just saw you overcome every problem I had from that experience. I am so thankful I found you on TH-cam.
Thank you! Since most of my work has been with automotive-grade sheetmetal, 1/8-inch (3.2mm) material seems heavy to me. But some people work with metal 20 times that thick every day, and form some fabulous things with it!
Hi Ron, thanks a lot for sharing your impressive knowledge with so many people around the world! It's always great to watch your videos and learn. even if I might not need to shape a thick wall cone it's very helpful to see the kind of finding a solution for a unique issue. Best regards, TOBi 👋😉👍
Nice job, that is a very ingenious way to form them. I have done small cones from 5/8 stainless by bump forming on a brake but those were a much shallower angle.
@@RonCovell most of the big ones,i.e. 2"thick aluminum with a 15' dia, I did were in two pieces. The smaller ones were one piece. I worked off the end of the die.
You know, I don't own a press brake, and it didn't occur to me that you can work off the end of the die. I can see lots of great possibilities with that setup!
Well done again ,I love projects like this, watched this video already three times , I am truly amazed at how your mind works in finding simple/practical solution to different problems.
Yes - that was quite a project. Perhaps someday I'll go into more depth about the construction. There were some special challenges, indeed. I did add just a little more detail about the process in this video: th-cam.com/video/Vr9mqC27fLs/w-d-xo.html
Wow Ron! You make these cones look so easy to make! Brilliant, as an earlier comment stated! Thanks for all your time and sharing all of your great technics! 👍😎
Thank you for sharing this beautiful technique for making such beautiful cones. The video was a great delight and joy for me to watch, such mastery over such a complicated and beautifully symmetric shape.
Matthew - I'm so glad you enjoy my videos! For what it's worth, I have not watched much TV for the last 30 years, but I love the vast selection of content available on TH-cam.
Ron! Brilliant again and has also confirmed an answer for myself regarding a collaborative project. The project will involve forming a three foot long odd shaped tube from 18g steel. For fun and interest I was going to use a highly geared down winch type gearbox to turn the former against a roller.
Trev - I'm so glad that you had a chance to view this video, and that you liked it! I hope you can find a way to use a similar idea for your collaboration. My opinion is that for a small number of parts, motorizing it might be more trouble than it's worth.
@@RonCovell you’re probably right there Ron, I wonder how much leverage it will take to move? But that’s the great thing about doing something like this. Sometimes you’re surprised about how easy it was and other times seemingly simple things are harder to achieve than expected.
Trev - I last used those cone-rolling fixtures more than 25 years ago, and I forgot how much leverage it required. If you look closely at the video, when I made the first bend, you'll see that I had welded a couple of extra feet onto the handle to make it easier to form. The tighter the radius of the bend, the more force is required!
@@RonCovell yes I got used to making some 4ft long sections from 20g in the folding machine, then I had to make one from 18g and I couldn’t believe the difference in force I had to use.
Nice work Ron! I was wondering if you could drill a series of holes in the large end of your mandrel or have a hexagonal lug on it to eliminate the need to weld a piece of metal to the cone material? You could just turn the mandrel with a dedicated tool handle to form the cone without the need to weld and cut off the handle each time.
That could probably work, but I think the screws that hold the blank to the mandrel would need to be beefed up, since the high torque loads would try to shear the heads off.
After watching this video, I'm just amazed. You are a true master of engineering. You use the K.I.S.S. concepts. You make things look so easy but I know it's not. Keep up the great video!
That is a great way to do it. I own a fab shop and will make that part in 2 sections and use a press brake and bump brake the half's to shape then sand the creases out. Faster my way but your way is cleaner. Another point is bump brake long cones is possible as is thickness. It is up to how big is the brake press.
I've done a good bit of the same, for frame work for motorcycles and cars, might I suggest you put a number of tapped holes in the large end of the form for the handle. I've done much the same, with a steel mandrel, weld the seam off mandrel, and pull it down after cleaning up the weld. I really like your setup for rolling, I've always freehanded the steel, and see much better results. Thanks for sharing this.
@@RonCovell Hi Ron, I've thought on this since I saw your video, it would be fairly easy to key or pin a gear on the end of the tapered roller, and crank it over with a lever and gear drive. That would also allow changing directions, and doing complex shapes beyond cones. I don't do much in that line any more, age and rotator cuff injuries, but thought you might find it of interest. If this "energy shortage" goes on, I might well be shaping some large cones for equipment for fuel. Semper Fi, John McClain
If you machine a hex into the end of the mandrel, you can use a big wrench to drive it instead of welding to the piece. Assuming the 10-32 screws are strong enough.
I just watched this again to remind myself about the techniques of welding fixtures to the parts and then erasing all evidence. I'm definitely going to be using some of these techniques in parts of the bespoke drives I'm making for large microwave radio dish antennas used in Earth-Moon-Earth communications instead of machining the cones from solid stainless. Another very useful video, thanks Ron
I am a machinist at the Green Bank Observatory and we make parts for radio telescopes. We have to make MASSIVE cones that end up connecting together to be often 6ft tall that starts at 4-5 ft diameter and ends at 5 inches or so!! We do it COMPLETELY out of either billet stainless steel or aluminum. It would be amazing to be able to save so much material by doing it this way!
My hat is off to you for making such large and precise parts. You must fill up multiple dumpsters with chips!
@Nathaniel Langston - I just met someone randomly yesterday while doing some volunteer work and we got to talking about all kinds of things and he mentioned visiting the observatory and how close it is to us in Ohio. I had never heard of it before and here you are. Pretty wild the small world experiences sometimes. Are these components structural or for wave guide?
Rich - I hope Nathaniel Langston sees your comment, and replies. I don't know how this works - I can certainly see all comments on my videos, and the comments on the comments, but I don't know what the commenters see when someone comments on their comment. If YOU know - let ME know.
@@RonCovell I added the @Nathaniel Langston just in case, but he still should have gotten a notification. Sometimes it is added automatically but other times not. I stopped getting new video reminders from all of the channels I'm subscribed to years ago and have never figured out why. Some things just remain a mystery.
Yes, Google and TH-cam work in mysterious ways!
You are the Bob Ross of metal forming, so relaxing and enjoyable to watch!
As a CAD guy that took some manual drafting classes, the contructions and template making are so interesting. Thanks for sharing Ron!
I'm so glad you enjoy my videos!
In the 60s Jr high schools had a thing called metal shop classes. Kids would layout and make this wonderful thing called a funnel.
I guess nowadays well paid youtube geniuses like this guy have to reinvent the basics that are now long gone.
Gonna put some happy little cones right over here...
I will never grow tired of your minimalist approach to no need of fancy expensive tools videos :D
Thanks. I learned a couple of years ago that people enjoy seeing how to do work with the simplest of tools.
I love watching these videos. Consistently, I realize a huge part of your success with these builds is the easily overlooked preparation and tool building aspect of a project.
Yeah, carefully thinking through a project and doing adequate preparation pay huge dividends!
I roll cones all the time up to 1/2" for mines and industrial applications. This is absolutely awesome, especially for branch and takeoffs in the field. Thank Ron!
So many TH-cam channels claim to be "Experts" yet the average people can see their flaws. This channel is THE metal forming expert.
Thanks for the kind words!
Your a badd ass I've looked to your work for many years especially when I was starting to shape metal. It's been about 20years now &hundred or so cars and motorcycle competed. I love that your still teaching me new things. Thank you for your commitment and love for this industry. It wouldn't be where it is today without you an your great teachings and knowledge nor would I... thanks Ron!!!!!
Wow - it takes a lot of doing to complete 100 cars and motorcycles. My hat is off to you for becoming a lifetime professional, and I'm glad I could teach you a few tricks along the way!
Once again, I am reminded that preparation and being patient enough to build the tool or jig rather than trying to take shortcuts are key.
You got it!
@@RonCovell and to always use the KISS principle (keep it simple S) many over complicate things. Regards Dennis
Another beautiful job Ron. It’s amazing what a little flat plate in threaded rod will help us with. I can’t express the amount of knowledge I learned from this video as always. Make On man.
Wow, thank you!
I am a retired Sheet Metal Worker,I still get a buzz watching a craftsman at work.
Calmly creating fixtures and anything is possible. 👍👍😎👍👍. Thank you Ron for another tutorial on how to form metal. The art pieces were really cool.
Glad you liked the furniture pieces, as well as the car parts.
As always. Amazing series. Thanks for being around and sharing your knowledge.
I appreciate that!
Great stuff. As a blacksmith, I've had to forge a lot of cones over the years for various projects, and it's always a bugger. I'm starting to learn a lot about sheet metal thanks to this channel and can see me doing more with it. Anything that doesn't involve tons of heat scorching me is a good thing in my book!
Well, certainly sometimes you need heat to make metal do what it doesn't 'want' to do - but with the right tools and techniques you can do a lot at room temperature.
This is absolute top notch how to! Thank you, Sir
This Old Tony brought me here.
Awesome, thank you!
Ron you have done it again, you have blown my mind. Making seemingly impossible shapes by using simple but ingenious tools and techniques. Amazing! Thank you so much for sharing this with all of us. It is truly a pleasure to watch a master at work.
Greetings from the Netherlands, Mark
Wow, thanks, Mark. I do appreciate your continued interest in my videos.
The Covell standard…excellent video production/discussion/demonstration/build….thank you for sharing/mentoring
Thank you kindly!
yesterday i used your rolation technique for the first time. Worked great. Thanks a lot for sharing your knowledge
Hey, I'm delighted that it worked well for you!
Ron, you are a true Master. Your work has amazed me for years. Thank You!
Wow, thank you!
Ron, if you explain an do it, it seems and looks so easy!
Every time when I am watching your videos, I am also impressed what you are able to realize with such easy tools!
Glad you are enjoying my videos!
You have such talent and wisdom. I greatly appreciate you sharing all that you have. I also use your videos to prove to my friend that fit up and layout are as important as the finished part!
Whoo, boy are fit up and layout important!
Calm, confident and very clear voiced instruction. You are surely a master teacher! Bending my ear and making me cone-sistant will make me a better teacher!
Wow, thank you!
Wonderful work Ron. You make it a pleasure to watch & learn with clear video work without loud music. 5 star. Machinist.
Thank you so much for the kind words!
Ron, I am excited to learn from you at the Metal Bash. See you in a couple weeks.
I'm sure we'll have a fantastic weekend!
WoW!! so much work for such a simple shape (ostensibly) thanks for a great video.
Glad you liked it!
Ron, As always, you do nothing but impress! I have a project coming up that I was bouncing around in my head as to the best way to get a good form on 1/8" material. Needless to say I now have a very simple and elegant answer.
Keep up the videos if you can they are always very interesting and useful to the less experienced and not so widely exposed of us.
Thanks again for this.
Mark.
Hey, I'm very glad you found this video interesting, and that it might actually help on a future project. I've been consistently uploading new videos every two weeks, and I'm trying hard to keep on that schedule.
this is brilliant.
Thanks!
I love all the approaches you have to various problems, gives me so many ideas
Great - I hope they will be useful someday soon!
I so appreciate your videos, Ron. The quality of your work is amazing. And your demeanor is a joy to experience. I absolutely love learning the processes you demonstrate for us. Thank you for passing on your vast knowledge of fabrication!
Wow, thank you!
That is an absolutely beautiful finished product!! Fantastic explanation as always!!!
Thank you so much 😊
another weapon in my frabracation arsenal , I've been looking for a way to roll cone's Thanks Ron
Hey, this could be just the ticket!
years ago I had a small business custom making motorcycle mufflers in stainless steel,, cones cones and more cone, intersecting cones and perfect polishes,, I dont miss it I make knives and swords now , but this vid did bring back some memories,, I was one of the last old school sheet metal workers, industrial manufacturing is so different now a days, I dont miss working in the big stainless fabrication shops, I have my small workshop and still have the rollers I made,, Nicely done on the video , good explanations and I like the jigs you used, some good ideas there,,
Hugo - thanks for chiming in. I'd be interested to know how you rolled those cones from thin stainless. It's not easy to do!
I have just finished a project at work making near identical parts. I formed the cones by making up a tool for the press brake. Basically it was a 20mm bar between two pieces of tooling . Which I used to press the steel in creases into a piece of 15mm hard rubber which was sat on a flat solid bottom tool. This produced the cone with nice gentle radius creases. My Aluminium mandrel had a large diameter straight section which I used to lock into my bench vice which has Aluminium jaws with a central vee machined into them. This locks everything in super snug. I then used a nylon dead blow hammer to smooth out the creases. After welding and cleaning I used the mandrel in the lathe to mount the cones and spun it up to polish the final parts. They came out lovely and the customer was delighted with them. Nice to watch you use a different technique to achieve them same result Ron.
Your technique sounds great! I wish I had a press brake - but since I don't, it forces me to be creative sometimes.
@@RonCovell Ron you certainly are creative. It's a pleasure to watch you work. Best regards from the UK
This video is the ultimate youtube content in my opinion.
If the landing page of youtube contained content like this the world would be a better place.
Thanks for the very nice compliment!
Oh. That weld job. Pro job, if there ever was one. It was a treat to watch. Thanks.
Thanks!
Ron, your instruction is incredible. Thank you and cheers from New Zealand!
You are very welcome! I hope to return to New Zealand - I've taught many workshops there, and toured quite a bit on both islands. It's a wonderful place!
I am feeling my creative juices salivating having watched just these few shaping videos...Thanks very much Ron
Glad you like them!
Ron, I get so excited whenever I see you have posted a new video! I always learn from you! Thank you for sharing your knowledge!
So nice of you!
Incredibly simple and effective.
Thanks!
Thank you, Ron, for sharing your technique! That will undoubtedly come in handy someday.
I hope so!
You have done it quite nicely and made it look like very simple and easy too. Great Brain
Thanks a lot 😊
I never get tired of seeing this master doing his amazing job
Thanks so much!
What a master! Innovative, imaginative and practical.
Wow - thanks for the high praise!
Fantastic video. I was so relieved when you welded the bending bar on, I was thinking there's no way I could bend that round........
It does take a lot of force. I tried holding the first bar into place with clamps alone, but it slipped off when the going got tough. Just a couple of small tack welds solved the problem with ease.
Wonderful Job ! I would only change one thing. Machine the come from steel, but make it 3/4 longer, and that 3/4 longer would be on the big end, and a machined hex shape, for a wrench to turn it instead of welding on an arm.
That sounds like a great idea!
Beautiful techniques, wish the video was out earlier, I had rolled a 500 mm copper cone using lumber mandrel, was a real pain
Well, at least you'll be better prepared the next time!
Fantastic presentation and clearly the author has a lot of knowledge and experience.
These builds are great to watch so much to learn from these videos
Glad you like them! More on the way.
Holy crap! Ron, every time I watch your videos, my mind is blown. I did not think it was possible to roll a cone out of 1/8" plate with that tight of a diameter.
I wasn't sure I could do it until I tried!
What a great video Ron, I'm going to use this method to make some cones for my smithing.
Go for it!
Another truly inspiring demonstration.
Thank you! Cheers!
THIS GUY NEVER CEASES TO AMAZE ME - IT'S ALL SO EFFORTLESS FOR HIM , HE'S LIKE A GENIUS , I WOULD THINK HE WAS SOME KIND OF ASTRO PHYSICIST OR MATH GENIUS OR SOMETHIN - GREAT TEACHER
Thanks so much for the kind words! I'm glad you liked the video.
I always fund myself fascinated by your level of skill, Ron 😊. Well done!
Cheers!
your fixturing is genius, will probably never make something like this but will use the idea for other projects for sure, Thank You!!
I certainly hope this idea comes in handy for you.
Another method to make a cone like this is to cut a disc, put a hole in the center, then draw it through a cylinder. The "coin ring" crowd has been doing this for a long time. They make a cone first, then draw it out into a ring and roll the edges.
I had never heard of that technique, but I quickly researched it on TH-cam. That's a pretty cool technique, and I would not have learned about it without your suggestion. Thanks a million!
I remeber trying to make a cone out of coke can tin back when I was a teen. I just saw you overcome every problem I had from that experience. I am so thankful I found you on TH-cam.
That's very good news!
Holy smokes, Ron. This is super cool. Thanks for sharing your extensive knowledge - it's really enjoyable watching your videos.
My pleasure!
Metal that thick really doesn't want to be formed, outstanding job!
Thank you! Since most of my work has been with automotive-grade sheetmetal, 1/8-inch (3.2mm) material seems heavy to me. But some people work with metal 20 times that thick every day, and form some fabulous things with it!
What a great explanation and fantastic results. Thank you for your videos Ron!
Thanks for watching!
Hi Ron, thanks a lot for sharing your impressive knowledge with so many people around the world! It's always great to watch your videos and learn. even if I might not need to shape a thick wall cone it's very helpful to see the kind of finding a solution for a unique issue. Best regards, TOBi 👋😉👍
Hey, you just never know when you might need thick-walled cone!
@Ron Covell 👍😄👍 #WordsOfWisdom
Nice job, that is a very ingenious way to form them. I have done small cones from 5/8 stainless by bump forming on a brake but those were a much shallower angle.
Well, bump forming is certainly a viable technique. Unless you have a HUGE window die, you'd almost have to make s cone in two halves.
@@RonCovell most of the big ones,i.e. 2"thick aluminum with a 15' dia, I did were in two pieces. The smaller ones were one piece. I worked off the end of the die.
You know, I don't own a press brake, and it didn't occur to me that you can work off the end of the die. I can see lots of great possibilities with that setup!
you are a metal wizard, just amazing
Thanks for the kind words!
Well done again ,I love projects like this, watched this video already three times , I am truly amazed at how your mind works in finding simple/practical solution to different problems.
Thank you very much!
I would love to see a video about how you fabricated the suspension uprights with the ball joints and tie rod ends...
Yes - that was quite a project. Perhaps someday I'll go into more depth about the construction. There were some special challenges, indeed. I did add just a little more detail about the process in this video:
th-cam.com/video/Vr9mqC27fLs/w-d-xo.html
Always a pleasure watching you work.
Thank you, sir!
Wow Ron! You make these cones look so easy to make! Brilliant, as an earlier comment stated! Thanks for all your time and sharing all of your great technics! 👍😎
I'm so glad you liked this video!
such precision work you do using this sheet metal techniques amazing skills and problem solving.
Thank you very much!
You are the Bob Ross of metal work! Great presentation.
Wow, thanks!
Thank you for sharing this beautiful technique for making such beautiful cones. The video was a great delight and joy for me to watch, such mastery over such a complicated and beautifully symmetric shape.
You are so welcome!
Tremendous work as always. Thanks for making this video!
I'm very glad you enjoyed the video.
As usual, thank you very much Mr. Covell!
You're very welcome!
This is why I stopped watching TV and am madly in love with TH-cam. You sir are a metal working god!
Matthew - I'm so glad you enjoy my videos! For what it's worth, I have not watched much TV for the last 30 years, but I love the vast selection of content available on TH-cam.
another thoughtful piece of work! stellar
Thanks so much!
Nice work, you are a master craftsman. Innovative methods and great results. Thanks for sharing.
My pleasure!
The design application are very interesting, a shape which has not been used over and over.
Glad you like it!
GREAT VIDEO RON, WOULD LOVE TO SEE MORE OF THIS HEAVY GAUGE METAL SHAPPING
You might enjoy this article I wrote:
www.motortrend.com/how-to/making-stainless-windshield-posts/
@@RonCovell THANKS RON
THAT was extremely COOL! Thank you for that!
Glad you liked it!
Ron sir you the best in fabrication. Genius man.
Thank you so much for the kind words!
Wow! This is genius, truly it is Ron! Thank you
Glad you like it!
Ron! Brilliant again and has also confirmed an answer for myself regarding a collaborative project. The project will involve forming a three foot long odd shaped tube from 18g steel. For fun and interest I was going to use a highly geared down winch type gearbox to turn the former against a roller.
Trev - I'm so glad that you had a chance to view this video, and that you liked it! I hope you can find a way to use a similar idea for your collaboration. My opinion is that for a small number of parts, motorizing it might be more trouble than it's worth.
@@RonCovell you’re probably right there Ron, I wonder how much leverage it will take to move? But that’s the great thing about doing something like this. Sometimes you’re surprised about how easy it was and other times seemingly simple things are harder to achieve than expected.
Trev - I last used those cone-rolling fixtures more than 25 years ago, and I forgot how much leverage it required. If you look closely at the video, when I made the first bend, you'll see that I had welded a couple of extra feet onto the handle to make it easier to form. The tighter the radius of the bend, the more force is required!
@@RonCovell yes I got used to making some 4ft long sections from 20g in the folding machine, then I had to make one from 18g and I couldn’t believe the difference in force I had to use.
You got it!
You, sir, are a wizard! Beautiful work!
Thank you kindly!
Stunning craftmanship.
Thank you!
Nice work Ron! I was wondering if you could drill a series of holes in the large end of your mandrel or have a hexagonal lug on it to eliminate the need to weld a piece of metal to the cone material? You could just turn the mandrel with a dedicated tool handle to form the cone without the need to weld and cut off the handle each time.
That could probably work, but I think the screws that hold the blank to the mandrel would need to be beefed up, since the high torque loads would try to shear the heads off.
After watching this video, I'm just amazed. You are a true master of engineering. You use the K.I.S.S. concepts. You make things look so easy but I know it's not. Keep up the great video!
Wow, thanks! I do work hard to keep things as simple as I can!
Amazing ingenuity. Thanks Ron!
Thanks for watching!
That was very interesting. A well thought out execution.
Glad you liked it!
This is a really good method for those materials that dont play nice with a lathe.... looking at you Titanium and Inconel...
Gosh, I've only used these cone-forming tools on mild steel, but I guess they would work on the more exotic stuff, too!
You have made my mind racing master Covell!
I hope you get some good ideas!
@@RonCovell boy, oh boy!
That is a great way to do it. I own a fab shop and will make that part in 2 sections and use a press brake and bump brake the half's to shape then sand the creases out. Faster my way but your way is cleaner. Another point is bump brake long cones is possible as is thickness. It is up to how big is the brake press.
Yes, I have seen huge cones made from VERY thick material made by bumping with a press brake. I don't own a press brake, so I can only dream!
I've done a good bit of the same, for frame work for motorcycles and cars, might I suggest you put a number of tapped holes in the large end of the form for the handle. I've done much the same, with a steel mandrel, weld the seam off mandrel, and pull it down after cleaning up the weld. I really like your setup for rolling, I've always freehanded the steel, and see much better results. Thanks for sharing this.
Great idea!
@@RonCovell Hi Ron, I've thought on this since I saw your video, it would be fairly easy to key or pin a gear on the end of the tapered roller, and crank it over with a lever and gear drive. That would also allow changing directions, and doing complex shapes beyond cones. I don't do much in that line any more, age and rotator cuff injuries, but thought you might find it of interest. If this "energy shortage" goes on, I might well be shaping some large cones for equipment for fuel. Semper Fi, John McClain
Thanks for giving this more thought, and sharing your ideas with me and everyone who reads these comments!
Awesome video! So glad youtube algorithm suggested this!
Hey, nobody is more delighted than I am!
Pure magic. Amazing handywork!
We aim to please!
I just stumbled across this video randomly. Great technique 👌 subbed
Awesome! Thank you! Be sure to check out some of my other videos - I have around 80 available on TH-cam.
If you machine a hex into the end of the mandrel, you can use a big wrench to drive it instead of welding to the piece. Assuming the 10-32 screws are strong enough.
You are correct. I do think it would require larger screws (or a lot more of the dinky ones)!
I just watched this again to remind myself about the techniques of welding fixtures to the parts and then erasing all evidence. I'm definitely going to be using some of these techniques in parts of the bespoke drives I'm making for large microwave radio dish antennas used in Earth-Moon-Earth communications instead of machining the cones from solid stainless. Another very useful video, thanks Ron
I had no idea this technology might work for the highly-precise fabrication needed for microwave communication!
thanks! I've been wondering how to make cones for various applications. Very useful for me!
Glad it was helpful!
Very nice method, worked well.
Randy - thanks so much! That means a lot, coming from you.
i'm so glad to see your video and how to make
I'm glad you enjoyed it! More videos on the way.
Another excellent tutorial! Thank you!
You are so welcome!
Interesting and informative as always,I would love to see how you would go about making a bullet shape like the dagmars on a 1950’s caddy.
I make a large bullet shape in this video:
th-cam.com/video/ES2g7OR9bic/w-d-xo.html
I went to a Rolling Cones Concert once. It was awesome.
I love how simple everything you do is
Shows just how spoiled we are with cad when everything had to be made this way before
Thanks - I like it when I can keep things simple, too!