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  1. #1
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    Default Building a sheet metal folder in India

    Elswhere in the forum I mentioned that I was in India recently.
    Part of my task there was to build a drying plant for food stuff.
    After spending much time before the trip trying to find a sheet metal shop to make some of the parts over there, it was clear that would be too expensive or they replied that they didn't have the capability... So the decision was made to train local people and to build a folder with them whilst I was there.
    What was required was a 4 foot wide folder with an operational capacity of 1mm thick sheet steel. Most of the work would be in 0.6mm gal sheet and perforated sheet. Almost all the folds were going to be just simple 90deg bends, but the design of the drying trays required box folding. These trays will be handled a lot and are expected to sustain wear and damage and would be replaced at intervals. So I decided to modify the simple folder to accommodate just the dimension of the trays to enable folding these completely.
    Since worktables are a rare commodity and my back doesn't bend like it used to for very long, we also build a sturdy work platform to mount the folder to. It will be used for laying out the rest of the work and later for processing, with the folder detached.
    The design was as easy as I could come up with. It consists of 3 pieces of 4"x4"x1/2" angle, 1" bar for hinges, G-clamps for tightening the top bar which is held in place by fixed stops.
    The setup has proven to be not only successful but also more capable than anticipated. It took 3 days to build - along with teaching two people welding and general steel fabrication skills. Oh, and making some inroads towards using PPE without being prescriptive - just using some of it myself most of the time and occasional lighthearted reminders. Pretty difficult when working at above 40 deg in the shade....
    IMAG2277.jpg IMAG2278.jpg IMAG2285.jpg IMG-20150612-WA0002.jpg IMAG2298.jpg IMAG2304.jpg IMAG2305.jpg
    Once completed, a whole lot of perforated trays were cut and made (after I developed the pattern and left one unfolded with all folds marked). We also folded all the runners for them in 0.8mm gal aheet and some doors (no photos sadly). Much of the rest of the construction were welded RHS frames with flat panels which were just cross-broken.
    20150627000216.jpg IMG-20150614-WA0013.jpg 20150627000245.jpg 20150627000359.jpg 20150627000802.jpg 20150627000955.jpg 20150627001014.jpg
    I loved the 'tin snips' I saw and bought in Bangalore. I had no idea they were available this big.... Very easy to handle and follow lines for long cuts. I now want a pair for my own workshop. Next trip....
    The whole assemly is not completed, but as progress continues, I might put up some more photos in this thread.
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  2. #2
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    Athelstone, SA 5076
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    Default

    Quote Originally Posted by jhovel View Post
    20150627000802.jpg
    I loved the 'tin snips' I saw and bought in Bangalore. I had no idea they were available this big.... Very easy to handle and follow lines for long cuts. I now want a pair for my own workshop. Next trip....
    they look like Gilbows
    I have a few pairs like that, that dad left

  3. #3
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    Aug 2014
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    North Queensland
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    Default Maybe this is the large snips.


  4. #4
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    Default

    Hi eskimo,
    I think you'll find you're looking at the wrong snips. have a look in ghe picture before the one in your post.

    Stuart
    p.s. stupid slow tablet typing lol. Also a few before the above is a picture the man himself is using them.

  5. #5
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    Default

    Hi Joe. Nice work on the folder, was it designed in the head or did you know what was required before you left? There might be an influx of folders, made in India, coming into Australia.

  6. #6
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    Default

    Quote Originally Posted by Stustoys View Post
    Hi eskimo,
    I think you'll find you're looking at the wrong snips. have a look in ghe picture before the one in your post.

    Stuart
    p.s. stupid slow tablet typing lol. Also a few before the above is a picture the man himself is using them.
    duh....how could I miss them

  7. #7
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    Default

    okay...they dont look like gilbows, but they do look like my hedge clippers but with looooonger handles

  8. #8
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    Default

    Quote Originally Posted by KBs PensNmore View Post
    Hi Joe. Nice work on the folder, was it designed in the head or did you know what was required before you left? There might be an influx of folders, made in India, coming into Australia.
    Well, they were designed on paper actually, a month or so efore I left. I had one of the Indians go looking for the materials, but due to his lack of construction knowledge and relevant English skills (the language there is Telugu), he couldn'd find the large angel iron to my frustration.
    Once I was there and we went to Bangalore together, all was revealed and I found everything needed easily with him.

    I made sketches for them to follow what was in my head.

    Eskimo et al
    The tin snips do indeed look like hedge clippers! But they are MUCH beefier forgings. At the hinge they are aout 1/2" thick. They come without handles. I welded on a pair of tubes for handles in proportioned (guessed) length.
    Here is me considering which size to buy:
    IMG-20150605-WA0056.jpg
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  9. #9
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    Nov 2006
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    Heidelberg, Victoria
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    Default Indian ingenuity

    Hi Joe,

    You tell a great story, any more snaps?

    Most intrigued with the Indian safety gear, especially the guy in sandals with the angle grinder.

    Ken

  10. #10
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    Default

    lots of pics and stories Ken.
    How about a pic of me welding - trying to fit in
    20150609_075420.jpg
    I really didn't want to show this..... but it was 42 that day and not a breeze. I just couldn't stand a t-shirt or boots... the towel was to wipe my face every couple of minutes just to see.

    IMG-20150614-WA0008.jpg
    With that much sweat on you, there was no chance of sparks burning me....
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

  11. #11
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    Nov 2006
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    Heidelberg, Victoria
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    Default In India

    Hi Joe,

    Looks like a lot of "flight rust" in India, is that the stuff they put on tools that come over here?

    Good to see you're getting stuck in, how's the grub there? Quick trips to the loo?

    Ken

  12. #12
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    Default

    No problems with food or loos. Took a week to get get used to the spices though. I made sure no unsterilised water touched my mouth though. I think that helped.
    Cheers, Joe
    retired - less energy, more time to contemplate projects and more shed time....

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