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Thread: Chill Out Rally. Behind the scenes - Trophy manufacture.

  1. #1
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    Chill Out Rally. Behind the scenes - Trophy manufacture.

    For anyone who may be interested, and in particular anyone who came to our rally would be aware that the region take some pride in having a unique offering with regards to our bike trophies. In the past 2 years these have been machined form three billets of aluminium on a three axis CNC machine. This year unfortunately do to circumstances beyond our control we no longer had that facility at our disposal at the right time so an urgent alternative had to be found. In the end we came up with a fabricated design that could be made with more available process. This is how it went.

    First up the Skull had to be redrawn so it could be made from 10mm aluminium plate water jet cut to get the profile. The "teeth" would be milled later.

    Click image for larger version. 

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    Next the bases were milled on a Bridgport machine from the material originally destined for the CNC version. It was designed to take a proprietary data plate which would be engraved with the categories.

    Click image for larger version. 

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    The pitch of the fins was selected to be the same as the fins on a Twin Cam engine.

    Click image for larger version. 

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    The bases were then masked prior to etch priming and painting.

    Click image for larger version. 

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    Next the uprights are machined from 25mm steel stock and the mount plates are TIG welded on.

    Click image for larger version. 

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    Bases now complete.

    Click image for larger version. 

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    Skulls have there teeth cut with a ball end mill and the eye sockets painted black.

    Click image for larger version. 

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    And now the finished trophy. The one on the Left is the new one and the one on the right the 2017 version.

    Ready to give away at the rally. Not too shabby even though I do say so myself. Time to start working on 2019 version.

    Click image for larger version. 

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    Last edited by Gizmo; 26-06-2018 at 10:25 AM.
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  2. #2
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    Re: Chill Out Rally. Behind the scenes - Trophy manufacture.

    Quote Originally Posted by Gizmo View Post
    For anyone who may be interested, and in particular anyone who came to our rally would would be aware that the region take some pride in having a unique offering with regards to our bike trophies. In the past 2 years these have been machined form three billets of aluminium on a three axis CNC machine. This year unfortunately do to circumstances beyond our control we no longer had that facility at our disposal at the right time so an urgent alternative had to be found. In the end we came up with a fabricated design that could be made with more available process. This is how it went.

    First up the Skull had to be redrawn so it could be made from 10mm aluminium plate water jet cut to get the profile. The "teeth" would be milled later.

    Click image for larger version. 

Name:	20180614_140404.jpg 
Views:	32 
Size:	111.5 KB 
ID:	30692


    Next the bases were milled on a Bridgport machine from the material originally destined for the CNC version. It was designed to take a proprietary data plate which would be engraved with the categories.

    Click image for larger version. 

Name:	20180614_094516.jpg 
Views:	32 
Size:	56.1 KB 
ID:	30693


    The pitch of the fins was selected to be the same as the fins on a Twin Cam engine.

    Click image for larger version. 

Name:	20180614_131305.jpg 
Views:	32 
Size:	116.5 KB 
ID:	30694


    The bases were then masked prior to etch priming and painting.

    Click image for larger version. 

Name:	20180614_135649.jpg 
Views:	32 
Size:	82.6 KB 
ID:	30695


    Next the uprights are machined from 25mm steel stock and the mount plates are TIG welded on.

    Click image for larger version. 

Name:	20180619_101050.jpg 
Views:	32 
Size:	51.9 KB 
ID:	30696


    Bases now complete.

    Click image for larger version. 

Name:	20180619_101102.jpg 
Views:	32 
Size:	136.1 KB 
ID:	30697


    Skulls have there teeth cut with a ball end mill and the eye sockets painted black.

    Click image for larger version. 

Name:	20180619_134535.jpg 
Views:	32 
Size:	90.5 KB 
ID:	30698


    And now the finished trophy. The one on the Left is the new one and the one on the right the 2017 version.

    Ready to give away at the rally. Not too shabby even though I do say so myself. Time to start working on 2019 version.

    Click image for larger version. 

Name:	20180620_115933.jpg 
Views:	32 
Size:	122.4 KB 
ID:	30699
    I shall treasure mine Phil, by default.


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  3. #3
    Join Date
    Dec 2014
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    Re: Chill Out Rally. Behind the scenes - Trophy manufacture.

    Brilliant job on them Phil, as always. Thanks for the work you out in.
    Hard Work Never Hurt Anyone - But Why Risk It!

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