Elevator Horns

 

The Control Horn on each elevator are made from 20 gauge cold rolled steel.  I hammered them using a 3x Rivet Gun.  It takes about 20 minutes to hammer each of the 4 halves. Go back to the old posts for an explanation of the tools, they worked really well.  I made a new block to hammer on from the limb of an Ash tree the power company cut down.  If you look close you can see the paths of the Ash Borers that caused it to be cut.

The template for locating the Cable Attach Holes sits nicely in the corner radius.

I drew the cut outline on the inside with another template. Then I added some cut lines on this side to follow with the band saw.  

I just used a piece of 1x2 next to the blade to support the metal while sawing.

I used the nibbler around the tabs, then back to the band saw and the 1x2 for the straight cut.

I marked the center line for the 1" spar tube, then put 2 marks for the outside edge.

I used the circle template as a guide to look down and draw a cut line.

I sort of followed the same process for marking the cut for the 3/4" rib tube.  I drew the center line, then the outside tick marks.

Then I used a 3/8" thick piece of aluminum to mark where the edge of the tube cut out touches the outside of the shell half.

Then I drew the cut line curve so it forms a 3/8" radius when viewed from the end of the rib tube.

The nibbler was used to rough cut the opening, which will be finished once I weld the shells together.

The parts are ready for assembly and welding.