Archive for August, 2006
August 29th, 2006
In a previous post on “What splines are best” I was hoping to get a response from the modeling fraternity to see what the material of choice was but with dismal results. Not one opinion, I can only assume that the majority of modelers no longer care or use the spline as a means of ensuring a quality surface, maybe the digital world has taken over and it’s just the case of scraping out the mill marks and calling it a day. Even so I’m sure that many modelers do use splines for controlling the surface and with that I will share my findings with using carbon fiber.
Since that posting our studio has made numerous carbon fiber splines with great success, gone are the twists in the spline that you associate with wood, now we have the option of using the straight carbon fibers. This success did not come overnight though, it took several attempts to get the right amount of resin to carbon fiber, the thickness was also a factor. With carbon fiber it tends to be more rigid than the regular wooden spline so a thickness of 6.0mm in wood is more flexible than a carbon fiber at 6.0mm. To get the same sort of feeling we found that the thickness would have to be reduced by 1.0-1.5mm for the same length and width on the carbon fiber spline.
The cloth that we were using had a thickness of approximately 0.012″ therefore twelve layers would give you a 4.0mm spline including resin, fifteen layers a 6.0mm spline and so on. These sizes are not exact but it will give you the general idea.
To ensure uniformity and flatness, the surface plate was used as a base for the resin lay-up, with spacers to control thickness. The first operation is to paste wax the plate and buff out to reduce the amount of grab the resin will have to the surface plate. On top of the lay-up a 6.0mm Plexiglas® sheet was placed together with a large Norton angle plate to flatten the the layers of the fiber glass to the desired thickness. The whole process required team participation to ensure minimal mess, laying down the carbon fiber with two people reduces twist in the weave and minimizes loose strands. The wet resin is worked into the cloth to eliminate any air bubbles or air pockets that will spoil the aesthetic look of the finished sheet, care has to be taken to place the Plexiglas® onto the spacers without introducing any air while the Norton angle plate is placed on top to squeeze out any excess resin until the Plexiglas® actually beds down onto the spacers.
The curing process is overnight and only the next day will tell if the surface is free from any air intrusions. The additional precaution at the setup stage will eliminate a lot of unwanted surface blemish giving a glass like finished surface. Luckily for us the outcome was successful, giving us a sheet 1650.0 mm x 300.0 mm x 4.0 mm in size, enough for four 800.0 mm x 75.0 mm, two 600.00 mm x 50.0 mm, one 1600.00 mm x 90.0 mm and one 400.0 mm x 50.0 mm carbon fiber splines.
You may well ask, “How do you cut up the sheet.” The answer is simply on a bandsaw but remember to use safety precautions such as dust masks, extraction system and safety glasses. These items are a must to keep the fine particles to a minimum. The bandsaw blade should only be used for this one task as the saw set will quickly be removed with this type of material, cut slowly and let the saw do the work and do not power push it through. Time taken cutting the material will reduce the amount of finish work later. Once the splines have been cut to width and length the edges can be flattened by using long board self adhesive sheets stuck to the surface plate. If the bandsaw cuts are such that there is minimal work to attain a completely flat edge then 120 grit is sufficient to finish the spline, if there is more than a little work, use a more aggressive grit such as 80 and then finish off with the 120. Sand the edge of the spline on the longboards using a bracket to keep the edge at ninety degrees to get the best results.
In a nutshell that is the easiest way to make your carbon fiber splines with minimal equipment. I found that they were very uniform in thickness and cut the hard clay easily. The only thing I found a little disconcerting was the weave, it’s very strange on the eyes when checking the surface for hollows compared to a wooden spline. The checked effect of the weave and the high gloss of the resin is a total reversal compared to the wood, it’s something you have to get use to I guess.
What do you think? Leave a comment or participate in the poll.
August 16th, 2006
Darren Rowse of Problogger sets the group writing project for this week as being, lists. It just so happens that it fits in nicely with the information that I would like to portray on this weblog. In essence, to compliment my claysculptors website by offering information to clay modelers/sculptors who need a central resources site for reviews on available modeling tools or how modeling tools perform in real world applications, couple this with material reviews, how do I topics and industry news, it should make for some informative reading.
With that in mind where would I start for this group writing project. The first thing that comes to mind is you cannot start any model or sculpture without a basic set of modeling tools. Anyone first starting out is always eager to scrape on the clay and try to create a smooth acceptable surface, so let’s start with a list of Industrial Clay Tool suppliers.
This first list will contain websites and individual people who are known to the modeling community for supplying these specialized tools at great prices, quality of workmanship and availability. I have tried to cover the entire globe by including suppliers from America, Europe and Australia, that way anyone interested in purchasing tools for their own use will be able to contact the nearest supplier to themselves to reduce the shipping cost. This list is far from complete but it does cover what I would call, “The standard for hand modeling tools.” Each of these individual sites will offer more than the suggested industrial tools so in addition, these links will also offer a mountain of invaluable information.
- Chavant
Chavant has been a supplier of premium modeling clays since 1892 when the original formula was developed by a French chemist. Today we find there are numerous grades of clay ranging from Fine Arts to Industrial Clay. Each of these clays can differ in hardness to suit your particular application. To compliment their modeling clays they also have available different size rakes and wire tools with a minimalist set of steels, all at a reasonable price. These can be purchased as a set or individually.
- Kemper tools
Kemper tools have been suppling specialized tools to the ceramic arts for over 50 years. They are renown for developing new tools to met the demands of sculptors and artists, with the majority of these tools being available through art supply warehouses. The more industrial type tools such as rakes and wires are readily available through an online catalog. I have not personally seen the industrial tools available at any of my local art suppliers.
- kolb
Kolb is a reknown German supplier of modeling materials for over 100 years and has been a long time leader in supplying industrial clays to many of the European studios, couple this with their outstanding tool selection it makes it a go-to site for tool purchasing. Many of the tools can be purchased individually or as a full set complete with carrying case. The tool selection varies from wiretools to rakes, individual steels, acrylic or aluminum radius kits and texture rollers. To purchase these tools it would appear that you have to download the form and fax your order through.
- Styling Clay International
Styling Clay International produces Chavant Hard Styling Clays and distributes them throughout Europe and the Middle East. To support the clays they have available the same tools as presented by Chavant but purchased in GBP.
- Cerra Modeling Tools
Cerra Modeling Tools are produced in Victoria, Australia and are manufactured from high tensile steel with injection molded graphite polymer handles making them extremely durable, light weight and solvent proof. All available tools are based upon industry standards which include rakes, wires, finishers, angle tools and acrylic curves. All purchases are by fax or email with a six weeks delivery from time of ordering. Tools that are in stock will be dispatched on receipt of payment.
- Kochi Corporation
Kochi Corporation is based in Torrance, California and is a major supplier to the West Coast studios of modeling tools and equipment, Japanese tooling board, rice paper tapes, design stationary, modeling films and sheets. Here you will find an assortment of modeling tools from major independant companies. Ordering is by way of a downloadable PDF form that is then faxed back to the home office with product requirement information.
- Randy J Hilliker
Sculpture tools by Randy J Hilliker is a small independent toolmaker who makes tools on demand at prices that are hard to beat. The selection available is confined to finishers, wires, rakes and steels. Although the overall appearance is not as good as the commercially produced sculpting tool the actual application is probably better due to experience of the manufacturer. Handles can be purchased in exotic timbers and are not the generic shape as typically associated with the mass market manufacturers.
- Modelling Tools
Modelling Tools are based in Germany and appear to be an outlet for Cerra Modeling Tools. They have the same basic selection as Cerra with the addition of carbon splines, shutline tools and an adjustable mouse. There are various methods of payment, including credit cards, paypal, wire transfer or business check. No doubt the quality of the tools is first rate covered by a twelve month manufacturer’s warranty.
As I said previously this is by no means a complete list, it only deals in websites that have the ability to be viewed in English. Any websites that also provide the same type of modeling tools associated with Industrial Sculpting and can be translated to an English text I would be very interested to be made aware of. I know there are several very good Japanese suppliers but because of the language barrier there is no way of posting the links. Even so all of the associated links should be able to supply any newcomer with the necessary equipment to start their career in clay modeling.
August 14th, 2006
On the wave of J.D.Powers and Associates 2006 Vehicle Dependability Study on August 9th, General Motors announced one day later that it will put into production the dramatic vehicle that they had on show at this years North American International Auto Show, the Chevrolet Camaro. The long awaited return of Chevy’s muscle car has prompted many an enthusiast to bombard the corporate Blog demanding its return.
Since the demise of the fourth generation Camaro in 2002 with a little over 42,000 units being sold, the pony car war was handed over to Ford Motor Company who now has the segment totally to itself with the Mustang. With Dodge expecting to bring to market its own vehicle, the Dodge Challenger in early 2009 to compete with the Ford Mustang what was GM to do. There can be only one answer, bring back the Camaro.
Rick Wagoner in his statement said, “The Camaro would commence production late in 2008 and be on sale in the first quarter of 2009.” The likelihood that the production vehicle will be very close to the concept will only wet the appetite for those already chomping at the bit. Couple this with improved fuel economy, better fit and finish and a rear wheel drive platform, things are certainly taking a turn for the better. Available in V6 or V8 format with stick or automatic transmissions. I can already see the next headline from the Pontiac brethren, “Where is our Firebird.”
With the Australian arm of GM, Holden, being the RWD specialists they will get the engineering task of bringing the Camaro to market with “no compromises” in the words of Bob Lutz, with North America getting the job of productionisation of the design. This can only be good news for everyone who is a diehard muscle car fan and no doubt in 2009, when the first cars come to market, we are going to see some extraordinary sale figures for both GM and DaimlerChrysler. Ford may be enjoying it’s solo existence as of now but those days are number as the pony war is soon to heat up.
August 8th, 2006
Just recently a colleague of mine decided to purchase a couple of clay mice from a renown German clay tool supplier, Kolb. He would collect them in England, his rational was, he was returning to the UK and it would be easier to have them shipped there and receive them quickly and bring the tools back with him. This way they would not be mislaid at the post office during his absence.
On receiving the items he was surprised to find out that they had been milled from aluminum extruded stock, the type of aluminum that is used for double glazed window frames. This type of aluminum is not the hardest grade but being purchased from a reputable supplier and coupled with German craftsmanship, he never questioned it but he did have his reservations. Generally you would never question the materials used or the workmanship, as in all German made equipment it is usually of the highest standard. These clay mice were machined nicely but would they stand up to the use on hard industrial styling clays, afterall they were manufactured for that very purpose.
The cost of these two items were 25.00 Euro’s for the small mouse (32.00 USD) and 33.00 Euro’s for the large mouse (42.50 USD) so the actual monies that were paid for these items was close to $100.00 with tax and shipping cost. When you consider that Industrial Clay Tool manufacture the same items made from steel, brazed together for strength and anodized for protection and aesthetic looks at a cost of an extra $50.00 then maybe the extra cost would be worthwhile. They are manufactured in the USA but the only drawback is you usually have to wait a while for them to be shipped. These tools tend to have a waiting period because of the popularity amongst the sculptors. They are what I call “The industries benchmark.”
OK, the small mouse from Industrial Clay Tool is $56.67 and the large one is $83.33, these can be purchased through Kochi Corporation who acts as the vendor for Industrial Clay Tool as they have no website of their own. My own clay mice are 20 years old and they have been used on the hardest clays known and have yet to let me down.
The only visual thing with my mice is it appears that the anodizing is rubbed thin with a little rust showing now and again due to handling.
With his return to the studio my colleague shows us his latest purchase and we all agree that it’s a little disappointing that they were made from extruded aluminum but we thought they would do the job nevertheless. I myself have made the same type of mouse from aluminum T-bar stock and have found it to work quite satisfactory, maybe not as nice in the visual stakes as the Kolb tools but even so the dimensions are very similar. This is what I use to use before the purchase of the steel equivalent and I still keep it, just incase I happen to misplace my steel mouse. I have made the steel type mouse using the Industrial Clay Tool mouse as a guide which you can see on my Claysculptors website.
With the projects mounting up in the studio the new tools were soon put to the test. This particular instance was to cut in the cowl line on a 1/3 scale model, not a big job by any means just a case of releaving the clay and extending the glass plane forward. For this task he was going to use the large mouse because the depth was at the maximium point for the small mouse. The clay we are using is Chavant I307, a reasonably hard clay that can be milled with good results and finished to a high level.
On the first cut to the cowl line the large clay mouse promptly folded over to the astonishment of my colleague making the tool totally worthless, with no chance of straightening the cutting face without snapping the clay mouse completely. From that moment, the high regard for these particular tools hit rock bottom and confirmed his first impression. The material was not strong enough to meet the task at hand.
For me, what comes to mind is, why didn’t Kolb state what grade of aluminum was used to make the tools. Nowhere on the website does it state the material used for the clay mouse even though you can clearly see that it is some kind of aluminum extrusion. There are so many grades of aluminum, from the very soft to the very hard that a quick statement indicating what is used can easily be looked up on the internet so that the buyer can determine whether the product is a good deal.
Needless to say the company has been contacted about this inferior product and my colleague is awaiting the outcome. Hopefully it will be resolved to everyones satisfaction.
August 2nd, 2006
As the rumors of the past week filter through, Peter Schreyer of Volkswagen/Audi fame is leaving the German company and heading to Kia to head up the Kia Global Design Operation. For Kia, this must be the coup of the century giving them the much needed credibility that is always hard to deliver in an environment of heavy weight car manufacturers. Kia’s quality and design language has improved dramatically over the last five years and couple this with a ten year warranty and market beating prices it’s hard to find a better deal. Now with Peter coming on board, his experience of Volkswagen’s no nonsense approach to quality materials and fit and finish will no doubt propel Kia to even greater heights.
With his new position he will be influencing the future design philosophy for Kia which can only have the competition more than a little concerned. I should imagine that we will be seeing a bolder more masculine looking Kia in the future rather than the cute Kia of today.
With the latest sales figures just released the momentum of the Korean manufacturing group Hyundai of which Kia is a part of, is in full swing, with the group enjoying a 3.7% rise in sales over the same period a year ago with July sporting a 4.5% increase in sales over the same period. With sales in an upswing what better time to bring on a new Design Chief, ensure the momentum, built confidence in the brand and pursue great new products. For me this is a totally different company to the one that I worked for in the early 90’s when it opened it’s first Design Studio in Southern California.
Today’s Kia has confidence, purpose in design and a resolve to become bigger, combine all these factors and it is only a matter of time before they will be snapping at the Japanese manufacturers heels, after all wasn’t it the same thirty years ago for domestic manufactures when Japanese cars started to make in roads to the Big 3’s domain.
Peter’s pedigree is unquestionable, graduating from the Royal College of Art in London, England, with a “Master of Transportation” design degree, chief designer for Audi, chief designer for Volkswagen. Worked on renown vehicles of today such as the Audi TT and the Audi A6, all in all Kia must be looking to the future with great anticipation.
