Flaring holes in large sheet?

[astro_al]

Hi guys. I hope someone has a flash of inspiration on this one...

I need to cover a 1.25 x 2.5 m sheet of 3mm or 1/8 steel sheet in holes and then flare them / dimple die them.

Basically I need to make a very big version of the surface of car ramps for a trailer.

I guess the holes will be about 1 inch. My biggest drill has about a 2 foot reach before the material hits the pillar.

So:

1. I might be able to manage it with my drill, but does anyone want to give me a radial arm drill, deliver and commission it, then buy me a pint for letting them do it? (Or alternatively know of one going cheap somewhere).

2. How can I flare the holes in 3mm sheet without putting it in a press (too big). The budget for this is tight, so I'm trying to avoid building a mobile hydro ram tool to press each hole. As retarded as it sounds, I wondered about getting the dimple die tooling and taking a sledge hammer to it. Any thoughts?

3. Anyone got cheap hole flares made from non-cheese steel?

4. Any ideas on how I can get the holes cut and flared with minimal cost?

Cheers, Al.

 

[wyn]

Mag drill for the holes.
For the flaring maybe rig up something similar to an agricultural post knocker to drop a guided weight onto the flare tooling.
Or could the flare tooling be operated by a hydraulic ram pulling it together through the hole.

Edit: didn't see you ruled out the last one

 

[Shox Dr]

I don't know if they are available over here but Harbour Freight do an Hydraulic Dimple die set that pulls the two dies together. So you can use in the middle of big sheets. Cost around a £100, try Northern Tools

 

[astro_al]

Thanks guys. Shox - do you know what they call that on Harbour Freight? I can't find it with various search terms...?

Al.

 

[Shox Dr]

I'll have a look in mo, bit busy now

 

[eddie49]

The site itself uses the American spelling "Harbor".
Perhaps the tool is this one:
http://www.harborfreight.com/hydraulic-punch-driver-kit-96718.html

 

[gordon stephenson]

After cutting your holes by whatever method you choose make up a simple bottom die, then use a 1-1/2" ball bearing or similar shaped object and a 7lbs hammer.

 

[Shox Dr]

The site itself uses the American spelling "Harbor".
Perhaps the tool is this one:
http://www.harborfreight.com/hydraulic-punch-driver-kit-96718.html

That's the one

 

[Shox Dr]

After cutting your holes by whatever method you choose make up a simple bottom die, then use a 1-1/2" ball bearing or similar shaped object and a 7lbs hammer.

The sheet may warp doing that way

 

[gordon stephenson]

Hi, I don't think there would be any problem,A nice sharp blow would do the job, Why should it warp any more than the other methods suggested? any expansion of the plate would go the by the easiest route, ie: towards the hole.

 

[Shox Dr]

I say it may warp as I seen dimple die sets been used and not fully closed both sides on to the material, I've also seen it happen on a turret punch with the sheet thickness not set correctly.

 

[astro_al]

Thanks guys. that tool looks perfect - the price is unbelievable. the only equivalent I found on this side of the pond was this at 15 x the price...:

http://www.primetools.co.uk/getinfo.php?product=17207

I'm thinking now I can 'just' drill all points on the sheet with my pillar drill, and either go with Gordon's hammer idea (love the cost factor) or rig up something for my tube bender ram to press against and use that.

Sometimes I wish I lived in the States...

I'm off to find some scrap, a steel ball and a hammer.

Cheers, Al.

 

[Shox Dr]

can't be that much to import one

 

[astro_al]

Usually runs about double the purchase price, once you've shipped it, got it through customs etc in my experience.

No worries, I have a vague plan now...

Al.

 

[piman]

Hello Gordon,

that will work well as long as the underside of the sheet is firmly supported over a suitable sized hole.

An alternative but slower way is with a large inverted socket that will just go into the hole, and a piece of say 2" pipe below and squeeze them together with some stud bar and large washers. The socket needs to be a large one with a good sized shoulder.

Alec

 

[hotrodder]

Given the number of flared holes needed i'd knock up some dimple dies to fit the harbor freight punch. Someones already selling 'em...

 

[astro_al]

Agreed, but if I did that I'd be working for free...

 

[hotrodder]

My bad, way i read the thread last time i managed to conclude you were going to buy the harbor freight punch

 

[eddie49]

There's a used hydraulic punch press on eBay now, originally from RadioSpares, auction ends in a couple of days, collect only, from Warrington. Item number 180528915989

 

[Dune]

Why not buy perf sheet and flare rather than spending hours drilling?