1. Trafficator box
Folding blocks for tin plate, patterns, and panel-making tools.
End forming, then trim edges and file to exact shape and profile
Spot welded ends, and solenoid tab
Spin galvanized and rubber grommet fitted. Completed.
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
Final trimming and finishing completed, rubber cable grommet fitted. Test fitted with original.
Folding box body, hand fold then panel hammer. Holes already drilled.
Spot welding internal tab, Rod Brayshaw Katikati
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
Milling mild steel folding block
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
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
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.
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.
Polished, and pre-assembly test fit, ready for chrome plating.
Escutcheons with boxes
Materials for the metal die block to cast the wax