making your own corrugated panels

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Bufferstop
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Re: making your own corrugated panels

Postby Bufferstop » Mon Sep 10, 2018 11:39 pm

Thanks for the files, proved one thing, it will need better resolution than PLA filament and my printer can manage! You've probably noticed that laying down a solid from repeated application of extruded plastic leaves a surface that has fine ridges on it. Line it up one way and the teeth of the roller get rounded off, probably OK if you were actually laying down the finished surface, but far too rounded to press clean corrugations. Turn it round and the tops of the corrugations start to resemble a hacksaw blade. I think this may be a job for a laser sintering tank, an order of magnitude better in resolution. Alternatively go back to the old methods, use some thick wall plastic pipe and a milling head to cut the grooves. Sorry that wasn't a solution but at least I now know how to import .stl files.
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peroni
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Re: making your own corrugated panels

Postby peroni » Tue Sep 11, 2018 2:52 am

There are a couple of hand tools that you can get to make the corrugated roofing, here is one such tool and a video that shows you how it is done:
http://www.brunelhobbies.com.au/ironmaker/ironmaker.htm
Secondly: Another tool is available in craft shops, it is used to make corrugated paper and it is called a Paper Crimper, here is a link below to show
you what it is, this is an American site but it should be available just about in all countries, I know it is here in Australia.
https://www.craftonline.com.au/collecti ... s-straight
Also on Ebay:
https://www.ebay.com/bhp/fiskars-paper-crimper

brit-in-bama
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Re: making your own corrugated panels

Postby brit-in-bama » Tue Sep 11, 2018 3:22 am

thanks bufferstop, and thank you for trying, I did think the layers would be a problem, it all looks so big when you draw it in cad, but in reality I know the sizes, so for now I will just carry on with my roller-mill as it is, it works and it was cheap to build, but I will still keep one eye open for either an SLA printer or machined rollers from some other device, once again thanks for your time and knowledge bufferstop.

hi peroni
yes I have had one similar to the top one (visiting dog chewed it up), and also I used a piece of the ribbon tape from the hard drive to the motherboard on a pc, and these are fine for individual panels, but at my last count on my next project it will take 600 individual panels just to cover the main building, and there are four more buildings of various sizes, and that would be back and finger-breaking work over several weeks, but with this little roller-mill, it will probably take a 1/2 hour or so, one hour at the most, because it can produce a strip 11 inches long, which is 12 complete panels in just under 10 seconds, plus I can just make them as I need them, oh, and my ex had that paper crimper and the ridges were just too big, probably fine for o-gauge or even gauge 1, but thanks for your interest and comment.

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End2end
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Re: making your own corrugated panels

Postby End2end » Tue Sep 11, 2018 11:21 am

I have been working on my station building and have been wracking my brains for a way to do it without any specialist tools or complicated mechanisms and I may have cracked it!
It's all in my head at the moment so nothing to show until I've built what I need, but I will post my idea hopefully later today.
The thing is, it may not be to scale. :?
Thanks
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Bufferstop
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Re: making your own corrugated panels

Postby Bufferstop » Tue Sep 11, 2018 12:42 pm

E2E, I've been hand producing them for years, using a spare Will's corrugated roof sheet. You know, the ones that scale to around a foot thick! I use turkey foil and a block of stiff foam to press it down into the grooves. You just have to treat them carefully until you have them mounted on the backing card. They are usually good enough to see the representation of the overlap, and occasionally I can get a full set of nail heads as well.
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Re: making your own corrugated panels

Postby End2end » Wed Sep 12, 2018 7:02 pm

Well my idea didn't work. :?
I tried gluing toothpicks side by side on 2 pieces of wood to make a press.
It came out rubbish. :lol:
Back to the drawing board or buying solution.

What is the part number for the Will's corrugated roof sheet please Bufferstop?
Thanks
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Re: making your own corrugated panels

Postby Bufferstop » Wed Sep 12, 2018 11:14 pm

Wills SSMP219 4 pieces corrugated asbestos - £3.95 from Gaugemaster. They were just the first I looked at. I couldn't find it this time but they also do a clear corrugated sheet, which is a more scale like thickness, but I seem to remember the corrugations were a bit oversize.
What would have happened if you had pressed the cocktail sticks into a block of plasticine then poured some of your Linka plaster into it?
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Re: making your own corrugated panels

Postby End2end » Thu Sep 13, 2018 12:04 am

Thanks Bufferstop. I just grabbed some.
Thanks
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Re: making your own corrugated panels

Postby Mountain » Thu Sep 13, 2018 9:41 am

Just thought I'd add some pictures of a prototype building as we are rebuilding it. We had neglected it a bit but now, withte massive help of my brother (s), and donated sheets along with the loan of scaffolding, it is slowly getting back to how its meant to be. I am not one for going up there though I have been up on the lower bits in the past with a paintbrush where I probably spent more time admiring the views of the sea and coast then painting!
We now have more strength to the structure with a few extra A frames. :)
Out of interest, the six main supports holding up the main part of the barn are railway rails, so it would make aa relatively easy modelling project to anyone who wanted to copy the idea in a smaller scale.
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peroni
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Re: making your own corrugated panels

Postby peroni » Thu Sep 13, 2018 11:05 pm

Hi brit-in-bama,

You are pretty right about the two methods that I mentioned especially when you need to make so many, I think your
fingers would be down to the bone by the time you made over 600 panels.
Bufferstop came up with the right idea, but finding the rollers would be the problem, after I done a bit more digging
I came up with two things: the corrugated rollers could be found in stepper motors but you would have to fine two identical
motors, and take out the rotors, also you need to find a motor with a lot of steps as the smaller amount of steps the bigger
the corrugations would be.

Here is another method that has been shown to work OK for this person.
https://www.youtube.com/watch?v=sAYunBL29gY&t=2s
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brit-in-bama
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Re: making your own corrugated panels

Postby brit-in-bama » Fri Sep 14, 2018 2:30 pm

thank you peroni for that link, I used to follow martin a couple of years ago, he has some great ideas, I did see others doing a similar thing with other substances, however, I do use a wood glue that dries clear, and will try that method on some ribbontape and see if I can make some clear panels and use them as roof lights, we have both clear and white in our workshop, so when I add some low level lights they should be translucent, I dont need that many so it wont be that hard. I did investigate the stepper motor avenue,but the one I had (dead) was a different kind, and only 10mm across the roller, thanks to all, this is a great forum.

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Re: making your own corrugated panels

Postby End2end » Fri Sep 14, 2018 4:16 pm

Bufferstop wrote:What would have happened if you had pressed the cocktail sticks into a block of plasticine then poured some of your Linka plaster into it?

I think they would end up the same as the plastic sheet. To thick.
Is there a way, perhaps with spray glue or something, to stiffen the foil once I've formed the sheet using the SSMP219 as a mould?
It will be glued to a card backing afterwards but I mean before that? As I need to cut the roof lights out of it.

While waiting for your reply Bufferstop I jumped the gun and purchased the SSMP216 Corrugated Iron sheets by mistake so will have that one as well. :lol:
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Re: making your own corrugated panels

Postby brit-in-bama » Fri Sep 14, 2018 10:23 pm

ok had a slow day this afternoon, so I tried the glue last night and it ended up simply too thick, it looked odd next to the foil, however I did try something else to make the sky-lights, ours are fiberglass and are a white rigid plastic, but both are slightly opaque, anyway whilst drinking my tea a drop splashed on a bit of tracing paper, and it went almost clear, so I sprayed it in semi-gloss clear acrylic spray, and after it dried it was quite stiff, but too thin, so I cut it half and used another coat of spray and stuck them together and let it dry for an hour, now it feels much stiffer, so you guessed it I passed it through my roller mill, and heres what I got out the other end
dcp_3924.jpg

as you can see it came out with good ridges, not quite as deep as the foil, but acceptable to me, and as you can see it is still transparent, and should look ok when lit from inside the building, I dont know if this will work on other processes, but it might, it you run something smooth pointed Plasticine tool to make the ruts, but its plenty stiff when its dry, I gave it another coat of spray when it came out of the mill, and now its almost rigid, hope some of you try this with ordinary cheap tracing paper, and see how t turn out.

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Bufferstop
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Re: making your own corrugated panels

Postby Bufferstop » Fri Sep 14, 2018 11:14 pm

I must have a go with the liquid detergent and PVA glue, I can see it being adaptable to any number of patterned surfaces. I already use it for cab front porthole windows. I wonder if you can paint on a second layer if you want a thicker sheet.
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Re: making your own corrugated panels

Postby BuffyMcBuffer » Tue Sep 18, 2018 10:10 pm

by jingo i think i might have just cracked it!

been racking my head about what this part is called and i finally found it searching the net

https://www.amazon.com/Boston-Gear-Pini ... inion+wore

first problem...... it's USA only, tried to look for drawn pinion bars but nothing easily available off the shelf so it looks like a visit to a local machinist if you want one of those

then i came across this

https://www.ebay.co.uk/itm/Home-Use-Too ... SwveRbe3BR

now that looks like the tool we need however i don't know what the size it will product

or even

https://www.aliexpress.com/item/Multifu ... 26330.html


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