1gibson,
I think you're right. I let them come up with the dimensions for the stare. It makes sense that with changes to the base and height it could be one piece. That's a really, really good point! I appreciate your help.
1gibson,
I may be confused.
They did drop the star (cross) in the flat sheet form the back and then solder the back tabs.
The star (cross) can't be one piece, the shape won't allow it.
MintJulep,
Thanks for the reply!
I think the problem with that is that you have to have large solder lines (e.g. 1" with common roofing irons) in addition to the bent pieces. That would make the front look unattractive.
Additional options would be to rivet it to the front or a combination of...
MintJulep,
I'd actually rather it wasn't, but with them fabricating it they have to.
I had considered that in the future the "face" could be stamped and then fabricated onto the box/flange, however then I'd run into all the really expensive tooling for stamping etc.
The company I had...
I figured I'd update you guys.
Thank you again for all your help! I really learned a lot and I appreciate all your advice.
I ended up contacting an architectural copper shop like Berkshire was talking about. They're going to look at it and either solder or weld it. This was the cheapest way...
Kenat - Theft will not be a problem. The flanges sit beneath lap siding and are nailed in. If they steal this they might as well steal something out of your house.
Berkshire - That's awesome! Leader heads are crazy to me. I can sweat copper and have put in a ton of 3/4" and 1/2" pipe, but...
All,
Thanks for all the input! I really appreciate your advice.
Some things I wanted to clarify:
The corner radii can be changed. The only reason they are square is because I did the Jpeg in Google Sketchup real quick.
Berkshire - Maybe the reason I was told it couldn't be stamped is...
Well honestly I'm a bit of an entrepreneur at heart (ok maybe more than a bit).
What I'd like to do is to produce a small amount to validate market viability and hammer out defects and then increase production.
So far I've been using my own money, but eventually I may seek a loan from the...
KENAT - thanks for the idea! I'll look into that. That may be a good alternative. Maybe I'll try to find out some more information in the "Paints/Coatings Engineering" section about adhesion and thicknesses. I saw one reference to plating up to .010" thick which isn't too bad.
stanweld - I am...
Also, I forgot to mention the design is hollow in the back. I didn't see how to upload multiple files. Here is another file. I anticipated filling the void with polyurethane foam or expanded polystyrene...
Dear Sir or Madam,
Good day. I have a questions regarding possible forming processes for what is essentially a flanged open sheet metal box with a raised degign (not embossed). Sounds easy right? Please keep in mind I'm a student (no this isn't homework) and it's way outside anything I'm...
