Homemade Corrugated Iron Roller (well, nearly!)
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- Опубликовано: 14 окт 2024
- Once again, I am in awe of those engineers and inventors who have gone before me. Even the invention of corrugated iron in the first place (in 1820, apparently) was a stroke of genius (and undoubtedly lots of work too). And then people made machines to roll it - and now I know how tricky that was.
I haven't given up on it at all, just need to do other things for a while..
Ok, here are some important website links. Please check them out..
Here's Tim's amazing guitar machine..
www.chordelia.com
here's our online store where you can see some of the craft things we make and sell..
www.wayoutweste...
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www.patreon.co...
and finally our FaceBook page / way.outwest.524 (Not quite sure what to do with this but we put photos and extra comments when we get around to it..)
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Sandra & Tim
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I learned a lot from this build - and went on to build a better one!
Check it out here.. ruclips.net/video/lNhEmNsELYo/видео.html
And so did we learn a lot. Thank you, not for all your hard effort but for taking the trouble to explain everything clearly. Then sharing it all with us. Looking forward to your clear thinking to diagnose and improve.
Experiments and learning is never wasted efforts Tim. I really enjoyed your problem solving.
I could't agree more.
Exactly! And saved other's time by sharing it! 😂
It's never a failure if you learned something.
Probably the best video I have seen this year. Definitely not a failure.
That was NOT a failure! It was a far better result than 99.9% of us would have come up with! The majority of us wouldn't even try it!
You dont need a LARGE MOTOR. You need a small third cog to reduce to. In other words, you need a Gear Ratio, and a motor strong enough to turn that reduced amount of required torque. I think its probably very doable at 4:1 or 5:1.
I look forward to seeing updates.
Definitely not a failure. This would be one of the best small scale / DIY / home project videos I've seen this year. You learned a lot and we learned with you.
This was really great. Thank you.
Thanks, Vitor : - )
Tim, as always, I sincerely respect your 'can do' attitude and willingness/courage to tackle new engineering ideas.
Thanks, William : - )
That was really ingenious! Really impressed with your engineering and building skills.
Thanks so much for sharing your efforts. I've been following the channel for a long while and I'm always impressed with your work. Inspiring stuff, in the shop and in the garden.
Thanks, Mason
Blessings for your hard and honest efforts to invent, and share your success and fails.
Ppl like you were part of the industrial revolution.
The tracer lathe was a win in itself. This is one of those RUclips videos that taught me something. Thank you for sharing.
loving these experiments
Thanks, Matthias. (Why are things so complicated!)
LOVE your ability to think old school. Back in the day they didn’t always have a metal shop or engineer to go to. I am very impressed and it was a great video. Well done.
Thank you!
Building a corrugated iron roller has been on my long list of things to do for years now. Thanks for sharing!
You are just a BRILLIANT engineer! I continue to be astounded at what you invent.
I love watching your thought process with these projects Tim.
I am in awe of ALL Tim's projects, working or otherwise!
Aw, thanks, Mandy!
Mini fails are just hurdles along the path to success. Love your thinking and work ;-)
All I can say, it's amazing how you love your dog.
way out guy just made things for me so easy, love you from india
You certainly did a great job creating this contraption, and it actually works!
It wasn’t wasted. It was a superbly entertaining video.
Beautiful video mate. Thanks for the taking me on the journey, I love projects like this
What I like about you the best is that you “do” things. Good for you!
We use what is called tank iron for making mining shaft collars, the metal is softer and does not kink
if you run it through a few times to get your desired curl.
Newer corrugated iron is more tensile and kinks
I didn't know that when I started, but you're right. Now I just have to find some in Ireland...
Best of luck with your project you are certainly willing to give things a go and something good always comes from that. Keep your eyes open for an old caste iron roller and one will turn up, they used them for tank making and bullnose sheeting and are still around unused and needing love
Well done Tim. You gave it a good shot.
That was an early version - it's working now..!
This is genious! Thank you very much for inspiration! I've never thought about combination of the ring roller and shaped rollers for this purpose!
I think you could made the rollers by aluminium casting which can be done in a backyard environment with ease especially for such simple shapes to be cast.
The fun and satisfaction of giving it a go, love how you turned up those wooden rollers, there's a lot of work behind the scenes in this video, you could do another one on some of the details. Could you show more of the turning with the square and round bits, thanks Tim.
This is a good start. If you look at commercial rollers the lower pair of wheels are fixed, but jack screw adjustable, in a triangular plate steel frame. Then all you need to do is apply force via bottle jack. It'll take some shimming but you'll get there in no time.
As far as input force goes, you simply need a bigger gear reduction. An old compressor motor plus a bit of bike chain and you'll be there in no time. When it's powered you'll be able to make many more cycles thus smaller displacement each cycle. That means even less input torque required.
Fascinating! I would have never thought of wood rollers!
Gee you put in a great effort. You are so clever to have built the device. Well done.
Thank you! Cheers!
I’m subscribing here just because your “failure” video, it’s amazing.
Hi ! From California USA ! I see you have some AMAZING candle stick holders in different sizes with the wood you used for this project. The wood grain design caught my eye right away. Beautiful with some stain or clear lacquer... just no steel center 😃 just cut them to different sizes & hollow out the center for a pillar candle. The bulky candle stick holders could go on a fire place mantel etc... let me know what you think ? They WILL be a hot item in your store.. oh.... maybe engraved with some animals or something ? PRECIOUS 💕🙋🏻
Ha!
I don't recall unsubscribing. Glad to find this channel again.
Those wood rollers were beautiful, really works of art!
Hi Tim,
I’m watching with interest in Australia. I salute your ingenuity and perseverance, well done Sir,
Cheers, Nigel 🍻
Thanks, Nigel : - )
We love watching your experiments and builds. Been watching for a long time, and enjoy your thought process!
To get Curved Corrugated Metal I noted the industry uses two operations....first Form straight Corrugated Sheet...then run the Corrugated Sheet again through a Second adjustable Set of Rollers to obtain required Arch needed!!!! This allows Metal Roofing to obtain/become Free Span Roofs (no Rafters or Roof Structures).....Great Video....Keep Up the Interests
So cool to see your last few videos building toward these bigger projects. I think getting a smooth roll without the kinks is probably down to the rigidity of the frame. Rethink that and I think you'd be there. A few more gears and you could get away with using a fairly small motor
Also, perhaps the corrugations on your rollers are too deep! When I've seen rolled corrugated steel in person it seems the corrugations have been allowed to get shallower along the bend.
Thanks, Ben. The problem is if the corrugations were shallower, then the sheet would be wider, so I'd end up with a pear-shaped piece, wouldn't I?
Ah yes, right you are.
Love experimenting, then contemplating the result then trying again and again, not sure how to solve this one but sure you can find a way
Good Work. The more you try the more you get better. That is how i got better. Every failure is a step closer to get better at what you are doing. The first version is never the best. You won't notice it but your mind now get more tuned into building better things. After a while you will notice yourself how far better you've gone.
interesting idea using the square pipe and pieces of ply around it , might work whell for making a thickness sander too
Yes, that's another tool on the list to make
Maybe not a perfect roller, but I bet it’s a terrific straightener. I need just that on the ranch. All my animal paddocks are covered in corrugated tin and the wind wrecks them, it’s a constant struggle to keep them in good shape. That machine would fit my needs perfectly
You have such a delightful voice and a fantastic approach to making things. I adore your work please continue to make such marvellous videos xo
Thanks, Sam : - )
genious this is absolutley fantastic fren I was looking into how to corrugate sheet metal for a mini niesen hut / iris hut / ww2 hut
And now you see why they cost so much huh? :)
Enjoyed and gave a Thumbs Up also
I like that you show all of your projects, not only the ones that went to plan. Great effort.
I have seen these planters and large water storage cylinders made of corrugated steel in a circle formation. I am not sure how many pieces they are made up of, however you could use half of one for the roof. If you find a planter/ water container that is 1.2m in diameter you could perhaps cut it up and attach it to two pieces of straight corrugated steel. It wouldn't be the same as one piece but I think it will be an easier option and perhaps more cost effective.
Thanks, but they're not available here at all : - (
I think you are almost there, don't give up‼️👍👍. Vinny 🇺🇸
I used to work for Corus in their profiling division. Curved sheets are/were part formed then full formed within the curving press. The change to peak and valley structure holds in the curve and reduces creasing.
Lubrication is also key. It reduced deviation, creasing and splitting.
Your design is fine... but:
A. Make the form 1-2 degrees more extreme than the formed sheet.
B. Roll half sheets: even the commercial equipment is cheaper at 1/2 sheet form factor because it's so much easier.
C. Use a pre loaded rope drive and a vehicle winch to rotate the rollers.
D. Multiple passes at fractional increases are vital. A 180 sheet on our standard hydraulic units was 5 passes. Only the "beast" that used a pre and process heated system formed them in 1 hit.
Thanks, Robert. Actually I made 40 passes to get to these curves! I have a new idea though...
@@WayOutWestx2 Ouch! 😂
Look forward to seeing it. Honestly... look at some of the stuff they do over in Africa. Saw a father and son team making steel drums using an old truck driven axle as a metal spinning lathe and seam welding with a bank of 10 car batteries! 😳 Mother of invention and all that 👍🏼
Thanks. For the effort and honesty!
Absolutely brilliant. Well done.
As mentioned below I vote for a geared down solution. And perhaps rounding out the rollers that are missing their nice round bits. That may be the source of your ripples in the sheet stock of the ripples are at a regular place in the finished profile.
Great job! And thanks for taking the time to make this video. You are much closer to your goal than you think.
Thank you! (No, the flat tops didn't line up with any of the kinks - interesting.)
Beautiful patterns on the turned wood rollers. Make more, finish them really nicely with sealant or lacquer or whatever, and sell them as art pieces to fund the project 😀
table legs!
You are one true genius, you made it very easy and affordable thing and thats too in wood. ...👍👌👏👏👏
Would gearing down the turning handle help? Obviously the total amount of work would be the same, but it might be much less tiring
Yes, you're right. I just want to sort out the kinks before I spend any more money on it
Thanks for sharing the experiment!
Very cool I've actually been looking for somewhere to buy just those rolled corrugated sheets. Well done sir!
You can make gears, is there a way to provide a mechanical advantage to the handle via a chain and gear instead of direct drive? You will have to complete more turns, but they will be easier.
Well done for the effort, time for a rethink.
Always interesting to see your new ideas. The problem seems to be the enormous forces involved to increase the curve. This is a hugh stress on the frame and you as you try to turn the handles.
The only thing I can think of that might help is heat. You're curving the corrugations across the grain, which is where it's stiffness comes from. You're compressing one ridge, and stretching the opposite valley. The result is many inches difference in length. F'ex, at 36" interior half circle at a 1" ridge/valley will be a total of 6" longer on the outside than on the inside. What you're rolling looks almost 2", which is a whole foot difference. Heat would help ease the expansion and contraction. Though it might damage the rollers...
The shelter is a good idea , but you need to turn the corrigations 90° . Go with the flow .
Once heard of a famous quote by someone that I can't remember. "Try, fail, try again, fail better." If this is not the perfect inspiration for how to ultimately reach your goal, I don't know what is.
I suspect that you will come up with what will work for you eventually Tim. I love your prototypes!👍
Fair dues to you for trying you made a great attempt I ve have often taught how to do this as there is numerous thinks you could make
Got a lot of ideas from this video. Thank you for sharing
I don’t think failure is a word anyone should ever use ,it is trying to figure something out and it is always improved upon till it works ,and I know you can use a cheap little motor with some pulleys and belts to make a gear reducer then the motor doesn’t need the torque , nice job and that’s what I do too ,take a break from a project until revelation comes !!👍
At least you ended up with great looking rollers. Maybe you could use them for rolling corrugated pasta, or as sculptures? The wood grain looks terrific.
I have often found the ability to do most any shop task can sometimes be a hindrance. Outsourcing some work saves time and money sometimes......GREAT engineering there on a tough build... G>
Thanks, Gerry. You're quite right - 'I wonder if I could make that myself' is a dangerous thought : - )
Fair play for you Tim I said it before and I say it again,there’s more in your head than you take out with a comb,,
Ha! Thanks, John : - )
I work for a company that does this by expensive machines every day. You have done well with minimal equipment.
Brilliant attempt- I enjoyed watching. I have no idea how to improve it, but good luck with the next attempt.
Thanks, Frank!
Thanks for posting, as I learned many many things, very interesting!!
I wasn't going to watch this. I live in a 1 bedroom apartment in a city with no room for rollers,LOL. but I am glad I did. I loved the idea even if it did not work %100. I was impressed when you switched from steel rollers to wood. so many people only know how to get to no, they never keep searching for yes. You did.
I wonder if you could try a different material for the roof. it is brilliant to come up with new uses for pallets.
There is a wonderful old book by ken kern titled The owner built home. it is crammed full of amazing old technology for alternative home building methods. On one of the pages was a design for Quonset type homes made from mostly cloth covered frames that were hoop-shaped and the cloth was permeated with a cement slurry. When the cement dried it created a strong roof and walls that was in a corrugated hoop shape. I wonder if you could make some hoop frames and cover them in burlap and add the cement slurry to them?
I’m no engineer, but it looks like you can benefit from having a couple of gear ratios, if your arms are hurting and stuff like that I’m pretty sure doing something with ratios and gears would be able to help on that front
That was perfect thank you wow I never even thought about wood !!!🙂👍
Love projects like this, particularly when someone else is paying and providing the muscle power. Well done!
At least we all know how corrugated sheet is curved, in case it comes up in a pub quiz!
Ive seen a machine like yours and they had the same issues, in order to solve that they've put 4 rollers on the top and 4 on the bottom and each couple had a bit more pressure on the shit so the stress on the machine was spreaded between all the rollers.
It worked really good but it did not solve the curve issiue and worked only for flat pannels
It is possible to build a multiple roller machine that the relationship between the rollers is chaning progressively so as the sheet is being corrugated its being curved at the same time, but that is adding way more complicity to the machine and deammand gear and chain system to time all of the moving parts together...
Interesting video. The tighter the radius, the more likely to get kinks.
The rolling of the flat bar worked well. How about rolling a few pieces of flat bar to make a set of ribs, then covering this with sheet steel or plastic screwed to the ribs. It is much easier to get the tight radius you desire with such a construction.
A less expensive method may be to make the ribs from PVC pipe. You would likely need to heat the pipe to get the tight radius, but you could make a template of the shape then heat and bend to the template a lot easier than rolling steel.
Dave.
Thanks for the suggestions. I hope one day to be able to show you why I'm holding out for this design..
Good effort and an interesting video.
interesting, cool that you could create the actual rollers out of ply, and they look kinda nice as well, almost like timber damascus with all the layers showing through. Gear ratio for the hand crank? maybe mess around with increacing the ratio of turns of the crank to turns of the rollers? idk how it would work with something that size though. Can you hook up a bike somehow? i feel peddling might be a lot easier than cranking by hand, leg muscles being a bit stronger and all.
If you don't try you'll never know, but that was an exceptional attempt!
GOOD GOING TIM
fine work. My work almost never works on the first go. Fun to watch
Learning experiences are always successful🏌
So the best way is to walk away brush off your hands and your injured self worth and do something you know how to.. Then overnight or a few days or weeks take another whack at it..I watched the guys with all the money to buy the correct machinery make some roofing material.It wasn't done in one roll through but several.Keep after it and thanks for showing us all your wit to go ahead with this project...great job..
I have a couple of corrugated iron curvers. Both of them motorised. One is a very very old set and one a newer set. One thing worth mentioning is that if you do not use corrugated iron that has been made for curving then you will have major problems. There are two types of corrugated iron. High tensile and soft feed. The high tensile corrugated is much thinner than the curving quality iron. In the old imperial system the gauge for curving quality iron is 24 gauge. The high tensile is 26 gauge. In the new money the curving quality is .65mm and the hi tensile is .42mm. You can curve the hi tensile but you can only slightly curve it. The curving quality iron can be curved down to a 350 radius if you have the correct rolls with very close bottom rolls. So you are on the right track. You should check though that you have the correct material to start with. I am in Australia in Queensland where we have a lot of curved roofs. Not sure if you can get soft feed curving quality corrugated in pommy land though. Hope this helps you in your quest. Personally I think you've done a great job with limited materials and knowledge of the subject. I do think though that you need steel rolls to do what you need. You will also need a very rigid frame.
Thanks for this, Phil. I'm trying to find someone here who even knows what I'm talking about. Perhaps it just doesn't exist here..
@@WayOutWestx2 I assume you are in England. It's fascinating to me that the home of where corrugated iron came from has more or less lost the knowledge of how to use those materials. Surely some company will know something about what you require. Perhaps ask some of the roofing companies.
Ireland
@@WayOutWestx2 Phil is absolutely correct about the two grades of sheet. However you've still got a fascinating experiment there. Maybe try is to heat the sheet as much as you can before attempting to roll it. The colder the metal is then the harder it will be to curve and the more likely it will be to kink. A bit of heat might make it easier and give somewhat better results. I also wonder how you'd go forming with that rig. Maybe try finding some really seriously thing scrap aluminium flat sheet and running it through. Cheers
You need rigidity of the rollers( like the heavy ones shown on that industrial one you pictured.) Then you also need guide plates to keep the material straight entering & exiting the rollers.
Hi Tim. I like you idea. If the house has a curved roof with ends does the sheet need to be corrugated? Plain sheet should be plenty strong enough at this size.
You're right and I might end up doing it that way - but it doesn't look as good : - )
The old school galvanised iron was much softer than the zincalume or colourbond sheeting we get now. The softer iron would have worked in your machine, but the new stuff is just way to hard. Thanks for sharing, was a good interesting video.
Thanks, yes that makes a lot of sense
I'm proud of your effort bro. Also, I enjoy your style and manner of speaking!!!!
Wish you lived in America near Tennessee, we’ve got those trees on our land you could use. Even a bunch of Osage orange and black locust.
Perfect!
I had the same idea. I figure wood would work ok. I didn’t have the nerve to go through with the idea. I’m glad to see that somebody did.
I immediately thought of the Anderson Shelter.
I am very impressed!
That was an amazing achievement! No mean feat to get to that level of corrugated sheet bending. For what it is worth I'd suggest that - once it is motorized- that you make smaller adjustments for each pass through the machine. Gradual deformation will help reduce the kinks. The video style was fun. The turned ply looked lovely too.
Thanks - but check out the latest video in this series - I've made some progress!
Never, never never never NEVER NEVER GIVE UP!!!!!
If at first you don't succeed, try and try again. After that you'll probably find you're flogging a dead horse.
What a great idea! I love your machine you are so inventive. Have you ever thought about doing a cheaper model with corrugated plastic and PVC piping for ridging/supports. At least it would be a cheap mock-up/visual even if it's not as effective. Hope you're able to work out all the kinks in your machine, I'm sure plenty of people would purchase these from you.
Thank you : - )
Getting the right profiles is important
If you used aquaplate (which they use for water tanks) it would not have kinked. Notwithstanding how bloody clever to make this. Well done.