Assignment 1: The Blister

This part of the assignment is to create an aluminium skin to adhere to the contours of Blister.

1. Use the jigsaw power tool to cut the middle part of the CNC template out and then use the router power tool to sand the excess bits off - the bits that connecting the middle part and the outer part of the template.

2. Take another template with the same tear drop shape, repeat step 1 to it and then use screws to screw two templates together.

3. There are different ways to approach to the shaping process, I chose the method of putting the aluminium sheet on the mould, using clamps to lock them together tight and then start hammering it.
(This method is learnt from the YouTube video posted on Russell's Blog: http://beil0014-2017.blogspot.com.au/)

4. To get a fast start, I use an egg-shaped mallet and hit on the side of the mould hardly
(Reminder: Be careful of the occurrence of tucks as they may cause the aluminium to crack, flatten them out immediately!)

5. Next step, I used an indirectly way to hit the aluminium by putting an egg-shaped mallet on the sheet and hit the mallet with another mallet. By doing that it allows me to hit a larger surface area and gets a smoother surface. Keep hammering it until the sheet has get to the desired depth.

(Reminder: Since aluminium has a relatively low limit to stretch than other material, such as steel. You have to be careful, not to get it too deep and caused the aluminium to tear.)

6. After finishing the general shaping of the tear drop, I used a pointy wooden block as my croking tool to tune up the edge.

7. After I have finished tuning up the edge, I use a marker to mark a cut line so it ends up with a nice and even flange.

8. Follow the marked line, use the snip to cut the excess parts off.

9. Use another snip to cut off/ fix the uneven bits from the previous cut.

10. Use sand paper to smoothen out the edge and clean the mark with WD40. Done!

11. Compare with my partner's blister.