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Column Covers For 70 Columns

posted Dec 13, 2011, 5:11 PM by Ray MAKES   [ updated Dec 13, 2011, 7:06 PM ]

We are currently completing a rush column cover project producing circular column covers.  Our shop is located in Delaware but this particular job is heading to New York. So the column covers had to be crated and shipped. This project was produced in such a short time we were only able to photograph them AS they were being crated for shipping! If you have a project, and you need it done fast, just give us a call and send us the drawings for a quote. Due to the contractors extremely tight schedule, these cols were made from unfinished aluminum and will be post finished in situ.

Aluminum Column Covers

Aluminum Column Covers

Aluminum Column Covers



Aluminum Column Covers

Aluminum Column Covers


Camera Mount II

posted Dec 12, 2011, 7:57 PM by Ray MAKES   [ updated Dec 12, 2011, 7:59 PM ]

A great project that required quite a bit of water jetting, rolling, and welding.  the details of this project cannot be disclosed any further.
Camera Mount

Camera Mount

Slitter for Non Metalic Materials

posted Dec 12, 2011, 7:05 PM by Ray MAKES

This was a great project!  We designed, engineered and built this Slitting machine used for the purpose of slitting non metallic mateials for fiber/non metallic stampings. This machine is now the "WORK HOURSE" for our client who is planning on replacing all of their other antiquated slitting machines with this new design.  Stay tuned as we add photos of the finished machine in situ, with the newly designed and built in feed table that directs raw materials as they are fed into the machine.


Slitting machine for fiber stampings

Slitting machine for fiber stampings

Slitting machine for fiber stampings

Slitting machine for fiber stampings

Slitting machine for fiber stampings

Launcher

posted Dec 12, 2011, 6:44 PM by Ray MAKES   [ updated Dec 12, 2011, 7:08 PM ]

This is a purpose built machine was designed to launch....something! Unfortunately we can not disclose any other information about this project, nor could we photograph it in its completed form.


aircraft launcher

aircraft launcher

aircraft launcher

aircraft launcher

aircraft launcher

Electrical Enclosures

posted Dec 11, 2011, 7:04 PM by Ray MAKES

This project was deceptively simple yet required careful attention to detail.  These boxes required alot of water jet cutting, CNC milling, CNC brake bending and welding.  Due to the nature of the project we could not document it in its completed form.  These images were taken prior to grinding the welds and finishing.

Electrical component box

Electrical component box

Camera Mount

posted Dec 11, 2011, 6:42 PM by Ray MAKES   [ updated Dec 11, 2011, 7:09 PM ]

This was a fascinating project that required quite a bit of machining, water jetting, rolling, and welding.  the details of this project cannot be disclosed any further.
Aircraft Camera Mount
Aircraft Camera Mount


Aircraft Camera Mount
Aircraft Camera Mount

Electronics Component Boxes

posted Dec 11, 2011, 4:05 PM by Ray MAKES   [ updated Dec 12, 2011, 8:03 PM ]

This Project was CNC intense!  We set it up on one or our CNC mills, the HAAS.  In order to produce one finished part per cycle, we set up 5 stations.  With this set up a raw block of material is placed in the first station on the right. then with each cycle it is moved down to the next station.  Once 5 cycles are complete, one finished box emerges every cycle.  "Normally", one operation is run on all the blanks, then the next operation and so on.  The disadvantage of this, is that all operation have to be complete before you get a single finished item.  At Diamond State Machining, we understand that even though an order may be for 500 units, you may need 20 or 100 at a time to keep your business flowing.


These photos are of the finished electrical enclosures and for comparison the solid aluminum blocks from which they were machined

finished boxes on raw aluminum block

raw block with finished boxes

finished aluminum box

finished aluminum box

finished aluminum box



These photos are of the electrical boxes being machined in the HAAS mill, one of several in our facility. here you can see the five stations from which this part was machined.  operation starts on the right and ends on the left.

machining in the HAAS mill

machining in the HAAS mill

machining in the HAAS mill



machining in the HAAS mill

Car Crusher Hinge

posted Dec 11, 2011, 2:44 PM by Ray MAKES   [ updated Dec 11, 2011, 3:28 PM ]

Here is a question: if you wear out a car crushing machine, where do you go to get it fixed? Diamond State Machining of course.  a few years ago we had the privilege of building a new hinge for a car crushing machine which had worn out severely.  Fast forward to 2011, and now we have had the opportunity of building the hinge for the remaining side!  Below are the images for the newly built car crusher hinge.  What is obvious from the photographs is the amount of precision machining needed to build this hinge.  The hinge pin below measures 4" in diameter and just over 20' long! We made bronze bushings that were pressed fit into the hinge sleeve.  To do this we heated up the hinge while simultaneously cooling down the bushing which we machined oversize for this purpose.  Once at temperature, the two components were quickly introduced to each other and fit together. When the parts normalized to room temperature the fit is permanent!!!
These images are of the hinge sleeve and
bronze bushings.  Note the threaded holes,
these are for grease fitting which will be
threaded once welding to the
crusher is complete
hinge sleeve with bronze bushing
hinge sleeve with bronze bushing
hinge sleeve with bronze bushing
hinge sleeve with bronze bushing
Note the threaded holes above, these are
for grease fitting that will be installed
after welding is complete.
inside of bronze bushing
inside of bronze bushing
Note the grease holes. there is a grease
reservoir between the steel sleeve and the
bronze bushing.  Once full a controlled amount equal to the amount added for maintenance is pushed between the bushing and the hinge pin.



These images are of the hinge pin. 
It was turned, Ground and Polished. 
It measures 4" in diameter and over 20' long.

Note the straightness of the pin and the surface quality

Drilling Pump Re-build

posted Dec 11, 2011, 1:47 PM by Ray MAKES   [ updated Dec 11, 2011, 2:06 PM ]

Being a jobbing shop, everyday we have the opportunity to work on new and different projects.  One of our commercial clients, regularly needs their drilling pumps repaired and/or re-built.  Your business requires that all of your equipment be up and running for every job and we understand that. That's why we offer emergency repairs and quick turn around for our business clients.  Below are a few images of the pump housing repair we performed. this particular pump required water jetting of the pump housing plate which is 3/4" thick and mounting flange which is 1" thick. We then machined and welded the mating surfaces.
new pump plate
The rebuilt pump end plate.  This side of the pump is the one which
receives most of the wear.  The flange is 34" in diameter and 3/4" thick.
The pipe flange we cut out of 1" thick material.
The connecting pipe is 6" in diameter.



new pump plate

original pump housing plate
Original pump housing end plate.  Here you can see how the
impeller has worn out the interior of the pump housing.



Electronics Gondolas

posted Nov 25, 2011, 9:31 PM by Ray MAKES   [ updated Dec 13, 2011, 8:35 PM ]

We are currently fabricating some incredible electronics gondolas whose ultimate purpose we cannot disclose.  These particular units are labor intensive aluminum fabrications requiring:
  • water jet cutting
  • CNC bending
  • precision threading
  • pressing of threaded inserts (nuts and studs)
  • extensive riveting
Unfortunately we cannot disclose any other information on this project.
Electronics Gondolas

Electronics Gondolas

Electronics Gondolas



Electronics Gondolas

Electronics Gondolas

Electronics Gondolas

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