Shop Bult Louver Die

I have a need to punch some louvers in an upcoming project. These things are pretty spendy. 500 to 800 dollars for a decent one. I did the same thing here as I did with the Tubing Straightener. Designed it in 3DCAD and am building it in the shop.
Here are some snapshots off my computer. The blue pieces are the punch and the white pieces are the die.
http://images108.fotki.com/v1279/pho...DIEASM5-vi.jpg
The back. You can see the actual punch in this pic.
http://images43.fotki.com/v457/photo...DIEASM2-vi.jpg
This pic shows the stripper plate in place. This plate contacts the sheet metal before the punch does. The die springs will help hold the sheet in place as the punch starts to work and also keep the metal from distorting to much.
http://images44.fotki.com/v1486/phot...RDIEASM-vi.jpg
I have gotten started on the build. The punch die is milled out and has holes laid out for drilling and tapping as well as the lower support plate that carries the punch die and shear plate.
The punch die.
http://images14.fotki.com/v390/photo...jpg?1426468662
Continued in next post.

All milled out and ready for screw holes.
http://images54.fotki.com/v104/photo...jpg?1426468659
I have a few pieces cut out but that is where I am at with this project.
Thanks for looking!
Mark

Hi Mark,

Very cool project. Keep the thread updated and we'll get the project added as soon as it's done. Neat stuff!

Ken

Great post, astroracer! Love those drawings.

Thanks! I'll try to get more work done this week. "Life" has been getting in the way the last few weeks...
Mark

I hear ya on the "life" thing. I'm getting tired of seeing car parts all over the house - I need to get busy out in the garage if I want to drive my project while I'm still limber enough to get in and out of it!

Ken

Got out in the shop for few hours today. i got the lower support plate drilled and c'bored and the punch die drilled and tapped. Surprisingly the two pieces bolted together so i must have done something right...
Drilling the base plate with guide holes. There are six of these that will be drilled out to .343 and then c'bored for a 5/16 SHCS
http://images55.fotki.com/v268/photo...1/photo-vi.jpg
One more to drill and it's ready for c'boring.
http://images108.fotki.com/v1279/pho.../photo1-vi.jpg
C'boring.
http://images43.fotki.com/v60/photos...1/photo-vi.jpg
At least all of the screws fit... :)
http://images14.fotki.com/v438/photo.../photo1-vi.jpg

continued in next post.

Once the base was ready I worked on the punch die. Set it up in the milling vise and drilled out the holes with 17/64 tap drill.
http://images16.fotki.com/v378/photo.../photo2-vi.jpg

http://images108.fotki.com/v613/phot...3/photo-vi.jpg
Tapping for a 5/16-18.
http://images46.fotki.com/v678/photo.../photo1-vi.jpg
Bolted in place.
http://images46.fotki.com/v678/photo.../photo2-vi.jpg

Thanks for looking.
Mark

Good work there Mark.

I'm a bit thick though, I think - what will it actually be used for :headscratch:

Regards

Doc :hattip:

Thanks Doc,
The punch will be used to make those "hot rod" style louvers you see on street rods and race cars. Here are some pics off my computer of the "test panel" I made while developing my punch design.
http://images59.fotki.com/v684/photo...6/photo-vi.jpg

http://images60.fotki.com/v1621/phot...6/photo-vi.jpg
Mark

Well talk about me having a 'Duhh' moment. Mark.

I get it now.

Thanks for the quick response, too :thumbsup:

Regards

Doc :hattip:

Progress looks good on that build.

Looks good do you plan on precutting slots in the sheet you are louvering?

And did you use a sharpie instead of layout fluid spray for those scribed lines? They look hand colored

Quote:

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Originally Posted by jere

Looks good do you plan on precutting slots in the sheet you are louvering?

And did you use a sharpie instead of layout fluid spray for those scribed lines? They look hand colored

---

Hey Jere, initially I do not plan on pre-slitting. I hope the way the punch is designed it will cut the sheet by itself. The proof will be in the pudding.
I used a Sharpie, yes sir. Quick and easy and it drys a lot quicker then the Dykem. :)

Haven't been out in the shop for a week. Had stomach flu for 4 days and am just getting back on my feet. Got out in the shop Friday afternoon and made some adjustments to the FrankenMill. The spindle was out of square to the table in both X and Y directions so I spent a couple of hours trueing that up. Also removed 95% of the backlash in the X lead screw and cleaned and lubed all of the ways. Took a couple of hours and, after being sick for a week I was pretty well done for the day. Anyway, the mill is working very well and getting the spindle squared up was a good thing.
This is the stripper block to help hold the work in place while punching and also to help strip it off the punch as it withdraws. This was a rough machining operation before finishing to size. I did this work last week before getting sick which made me realize how bad the spindle alignment was. You can see the lines in the work caused by the out of square spindle. I had some work to do to get it right. They were very prominent.
http://images108.fotki.com/v1279/pho...MVC112F-vi.jpg
Just looking at the block you can see the corners are not square...
http://images55.fotki.com/v268/photo...MVC113F-vi.jpg
After truing up the spindle I got a much smoother finish with no edges to catch with your finger nail. I am pretty happy with this setup. :) i was using a 1" dia. end mill so, if there was anything amiss it would be evident.
http://images57.fotki.com/v256/photo...MVC116F-vi.jpg
Continued next post...

After drilling and tapping for some shoulder bolts I mocked up the bolts and die springs that will be the working features of the stripper plate.
http://images60.fotki.com/v1621/phot...MVC135F-vi.jpg
Sitting in approximate orientation to the punch die. The stripper plate will be bolted to a 1" thick upper punch plate that carries the louver punch. I have to order that steel tomorrow.
http://images42.fotki.com/v28/photos...MVC137F-vi.jpg
Mark

Got some more work done on the die this past weekend. I made the upper punch plate and have the punch block and the punch itself roughed out.
Here are some pics of the upper plate with the stripper plate installed.
http://images15.fotki.com/v223/photo...MVC074F-vi.jpg
http://images14.fotki.com/v437/photo...MVC076F-vi.jpg
Compressing the die springs in the vise. Everything works nice and smooth.
http://images58.fotki.com/v450/photo...MVC077F-vi.jpg
Sitting in place on the lower die.
http://images16.fotki.com/v377/photo...MVC082F-vi.jpg

Here are the punch and punch block. I still have to drill the mounting holes but the hard work is done. Shaping the punch will be the last thing I do. I should be able to have this finished up this week.
http://images108.fotki.com/v1279/pho...MVC042F-vi.jpg
The punch is made from a piece of 5/8" plate and the punch block was cut from a piece of 1 3/8 x 4". I will get everything bolted up and trued before I shape the punch.
http://images34.fotki.com/v1523/phot...MVC044F-vi.jpg

Just a note about cutting and my using my Taiwanese 4 x 6 bandsaw. I have had this saw since 1978 and have spent a lot of time getting it to run and cut consistantly. When I cut out the punch block I mounted it vertically in the saw. This is a five inch tall piece when clamped in place.
http://images60.fotki.com/v308/photo...MVC083F-vi.jpg
The saw took about 10 minutes to chew it's way through this block.
http://images34.fotki.com/v1606/phot...MVC032F-vi.jpg
When it was done, the difference in width from the top to the bottom of the cut was about .001. :)
Top of the cut.
http://images46.fotki.com/v678/photo...MVC037F-vi.jpg
Bottom of the cut.
http://images46.fotki.com/v677/photo...MVC036F-vi.jpg
I think that's pretty good for a cheap azz saw. :)

I have a jet 4x6 (2nd gen) that had that same color. No way it could pull off a long straight cut like that (too much sloppy in the pivot axle area). Impressive work

I've been sidetracked a bit by mowers and spring yard work but I've gotten a bit done on the press. I have all of the holes drilled and everything bolts up and I am in the process of shaping the actual punch and getting it polished up. Right now it is in hand file mode to sneak up on the shape. I hope to give it a tryout this weekend...
http://images49.fotki.com/v302/photo.../photo2-vi.jpg

http://images49.fotki.com/v302/photo.../photo3-vi.jpg

Initial shaping was done on the mill with the cheap angle vise. It did the job.
http://images14.fotki.com/v437/photo...9/photo-vi.jpg

http://images14.fotki.com/v438/photo...9/photo-vi.jpg
Continued in next post.

All sharp edges in this pic.
http://images108.fotki.com/v1221/pho.../photo1-vi.jpg
using the flap grinder to soften the edges and round the corners.
http://images20.fotki.com/v193/photo...9/photo-vi.jpg
I'll smooth this out with some emery paper but it doesn't have to be perfect. All of this is on the underside of the louver anyway. it just has to be consistant.
http://images42.fotki.com/v1569/phot.../photo1-vi.jpg
Mark

WOW that's a keeper astroracer real nice....:O)

Nice job Mark. Thanks for posting such a comprehensive, well-organized build thread. Looking forward to updates.

Al

Thanks guys! I didn't take the time to finish this up over the weekend. I was installing a DRO on the FrankenMill and that, with a little bit of yard work and some garage saleing ate up my weekend...
Mark