Replicating Maximall Fuel Gauges

[ulpilot]

My current project is replicating the Maximall Fuel Gauge for the Fokker DVII.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/1z2ljfd_zpscb12a7b4.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/1z2ljfd_zpscb12a7b4.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/1z2ljfd_zpscb12a7b4.jpg.html%5D%5BIMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/1z2ljfd_zpscb12a7b4.jpg%5B/IMG%5D%5B/URL")]


I was loaned an original to work from and after dissembling, measuring I drew it up in CAD. This way I can double check my measurements, clearances, etc. This also helps me decide the best ways to manufacture the parts and create fixtures.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/gaugeassembly_zps7c01098a.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/gaugeassembly_zps7c01098a.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/gaugeassembly_zps7c01098a.jpg.html%5D%5BIMG%5Dhttp ://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/gaugeassembly_zps7c01098a.jpg%5B/IMG%5D%5B/URL")]


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/explodedgaugeassembly_zpse6e54f2b.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/explodedgaugeassembly_zpse6e54f2b.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/explodedgaugeassembly_zpse6e54f2b.jpg.html%5D%5BIM G%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/explodedgaugeassembly_zpse6e54f2b.jpg%5B/IMG%5D%5B/URL")]


Instead of subcontracting the patterns for the castings I decided to give it a try. The head pattern maker at the local foundry was very helpful, and patient with me.



http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/100_1211_zpsfc561ccd.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/100_1211_zpsfc561ccd.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/100_1211_zpsfc561ccd.jpg.html%5D%5BIMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/100_1211_zpsfc561ccd.jpg%5B/IMG%5D%5B/URL")]


For my first time I think the results are pretty good.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/100_1213_zps5f977113.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/100_1213_zps5f977113.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/100_1213_zps5f977113.jpg.html%5D%5BIMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/100_1213_zps5f977113.jpg%5B/IMG%5D%5B/URL")]


More to come.

[Jerry Petro]

Hello,
I recently purchased these two similar gauges from Ebay. I managed to get them apart and cleaned up and except for one broken spring they are in good condition.

3841

3842

I understand how these work , you pull the wire/string and the gauge needle turns, on releasing the string the internal spring returns the needle to zero.
My question is , what happens inside the tank ? What is the mechanical arrangement that provides the force to pull the string/wire ?

[ulpilot]

String attaches to a metal float that rides in a stand pipe in the tank. Weight of the float pulls the string down.

[Ron Blum]

ulpilot: ur awesome! Thanks for sharing.

[nlebens]

Looks great! How do you paint the instrument dials? Is there a way to do that at home?

Thanks!

[ulpilot]

Looks great! How do you paint the instrument dials? Is there a way to do that at home?

Thanks!

The dial faces are a whole separate project! Will be showing that later. Short answer, Enameled and screen printed.

[ulpilot]

In the process of machining the cases.

http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140511_163553_634_zpsab1fc5ab.jpg (http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140511_163553_634_zpsab1fc5ab.jpg.html)

Here are the main pulley blanks after lathe work.

http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140216_190641_749_zps990224fc.jpg (http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140216_190641_749_zps990224fc.jpg.html)

And after coming off the milling machine. Each weighs just a few grams.

http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_115519_897_zpse33f93e5.jpg (http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_115519_897_zpse33f93e5.jpg.html)

Hubs for the pulleys.

http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/ea73cf86-a10d-4545-8e20-2f04d2f790a2_zps67bd7c4f.jpg (http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/ea73cf86-a10d-4545-8e20-2f04d2f790a2_zps67bd7c4f.jpg.html)

Heading back to the shop, more to come

[ulpilot]

Just picked up the dial faces today. The originals were enameled with the markings printed. For those that don't know, enameling is a process the fuses glass powder on to the base metal. Was a very common method in the past, but not so much any more. First I made the blanks from steel, they also had to be cupped slightly.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140311_193112_136_zps90b544c6.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140311_193112_136_zps90b544c6.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140311_193112_136_zps90b544c6.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140311_193112_136_zps90b544c6.jpg%5B/IMG%5D%5B/URL")]


Took me awhile searching the internet to find someone that still does enameling. Then I found an artist studio 20 miles from me that teaches enameling! The instructor took interest in the project and did the enameling for me. Then stopping in at a graphics company that I pass everyday on my commute, found another kindred spirit that had done similar work on an old car. Here is the result, almost perfect!


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140521_181700_961_zps968f9bca.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140521_181700_961_zps968f9bca.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140521_181700_961_zps968f9bca.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140521_181700_961_zps968f9bca.jpg%5B/IMG%5D%5B/URL")]

[ulpilot]

Been awhile since I posted, lots going on so computer time has been limited.


Each gauge uses four gears, I made up blanks and then borrowed time in a Wire EDM machine to cut the gears.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_154258_432_zpsb8765a9b.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_154258_432_zpsb8765a9b.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_154258_432_zpsb8765a9b.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140222_154258_432_zpsb8765a9b.jpg%5B/IMG%5D%5B/URL")]


Cut 40 gears in less than 2 hours!


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140308_110548_709_zpsac36a5b2.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140308_110548_709_zpsac36a5b2.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140308_110548_709_zpsac36a5b2.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140308_110548_709_zpsac36a5b2.jpg%5B/IMG%5D%5B/URL")]


Some of the interior parts, Parts on the left need to be bent.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140322_185045_852_zps65cfd1ec.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140322_185045_852_zps65cfd1ec.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140322_185045_852_zps65cfd1ec.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140322_185045_852_zps65cfd1ec.jpg%5B/IMG%5D%5B/URL")]


After bending.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140406_150237_675_zps8346ff17.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140406_150237_675_zps8346ff17.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140406_150237_675_zps8346ff17.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140406_150237_675_zps8346ff17.jpg%5B/IMG%5D%5B/URL")]


Some of the gear assembly, 6 pieces in each assembly.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140530_182630_830_zps5e0a9e4e.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140530_182630_830_zps5e0a9e4e.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140530_182630_830_zps5e0a9e4e.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140530_182630_830_zps5e0a9e4e.jpg%5B/IMG%5D%5B/URL")]


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140602_193935_349_zps08a00d91.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140602_193935_349_zps08a00d91.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140602_193935_349_zps08a00d91.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140602_193935_349_zps08a00d91.jpg%5B/IMG%5D%5B/URL")]


More coming.

[Mike M]

absolutely impressive! so much more than the competition offers.

http://www.arizonamodels.com/product_info.php/products_id/78

[Blue Chips]

As interesting and impressive as your work is it also interest me, what is the story behind this reproduction need if you are able/willing to share?

Thanks
Ken

[ulpilot]

But theirs are just for R/C Models, mine are for full size man carrying replicas.

[ulpilot]

As interesting and impressive as your work is it also interest me, what is the story behind this reproduction need if you are able/willing to share?

Thanks
Ken


There are builders, collectors and restorers all over that need/want things like this, very small market.

[Ron Blum]

Very impressive. I almost want to go out and buy and antique just so I can use one of your gauges! Thanks for sharing your artwork.

[ulpilot]

Been so busy I forgot to update this thread, sorry for the delay.


Fuel Gauges have been finished and shipped,. Here are a couple of shots ,


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140629_175029_005_zpse6387142.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140629_175029_005_zpse6387142.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140629_175029_005_zpse6387142.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140629_175029_005_zpse6387142.jpg%5B/IMG%5D%5B/URL")]


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140723_193855_433_zps7db5d40b.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140723_193855_433_zps7db5d40b.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140723_193855_433_zps7db5d40b.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140723_193855_433_zps7db5d40b.jpg%5B/IMG%5D%5B/URL")]


Retainer rings for holding in the glass


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140724_185203_169_zps06d3026d.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140724_185203_169_zps06d3026d.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140724_185203_169_zps06d3026d.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140724_185203_169_zps06d3026d.jpg%5B/IMG%5D%5B/URL")]


Ready to go.


http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140704_111951_021_zpscb6b232a.jpg.html]http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140704_111951_021_zpscb6b232a.jpg[/URL (http://[URL="http://s76.photobucket.com/user/ulpilot303/media/Restorations/Maximall%20Fuel%20Gauge/IMG_20140704_111951_021_zpscb6b232a.jpg.html%5D%5B IMG%5Dhttp://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Maximall%20Fuel%20Gauge/IMG_20140704_111951_021_zpscb6b232a.jpg%5B/IMG%5D%5B/URL")]




Next project is the restoring and replicating of German airspeed indicators. One of the most fascinating aircraft instruments ever mass produced.




http://i76.photobucket.com/albums/j6/ulpilot303/Restorations/Anemometer/Original%20Anemometer/anemometer_zps68b641eb.jpg (http://s76.photobucket.com/user/ulpilot303/media/Restorations/Anemometer/Original%20Anemometer/anemometer_zps68b641eb.jpg.html)

[champ driver]

Extremely interesting, please keep up updated.