Hi, I am considering the following project and would appreciate any input!
I need to remove some minor dents from a lamp shade that is made of relatively thin aluminium and looks like it has been formed by spinning in the first place (See photos)
Possible ways forward:
My initial thoughts were to use the wood lathe with a wood forming tool to smoot out the dents (with no wooden forms). I gathered that, generally, one should not turn anything with metal in it, but not sure the rule applies as what I have in mind, as it’s not technically turning. Any opinion @woodlathetechs ?
Use a hammer and dolly set, as suggested by @ed_win. This looks like the best way forward, but I don’t really trust my finesse with a hammer. I hammered the lamp into shape in the first place and did not do a great job (photos are pre-hammering)
that shade really looks like it was made by metal spinning.
The theory behind it is very simple but the execution apparently is everything but simple.
I never tried but I have seen a few videos where very experienced machinists have miserably failed at it.
In regards to the possibility of performing this at the Makerspace, I don’t think it is doable, but I will leave the last word to the techs @woodlathetechs@metaltechs
As with most things - practice makes perfect (or at least to within tolerance). I’d give the hammering another go but practice on some similar thickness scrap until you get a feel for it. Sheet metal shaping is a real skill. You could maybe try making some gently curved wooden forms (an inside and an outside curve) then use a mallet try and flatten the metal in to the desired shape.
A shiny, reflective lamp shade is going to highlight all the flaws and be quite unforgiving, getting this back to factory finish is likely unachievable but if you can live with a few wiggles it’s probably salvageable.
Also be aware that aluminium work hardens so too much bending (via any method) could cause it to crack.
Metal spinning is much more difficult and potentially dangerous than a hammer and dolly. I’m going to have to say it’s a no go on the Metal Lathe. Sorry
Tap away gently on a solid supportive surface. It’s the support behind the dent that focuses the force. If the support is profiled to your target shape that will help. If you don’t want to put divots in the surface use a soft faced hammer or a soft drift - wood / copper. Don’t stress too much as it’s already dented. You can make it worse but unlikely. Have fun.
On the metal bench next to the pillar drill in the metal shop there are a couple of shaped heavy dollies that you can use for that purpose.
I think one is not that far from the radius you need…
I will try to dig them up and put them somewhere “findable” on Friday if you still need them by then!
Thank you Stefano, that would be lovely. I am planning to come down tomorrow afternoon and Thursday night, but not sure after friday.
Timing-wise it might be better if you can point me roughly in their direction!
Fair enough!
they are next the pillar drill, I am in tonight, so I will put them somewhere sensible and post a picture! (that is if I remember… but ill try my best)
First of all, I apologise, I forgot to take a picture for you.
Thanks to @Howard I found out we have a full set of panel beating tools that I was not aware of.
they are in one of the big white drawers in the metal shop, and for some weird reason the case has been labelled " SHOES REPAIR " (don’t ask why, nobody has the faintest idea hahaha)
Feel free to search for them, they are in a small-ish case in one of the white drawers (left-hand side white cabinet)
Only thing I ask, once you are done please put them back in the same place, we are in the process of reorganising the shop, and tools go walking so often and so far!
