1899 Hall Bicycle Alarm

[Powder Keg]

I've been out in the shop making chips\o/ This whistle was missing a few parts. I'm going to make new ones going off pictures that I found on the net.

To get started it needed a plunger button. I chucked up a piece of shaft and turned a profile on the bottom.

1899 Hall Bicycle Alarm

I then cut it off and turned it around and machined the top profile.

1899 Hall Bicycle Alarm

The top mount was missing. There is a link between the whistle and the clamp. I made that next. First I cut off a piece of stock.

1899 Hall Bicycle Alarm

Then I drilled a hole for the plunger to go through and milled a slot so the whistle can be adjusted.

1899 Hall Bicycle Alarm

Then, using a hand held grinder I shaped the outside profile.

1899 Hall Bicycle Alarm

Next I got started on the clamp pieces. A little layout blue and some chicken scratches I have the positions for a couple holes.

1899 Hall Bicycle Alarm

I use a block of wood to back up the thin metal. It makes it easier to drill.

1899 Hall Bicycle Alarm

Then off to the band saw. The drilled holes were just to get nice rounded corners. The rest of the clamp was cleaned up with a file.

1899 Hall Bicycle Alarm

Lots of filing and here is where we are now. I'm now making a press block to shape the clamp pieces.

1899 Hall Bicycle Alarm

Hope you enjoy watching:o)

~Wes~

[daz]

Tut Tut, using one of those fine wee cutting discs as a grinding wheel, naughty boy
I done the same last week but took it a bit too far, glad I had my safety googles on but I wish I had bothered to look for my full face mask.
Good work though, that thing looks pretty interesting and it's nice to see old things brought back to life and given another chance 

well done

[andyf]

What a splendidly complicated contraption, Wes!

Were they run continuously to warn pedestrians that an almost silent bicycle was approaching, or were they dropped onto the wheel when needed, and lifted off when the way was clear?

Not quite the right time period for your 1¼d, but still a splendid accessory for it.

Andy

[Powder Keg]

I needed the thin disc to grind the profile. Hardly any pressure was required to do the grinding this is a pretty small part. Glad you like it:o)

~Wes~

[Powder Keg]

Andy, There is a spring that lifts the whistle off the wheel. To operate you press down on the plunger that I'm making. I still need to find the spring. I have a PDF of the whistle patent drawing. Can anyone convert it to a JPEG?

~Wes~

[Rob.Wilson]

Hi Wes ,, you sure do come up with some dam  interesting projects , coooooool whistle 


Rob

[dsquire]

Andy, There is a spring that lifts the whistle off the wheel. To operate you press down on the plunger that I'm making. I still need to find the spring. I have a PDF of the whistle patent drawing. Can anyone convert it to a JPEG?

~Wes~

Wes

Is it possible to bring the PDF up on the screen and scale it to the required size. Now do a screen capture. Depending on what you use for software you should get it in *.png or *.jpg format. Myself I use Irfanview for viewing photos or Screen Captures. Its free and works a treat.

Cheers 

Don

[Powder Keg]

I'm going to try and age the parts a little. The parts I made I'm not to worried about but the zinc plated stuff sticks out like a sore thumb. To clean the scale and the zinc off the parts I'm soaking them in vinegar and salt.

1899 Hall Bicycle Alarm

~Wes~

[PTsideshow]

The vinegar will remove the plating. But keep an eye on it, rinse well with baking soda to neutralize the PH and dry with a soft cloth.If left to air dry it will and can rust.  The vinegar/salt mixture is an old time quick rust patina method. It will rust it quick, rinse well with baking soda to neutralize the PH then dry completely. Be warned that the rusting may continue after you are done even when clear coated.
Metal sculpture artists have that trouble, that it will continue to oxidize.
Looking good so far.
I have posted a number of photos in a thread on using vinegar to remove galvanized plating.

[Powder Keg]

Thanks for the heads up Glen. In this case that's will be a good thing. The fellow I'm fixing this for wants the new parts to match the old ones.

Here they are this morning. Soaking in baking soda to neutralize the PH.

1899 Hall Bicycle Alarm

It took a couple days extra to get the plating off but they are now bare metal.

Stay tuned...

~Wes~

[PTsideshow]

If you want all parts that are ferrous to have the same level of rust patina. There is something you can do. The electrolysis method of rust removal can be made to develop rust, by merely reversing the positive and negative connections Now before some start about what a load of **** here's a link. Reverse Electrolysis the perfect antique patina on new metal parts
  

[Powder Keg]

Thanks for the link Glen.

Here are all the parts cleaned and ready to be finished.

1899 Hall Bicycle Alarm

I made a quick bending jig out of a piece of oak.

1899 Hall Bicycle Alarm

Here it is in my press.

1899 Hall Bicycle Alarm

Looks pretty good to me! Here is an original and the newly bent piece.

1899 Hall Bicycle Alarm

All assembled. It looks pretty good I think.

1899 Hall Bicycle Alarm

Anyone see the piece that I missed? The little clamp under the spring. Grrrrrrrr!

1899 Hall Bicycle Alarm

I'll get that made and soaking.

Later,

~Wes~

[PTsideshow]

Looking good so far, very nice job.

[Powder Keg]

There was a little work in that little part. It started out as a piece of scrap metal:o) I cut it off and laid out the holes and circles.

1899 Hall Bicycle Alarm

Then a little filing.

1899 Hall Bicycle Alarm

And a little more filing.

1899 Hall Bicycle Alarm

I then cut it off and filed the other end to shape.

1899 Hall Bicycle Alarm

Then I bent it to shape.

1899 Hall Bicycle Alarm

Now I'll soak in vinegar so it matches the other pieces.

Later,

~Wes~

[dsquire]

Wes

Damm your smart. I was trying to figure out in my head how to make it. None of my ideas were near as simple or as good as yours. You make it look so easy. Thanks for letting me watch over your shoulder.

Cheers 

Don

[PTsideshow]

Smart hell, he is better than damn good to drill the holes first and then bend it and have the holes line up like they do!!          way to go Wes

[dsquire]

Glen

Now that you mention it and I think of it for a minute.    That is awful damm good to drill first and then bend and have everything right where it is supposed to be. As we have always suspected Wes is not your average weekend metal basher. That boy has got talent.

Cheers 

Don

[Powder Keg]

1899 Hall Bicycle Alarm

[Stilldrillin]

So sorry, I missed most of this build Wes. 

Don't care if it does make you blush...... You're a metal magician! 

David D