We recently a received an enquiry from one of the industry leaders in classic car restoration to produce 4 sets of 1920s brass headlamps.
Due to the age of the brass headlamps, there were no drawings but we were provided with a sample piece.
Having worked closely with our customer for several decades, we discussed the manufacturing process and how we can match to the original sample.
Without having a set of drawings for reference, our Works Manager methodically took the dimensions and profiles, so that we could begin the process of making tooling.
There were several stages of manufacturing involved to produce the spun brass headlamps, which began first with tooling.
Stage 1 – Tooling
To produce the brass headlamp spinning, this required four different tools.
All 4 tools were machined from a solid S275 billet, based on the dimensions we had taken from the sample piece.
During the spinning process, there were minor adjustments after running test pieces.
Having the capability to manufacture our tooling in house, enables any adjustments to made at that moment, as opposed to lengthy delays going back to a sub-contractor supplying tooling.
Stage 2 – Sheet Metal Work
The second stage involved guillotining 1.5mm brass material into a square large enough to circle a brass blank.
When the square is guillotined, it is then placed onto the circle shear, which cuts the required diameter circle.
To spin the base and headlamp bezel, both require a circular brass blank.
For the main body, a rectangular strip is guillotined and then rolled before being seam welded.
Stage 2 – Initial Draft Spinning for Headlamp Base
There are several spinning processes required to manufacture the headlamps.
In this video you can see the CEO Phil Kemp, spinning the first daft of the base.
The draft spinning is then sent to be annealed to make it more malleable for the next stage of the spinning process.
Stage 2 – Final Draft Spinning for Headlamp Base
After the draft spinning is returned from annealing, it is then ready to have the final draft spinning.
In this video you can see the CEO Phil Kemp, applying pressure using the hand tool to form the final form of the headlamp base spinning.
He will then skim the spinning to ensure that is to the correct dimensions.
Throughout the entire spinning process, Phil will be taking regular comparative measurements against the sample piece, to ensure that he is maintaining the required dimensions.
Stage 2 – Spinning the headlamp body
The next stage in the spinning process is to spin the main body of the headlamp.
This spinning is formed by applying pressure to a rolled brass band.
This part has two spinning process to form the top of the body, which located the headlamp bezel with the glass.
After both parts are spun, it was essential that both parts are matched to create a tight fit.
This process requires some of the material to be skimmed from the main body to ensure.
In the images below, you can see the matched parts for the main body.
Stage 2 – Spinning Headlamp Bezel – Draft
The final stage of the headlamp manufacturer, is to spin the headlamp bezel.
This process is similar to spinning the base of the headlamp but requires the centre of the spinning to be cut out to locate the headlamp glass.
In this video, you can see Phil spinning the first draft before it is annealed.
Annealing
To make the brass more malleable to spin the next stage of the headlamp bezel, heat is applied to the material.
This process requires the metal to get to a certain temperature.
If too much heat is applied to the brass, it will burn a hole through the material.
Stage 2 – Spinning Headlamp Bezel
In this video you can see Phil working on the next stage of the headlamp bezel.
Before Phil can commence with spinning the next operation, he first needs to cut out the front of the spinning, so he has access to spin inside of the headlamp.
A bladed hand tool is used to gradually remove material until the ctr. of the headlamp is free.
In this next video you will see Phil spinning the return of the headlamp bezel.
Stage 2 – Spinning Headlamp Bezel Bead
In this video you can see Phil and our trainee spinner Matt working in unison to spin the return bead.
This bead is required to ensure that the headlamp bezel locates on to the main body.
Stage 3 – Brazing
Now all of the spinning parts are produced it is time to assemble.
The brass headlamp has a removable headlamp bezel, to allow access to the bulb, so this will require no brazing.
As the main body is made of two individual spun parts, these require brazing to create one main body.
We are very fortunate to have a highly skilled welders, who make this process look effortless.
Final Piece
Here is a an image of the sample and the newly spun brass headlamp.
This is just another a high quality part manufactured at Artec Engineering Ltd., which further enhances our reputation as one of the industry leaders in metal spinning.
We are renowned as the ‘go to’ metal spinning company, who continue to produce spun parts that other companies can not.
Get in touch
Having the capability to complete all metal spinning, fabrication, welding, machining and fabrication in house, we can ensure that the quality of the parts meets the required high standards we pride ourselves on and the lead time is reduced.
If you have an existing or new project then please get in touch to see how we can assist you.
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