1. Trafficator box

Folding blocks for tin plate, patterns, and panel-making tools.

Folding blocks for tin plate, patterns, and panel-making tools.

End forming, then trim edges and file to exact shape and profile

End forming, then trim edges and file to exact shape and profile

Spot welded ends, and solenoid tab

Spot welded ends, and solenoid tab

Spin galvanized and rubber grommet fitted. Completed.

Spin galvanized and rubber grommet fitted. Completed.

Marking out tin plate using template. Original box shown in centre.

Marking out tin plate using template. Original box shown in centre.

Box bodies ready for final finishing and spot welding of ends and solenoid tabs

Box bodies ready for final finishing and spot welding of ends and solenoid tabs

Final trimming and finishing completed, rubber cable grommet fitted. Test fitted with original.

Final trimming and finishing completed, rubber cable grommet fitted. Test fitted with original.

Folding box body, hand fold then panel hammer. Holes already drilled.

Folding box body, hand fold then panel hammer. Holes already drilled.

Spot welding internal tab, Rod Brayshaw Katikati

Spot welding internal tab, Rod Brayshaw Katikati

First production batch panel steel to original gauge.

First production batch panel steel to original gauge.

2. Escutcheon Plate

Trafficator on an orignal MG PA showing placement and fitting of original trafficator escutcheon plate

Trafficator on an orignal MG PA showing placement and fitting of original trafficator escutcheon plate

Milling mild steel folding block

Milling mild steel folding block

Folding detail taking shape of formed escutcheon plate. Top remains flat, and tabs ensure plate retains correct size.

Folding detail taking shape of formed escutcheon plate. Top remains flat, and tabs ensure plate retains correct size.

Pre-production escutcheon. Clear packaging tape protection layer on folding surface. Shown with mounting box

Pre-production escutcheon. Clear packaging tape protection layer on folding surface. Shown with mounting box

Completed escutcheons, nickel-chrome plated

Completed escutcheons, nickel-chrome plated

3. Arm

Lost wax investment casting using a metal plate sandwich mould for a brass moulded nickel-chrome plated arm.

Complete trafficator removed from the box

Complete trafficator removed from the box

Sandwich mould started with brass base plates, and location pegs. Mould section and insert for the bulb area machined. Mould sections allow for 1.5% shrinkage.

Sandwich mould started with brass base plates, and location pegs. Mould section and insert for the bulb area machined. Mould sections allow for 1.5% shrinkage.

 
Tooling and laser cut brass .025" (0.64mm) escutcheon plate blank. At top first trial using rubber hydroforming method.

Tooling and laser cut brass .025" (0.64mm) escutcheon plate blank. At top first trial using rubber hydroforming method.

Folding edges with hammer on to steel block in to gusset on folding block. Protective brass clamping sheet on the front

Folding edges with hammer on to steel block in to gusset on folding block. Protective brass clamping sheet on the front

Top shape in progress. For production the complete outside fold to be done first, followed by inside fold, then cut outs removed and folded.

Top shape in progress. For production the complete outside fold to be done first, followed by inside fold, then cut outs removed and folded.

Polished, and pre-assembly test fit, ready for chrome plating.

Polished, and pre-assembly test fit, ready for chrome plating.

Escutcheons with boxes

Escutcheons with boxes

 
Materials for the metal die block to cast the wax

Materials for the metal die block to cast the wax

Revised mould plates with 12mm laser cut and ground steel top and bottom plates. Arm pattern also shown

Revised mould plates with 12mm laser cut and ground steel top and bottom plates. Arm pattern also shown