Hi Everyone
Work is continuing with the KyKo project and now I have started work on the base and cage for the fan version.
I will not be using the materials supplied in the kit or following the directions and plans. My desire is to create a much more accurate model of the original fan. I do own an original fan, but it is missing the cage. I have collected enough information that I hopefully will be able to make a correct cage for my model and also my full sized one.
Both the base and cage were designed to be easily knocked down for transport. The cage is split into two halves, at 3 and 9 o’clock. The base has three nicely curved legs, a lower platform that anchors the legs and holds the burner. The legs lock into the upper platform that also serves as the mount for the engine.
Looking at the patent drawing you can see how the base is constructed.
This is a photo of my fan to give you an idea of where I’m heading. I have seen photos of two different heights of bases, Mine is the tall one and the other is somewhat shorter.
I picked up this fan for a pretty reasonable price on eBay as it was missing one of its legs. In this photo it has three new legs that I made for it. After coming up with the design and process to manufacture the legs, it will be straight forward to cut everything in half and make a small set.
Here you can see how each leg has two hooks that engage in slots in the upper base, as the leg is swung into position it gets locked into place. The lower base keeps the legs in place.
Starting out the base was laser cut from 24ga galvannealed steel.
The three sides were then bent to 55 degrees like the original. The bends cannot go all the way to the ends, or you would have a mess where they come together. They could be notched for some bend relief but that is not how the original was done. It was probably done in a press with a punch and die that formed the whole thing in one shot.
My choice was to design a hammer form and 3d print it in solid Nylon. This tool will clamp onto the base and allow the three ends to be gently formed into shape. It locates by the arc over the two dowel pins and the single screw out on the point. The hole in the sheet metal will be used for foot and retainer clip, so it was not added only for the hammer form.
This is what it looks like assembled.
And assembled on to one of the sheet metal blanks.
Here it has been taped into shape, it has a little curve to it, which is exactly how the big one looks. This detail needs to fit into the inside corner of the formed sheet metal leg.
Here is a shot of the finished part.
More to come, thanks for checking in.
Dave
