After the CAD work was finished it was time for Brett to get started cutting, welding and rolling some steel.
First all the points were cut using a plasma table. The flat points were then loaded into a press brake where they were folded at the center. Next, the center cylinder was rolled from a rectangular piece of flat steel. After that was complete, the gas metal arch welder was used to tack and final weld these 5 pieces together.
It was also at this time that the smaller intermediate vanes were pressed and welded into place.
The large outer ring and degree markers were next. Four separate arched pieces were used to form the oval.
These were cut using the plasma table. Notches were cut out of the arches for each degree marker to slip into. This made for a very clean assembly. The arches were all welded together to form the sturdy outer ring.
Next the compass was welded to the outer ring, and it was really starting to take shape at this point.
The dome took the most amount of time to complete. Its made of a series of steel rings stacked on top of each other, welded together, then set into the CNC machine for cutting. Brett took the time to caliper and position each ring on the next for proper placement. The rings were clamped for a secure hold and welded on the inside to make a solid structure. Finally, it was loaded into the CNC machine where our map was cut.
For the final fabrication step, the compass and dome were attached.
