Killed a few hours in the machine shop....

HRPufNStuf · 07-17-2007, 04:31 PM

I had to take a few weeks holidays and spent some time over at my dads machine shop over the last few days.

Started with about $150 worth of 6061 Aluminum (4 X 7" X 1.5" round stock)

http://s140.photobucket.com/albums/r...rrent=cap1.jpg

Then a little rough machining on the lathe....

http://s140.photobucket.com/albums/r...rrent=cap2.jpg

starting to take shape

http://s140.photobucket.com/albums/r...rrent=cap3.jpg

Had to make a test fit mandrel for the M60X2 thread aswhat tese are going on wouldn't fit on the lathe.

http://s140.photobucket.com/albums/r...rrent=cap5.jpg

Then onto the dividing head /milling machine for some Hex action

http://s140.photobucket.com/albums/r...rrent=cap4.jpg

Finished products...for those that have not guessed yet....They are billet machined Gemini caps..

http://s140.photobucket.com/albums/r...rrent=cap6.jpg
http://s140.photobucket.com/albums/r...rrent=cap8.jpg
http://s140.photobucket.com/albums/r...rrent=cap7.jpg
http://s140.photobucket.com/albums/r...rrent=cap9.jpg

The original caps had a 3" emblem that I could not get in anything other than vinyl, so I opted for a slightly modified design to incorporate either of the latest 2.5" caps in the center. Not sure which one of the colour/types I like better. I figure I can decide after the wheels/caps are painted. Cutting the threads sucked the most as they are slightly undersize from M60 to accomodate the Volvo paint finish. I also inlcuded the O ring groove to ensure they stay tight on the wheel.
This project took a little longer than I had originally planned...sure wish I had a CAD controlled lathe/milling machine...
A full set of metric thread gears for the lathe (Austrian made) sure helped.

Delfosse · 07-17-2007, 04:35 PM

pimping!!!!

MikiK · 07-17-2007, 04:43 PM

Wow...160 dollar centercaps. Don't lose them.

project volvo · 07-17-2007, 04:44 PM

i thought u were trying to make your own spacers or even rotors at first rofl!?!?

nice job

RunItRich · 07-17-2007, 04:44 PM

Fanfriggintastic.

HRPufNStuf · 07-17-2007, 05:32 PM

$160 CDN for all four pieces is pretty cheap compared to finding OEM center caps (which are NLA)
Gemini caps were originally listed as $150 each from the dealer.
I tried calling lots of places for caps and no one has them even used ...I even callled ATS in Germany to see if they still had any NOS caps....

I'd hate to lose one of these though....LOL!

Quote:

Originally Posted by MikiK

Wow...160 dollar centercaps. Don't lose them.

blkaplan · 07-17-2007, 05:54 PM

wow, awesome stuff! Those would look really hot black anodized.

billet caps ftw.

neptune · 07-17-2007, 06:03 PM

Nice job. It is very nice to see people making replacement parts now that things are going NLA.

I like your innovative center cap solution. I would personally be tempted to try cutting the logo into the metal using a waterjet, then painting it black, but that adds a bit of expense and probably wouldn't look any better.

VolvoPunch · 07-17-2007, 08:16 PM

Thats a nice quality job you did there. Very nice machine work.

foggyjames · 07-17-2007, 09:09 PM

That's deeply awesome Patrick - I like it!

cheers

James

Vol242vo · 07-18-2007, 01:39 AM

Good idea! I bet you might be able to sell those to Gemini owners?

dmcgee · 07-18-2007, 03:08 AM

god i hope so..

Josepilove · 07-18-2007, 03:59 AM

haha, yea i thought you were turning up aluminum rotors too.

ZyreX · 07-18-2007, 06:43 AM

Friggin nice, but for the love of god, hotlink the pics! I'm rarely bothered to read threads with links to pics..

but since I'm at work and nothing to do, it was okay :P

chree · 07-18-2007, 09:30 AM

This is awesome. You program the year you want to travel to on the digital gauge right?

Photo Sharing and Video Hosting at Photobucket

Evan780 · 07-18-2007, 02:19 PM

Excellent work!!!

Chigga 744SE · 07-18-2007, 02:36 PM

wanna sell 'em? I'm sure me and G@ttigang want a set each.

dmcgee · 07-18-2007, 06:49 PM

Quote:

Originally Posted by Chigga 744SE

wanna sell 'em? I'm sure me and G@ttigang want a set each.

I'd buy two sets

McLovin · 07-19-2007, 01:22 AM

Yep. Totally thought you were goin' for a set of aluminumm rotors.

YLD244 · 07-19-2007, 03:09 AM

dammit linky no worky... some photobubket maintenance thingo

Biesey · 07-19-2007, 11:39 AM

That is spectacular... and looks awesome!!! Good work Patrick!!! Did you ever get in touch with the guys at Rapid Wheel?

HRPufNStuf · 07-25-2007, 08:07 AM

Yup, there is a flux capacitor in the trunk..LOL!

Quote:

Originally Posted by chree

This is awesome. You program the year you want to travel to on the digital gauge right?

HRPufNStuf · 07-25-2007, 08:15 AM

Quote:

Originally Posted by Biesey

That is spectacular... and looks awesome!!! Good work Patrick!!! Did you ever get in touch with the guys at Rapid Wheel?

Hi Dan,
Didn't get a chance to talk to them yet... I'm picking up another pair of Geminis on Friday and I'll see how they look. I might just need two refinished + about 6 caps.
I di find alocal shop, but I'm not sure how good they are..

HRPufNStuf · 07-25-2007, 08:21 AM

Quote:

Originally Posted by Chigga 744SE

wanna sell 'em? I'm sure me and G@ttigang want a set each.

I thought it might be an option to make sets, but in truth they took a couple of days to make and my wife was not happy with the time I spent just on this set. My dads shop is also more set up for prototyping and not production work....If some one wants to make these or get a quote from a shop, I can supply a better version of the sketch below.( I made a few changes to the working copy in the shop).
Alternatively, if someone can convert the sketch to a CAD drawing, it would probably make this an even more viable option. I've also been toying with doing some castings of the original Gemini caps and then just turning the threads. I've got a few bent and cracked volvo wheels I was saving to melt down.

http://s140.photobucket.com/albums/r...rent=cap10.jpg

Biesey · 07-25-2007, 12:17 PM

hey Patrick,

I'll do a cad file for them, just need to find some spare time.

07-17-2007, 04:31 PM	#1
HRPufNStuf Board Member Join Date: Dec 2003 Location: Stittsville, Ottawa, Canada	Killed a few hours in the machine shop.... I had to take a few weeks holidays and spent some time over at my dads machine shop over the last few days. Started with about $150 worth of 6061 Aluminum (4 X 7" X 1.5" round stock) http://s140.photobucket.com/albums/r...rrent=cap1.jpg Then a little rough machining on the lathe.... http://s140.photobucket.com/albums/r...rrent=cap2.jpg starting to take shape http://s140.photobucket.com/albums/r...rrent=cap3.jpg Had to make a test fit mandrel for the M60X2 thread aswhat tese are going on wouldn't fit on the lathe. http://s140.photobucket.com/albums/r...rrent=cap5.jpg Then onto the dividing head /milling machine for some Hex action http://s140.photobucket.com/albums/r...rrent=cap4.jpg Finished products...for those that have not guessed yet....They are billet machined Gemini caps.. http://s140.photobucket.com/albums/r...rrent=cap6.jpg http://s140.photobucket.com/albums/r...rrent=cap8.jpg http://s140.photobucket.com/albums/r...rrent=cap7.jpg http://s140.photobucket.com/albums/r...rrent=cap9.jpg The original caps had a 3" emblem that I could not get in anything other than vinyl, so I opted for a slightly modified design to incorporate either of the latest 2.5" caps in the center. Not sure which one of the colour/types I like better. I figure I can decide after the wheels/caps are painted. Cutting the threads sucked the most as they are slightly undersize from M60 to accomodate the Volvo paint finish. I also inlcuded the O ring groove to ensure they stay tight on the wheel. This project took a little longer than I had originally planned...sure wish I had a CAD controlled lathe/milling machine... A full set of metric thread gears for the lathe (Austrian made) sure helped. Last edited by HRPufNStuf; 07-17-2007 at 04:39 PM..

07-17-2007, 04:35 PM	#2
Delfosse VFL Join Date: May 2006 Location: Forest City, NC	pimping!!!! __________________

07-17-2007, 04:44 PM	#4
project volvo spoolakowski Join Date: May 2005 Location: from Burlington now Farmington,CT	i thought u were trying to make your own spacers or even rotors at first rofl!?!? nice job __________________ SIG

07-17-2007, 05:54 PM	#7
blkaplan 50 shades of beige Join Date: Jul 2002 Location: Rockville, MD	wow, awesome stuff! Those would look really hot black anodized. billet caps ftw. __________________ www.BEIGEPOWER.com Kaplhenke Racing Facebook

07-17-2007, 06:03 PM	#8
neptune 2.1L 2.3L 2.8L 2.8L 2.8L Join Date: Jun 2004 Location: Mountlake Terrace, WA	Nice job. It is very nice to see people making replacement parts now that things are going NLA. I like your innovative center cap solution. I would personally be tempted to try cutting the logo into the metal using a waterjet, then painting it black, but that adds a bit of expense and probably wouldn't look any better. __________________ www.neptune242.com 1984 245 GL \| 1980 Bertone Coupé

07-17-2007, 04:43 PM	#3
MikiK Board Member Join Date: Mar 2007 Location: Cumming, GA	Wow...160 dollar centercaps. Don't lose them.

07-17-2007, 04:44 PM	#5
RunItRich Throw some fuel at it. Join Date: Jan 2007 Location: ArmPit Of America N,J	Fanfriggintastic.

07-17-2007, 09:09 PM	#10
foggyjames Ryan's spanner monkey Join Date: Jan 2004 Location: Lincoln, UK	That's deeply awesome Patrick - I like it! cheers James __________________ '05 V70 D5 '88 360 Turbo Intercooler '84 360 GLT '81 343 GLS R-Sport '80 343 DL '69 164 PM me if you're looking for Euro parts!

07-18-2007, 01:39 AM	#11
Vol242vo Hi, I'm Amanda Kutlewith Join Date: Feb 2005 Location: Spokane, WA	Good idea! I bet you might be able to sell those to Gemini owners? __________________ -Derek- '78 242 Click Here for Project Thread

07-18-2007, 03:59 AM	#13
Josepilove Box Car Kid Join Date: Mar 2006 Location: Ann Arbor, MI	haha, yea i thought you were turning up aluminum rotors too. __________________ Volvos? We don't need no stinkin' Volvos.

07-18-2007, 06:43 AM	#14
ZyreX Board Member Join Date: Jun 2005 Location: Norway	Friggin nice, but for the love of god, hotlink the pics! I'm rarely bothered to read threads with links to pics.. but since I'm at work and nothing to do, it was okay :P __________________ '83 Volvo 240 '05 Volvo V70 2.0T '13 Volvo V40 D3

07-18-2007, 09:30 AM	#15
chree Chris Join Date: Aug 2006 Location: Atlanta, GA	This is awesome. You program the year you want to travel to on the digital gauge right? __________________ Chris PartsForSpeed.com eBay Store PartsForSpeed.com Performance Parts Web Store

07-18-2007, 02:19 PM	#16
Evan780 Board Member Join Date: Sep 2005 Location: Massachusetts	Excellent work!!! __________________ 1990 Volvo 780 Bertone 245,XXX -RIP - 1994 Volvo 945ti 147,XXX+

07-18-2007, 02:36 PM	#17
Chigga 744SE Taiwan Panda Racing Unit Join Date: Nov 2002 Location: On. Canada	wanna sell 'em? I'm sure me and G@ttigang want a set each. __________________

07-19-2007, 03:09 AM	#20
YLD244 Board Member Join Date: Jan 2003 Location: Sydney, Australia	dammit linky no worky... some photobubket maintenance thingo __________________ Marc YLD244 - '76 244 GL MAD740 - '89 740T Tank - '69 144 B20A 5 speed

07-19-2007, 11:39 AM	#21
Biesey Board Member Join Date: Jan 2007 Location: Oshawa Ontario	That is spectacular... and looks awesome!!! Good work Patrick!!! Did you ever get in touch with the guys at Rapid Wheel? __________________ - Dan 1994 Volvo 850 \| 1992 Volvo 240 \| 1971 1800e

07-25-2007, 12:17 PM	#25
Biesey Board Member Join Date: Jan 2007 Location: Oshawa Ontario	hey Patrick, I'll do a cad file for them, just need to find some spare time.

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