horn insulating plate

RonS

Had an occasion to remove the steering wheel from my 53 Hornet. I almost forgot what a flimsy thing the clear plastic horn ground insulator disk is. I am referring to the part that also holds the horn ring behind the steering wheel with 3 screws. Has any one reproduced these, or is a after market substitute available? I can't believe that there is no shortage of these. Has anyone used some thing else?

bob ward

I've just been through the same exercise. The clear plastic insulator was quite OK when it was new, but it fatigues and cracks and over the years.



It is the sort of item that would lend itself well to reproduction on a CNC milling machine. Once the programming is done, they could be effortlessly turned out in small batches.

RonS

Whats a cnc milling machine?

Unknown

A machine tool that uses programs to automatically execute a series of machining operations



Computer Numerical Control, CNC is an acronymn used to describe a machine tool that can make a product based on following the computer program fed into it.



There are programs which can be used with a picture or a scan of an original part which will replicate the machine instructions needed to drive the type of machine tool needed to replicate the original part.



The following is another option for producing these types of parts... (no personal endorsement)...

It is uncommon to find stereolithography machines anywhere but in large companies. However, there are service bureaus that can make the advantages of stereolithography available to smaller shops and individuals. For example, PT CAM (Piedmont Triad Center for Advanced Manufacturing, 336-275-2060, 2105 Yanceyville St, Greensboro, NC, 27405.) will do stereolithography for $55/hour, as well as allowing companies to purchase blocks of time for as low as $30/hour. That's not cheap, but compared to purchasing your own SLA and resin or having parts machined, it is a real bargain. You can e-mail your CAD design to PT CAM and, in many cases, get your parts shipped back to you in a day or two. The short cycle time is one of the most appealing things about stereolithography!

RonS

OK I saw that on Jay Lenos Garage.I wonder if there are enough folks in need so that KGap could profitably sell 'em.

RL Chilton

RonS wrote:

OK I saw that on Jay Lenos Garage.I wonder if there are enough folks in need so that KGap could profitably sell 'em.

And that continues to be the $20,000 question, doesn't it?

bob ward

RonS wrote:

OK I saw that on Jay Lenos Garage.I wonder if there are enough folks in need so that KGap could profitably sell 'em.

Like most low volume reproduction projects, it firstly needs someone to take charge of it, invest the time, and make it happen.



The first step for the volunteer would be take an insulator to a few of the smaller CNC outfits and get ball park figures for a) the programming and b) the cost per item in batches of say 20 at a time.



If there is an HET member with the programming skills and/or a CNC machine who will work at mate's rates that makes the project more feasible.



After that you can figure out if they are going to be a seller or not. At $10 to $20 a piece they would probably sell. At $50 I would be patching up the old one and burying it back in the steering wheel for another 10 years.

dougson

............... Or, install a aftermarket button on the column I think I am facing the same issue with my '54.

coverton

I am not sure I have seen the plastic part afore mentioned,but I have asked my buddies next door at the machine shop [nest to the Body Shop at the CC]- to make me a few spacers for a fuel pump-quite simplle for a Dimensions machine but did need an old one to scan. Do you fellows think this to be similar ??

bob ward

coverton wrote:

I am not sure I have seen the plastic part afore mentioned,but I have asked my buddies next door at the machine shop [nest to the Body Shop at the CC]- to make me a few spacers for a fuel pump-quite simplle for a Dimensions machine but did need an old one to scan. Do you fellows think this to be similar ??

The insulator is a disc maybe 5" diameter x 1/4" thick with a few holes and recesses in it. If that machine shop has equipment that can scan items and then produce from the scan you may well be on the right track.

Unknown

mine was beyond repair. so i borrowed one from a buddy and made a silicone mold of it and then made a copy out of alumilite resin. its an off white color instead of clear but nobody is going to see it behind the cap.

35 Terraplane

Although I have a 35 Terraplane I’d be willing to take this on for the 50’s guys. I have a CNC mill and can program it. When I’m thinking of strong clear plastic I’m thinking polycarbonate AKA Lexan, Hyzod. I’d need an original part to measure. If someone can post the thickness required I can check on pricing for the sheet stock. If anuone interested let me know.

Tom King

Auburn,NY

bob ward

35 Terraplane wrote:

Although I have a 35 Terraplane I’d be willing to take this on for the 50’s guys. I have a CNC mill and can program it. When I’m thinking of strong clear plastic I’m thinking polycarbonate AKA Lexan, Hyzod. I’d need an original part to measure. If someone can post the thickness required I can check on pricing for the sheet stock. If anuone interested let me know.

Tom King

Auburn,NY

Thanks for the offer Tom. You will need an original to measure for manufacturing as you say, but for pricing, in round figures, OD is 2.5", 2.44" across the flats, the centre hole is 1.375". Thickness is around 5/16", if you work on 3/8" or 10mm material you will be covered. The back is plain, the front has a recess to locate the curved wire, there are 3 through holes. The internal corners of the 'tongue' can be radiussed, they don't need to be square like they are on the original.



You can see from the photo that the insulators crack and get repaired, they flex a little every time the horn ring is pressed.



I've been away for a few days, I'm a little surprised you haven't been peppered with info on this.

35 Terraplane

Bob,

I'll look for 3/8" or 1/2" material this week. I've had an offer from a club member to send me an original for measurment. I'm hoping to get some sample material from one of the vendors I deal with to make a prototype. I'll keep you posted.

Tom