Making Springs

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Making Springs

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  • #15477
    Rob Manley
    Participant
      @robmanley79788

      something smells fishy

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      #54295
      Rob Manley
      Participant
        @robmanley79788
         Hey all, I have to make three half scale versions of some full size springs I have.  The trouble is they use large diameter wire, are fish-bellied in shape and quite tightly wound for their diameter.  The large  full size one can be seen below.  Any ideas on how to make these would be great – the first one to come up with a sensible answer gets a free wish.

         The main spring is for the front suspension and the rear smaller springs are for under the seat on this:

         Rob.
        #54308
        JasonB
        Moderator
          @jasonb
          What about turning a wooden former to the profile you need, wind the spring around that and then burning it out before heat treating the spring.
           
          Jason
          #54315
          Rob Manley
          Participant
            @robmanley79788
            Hmm, that sounds quite a good idea.  Do you think it would be possible to bend it hot and therefore get it as tight as possible?  Has anyone done it using this method?
             
             Rob. 
            #54316
            Bogstandard
            Participant
              @bogstandard
              As Jason has mentioned, but instead of burning it out, make the former in quarters, held together by soft wire. As the spring expands after forming, cut the soft wire and extract the quarters out of the open ends.
              Depending on the size of the end holes, you might have to make the former with a central core that will come out of the hole and a segmented shell around the outside, with each piece being able to pass thru the end hole.
               
              It is not as difficult to do as you might think.
               
               
              Bogs
              #54320
              Richard Parsons
              Participant
                @richardparsons61721
                Hi there Jason.
                If you are going to make this your core hobby you may like this idea
                 
                 

                Apart from using formers there is another way of making springs (there usually is).

                To do it you need three rollers, Two are the feed rollers which feed the wire/bar. The third roller forms the coil. This is done by the position of the third roller to the bar being fed. If the third roller is just touching the fed bar no coil will form. If the third roller is raised a coil will form just as in a set of ‘slip rolls’. The radius of the coil is determined by position of the third roller If the axle of the third roller is angled to the axle of the feed rollers spirals can now be rolled. The angel of the third roller with respect to the feed rollers determined the pitch of the spiral being formed. 

                By controlling the radius of the coil and its pitch and changing them ‘in flight’ you can make almost any spring you like.

                You can also heat the feed rod.

                Bogs – That isa good idea if you only have a few to make.

                #54328
                Keith Long
                Participant
                  @keithlong89920

                  Hi Rob

                  I know it goes against the grain to say this, but you might just find it cheaper and easier to get them made by a spring specialist. In the dim and distant past I’ve had special springs for rally cars made to my own spec for virtually the same price as buying a standard spring from the makers. You are most likely to find such places advertising in the motorsport papers and magazines – eg Motoring News. With modern machinery it’s a piece of cake for them to make a one off as well as seveal hundred off. They’ll ask you for basics such as length, diameter, wire size or spring rate and calculate the rest.

                  Worth a bit of asking around before you start making formers etc. If yours are half full size the wire will fight back!!

                  Keith

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