What stunned me is that with just study, cerebration, (and the expert computer work of my smart Dutch Engineer to build my dreams in 3D), and no previous steel-forming experience, (beyond bending 1/8” steel rods by hand), I, (a sinner), could do this!
It required making a giant 80 year old (straight orthogonal curving only) steel rollers, 4 muscle-men pushers and a crane above, PRECISELY track my computer generated guide line as the rollers pulled in the flat steel plate.
Theoretically, this guideline, printed on paper and aligned on the flat steel plate, should guide the orientation of the steel plate to the rollers.
These roller machines expect incoming flat steel plate to enter between the massive rollers, orientated exactly 90 degrees to the length of the rollers.
But we wanted to advantage of the fact that steel entering at an angle, gets a twisted spiral curve to the steel late. That is always avoided!
Well we prepared a theoretical and totally unproven idea, that we could use this effect to accurately deform the steel plate exactly to our computer plan.
Our engineer advised me to have the line always enter the rollers at exactly 90 degrees. This way, by a miracle, all the panels gained progressively varying radii, (different on each side), to deliver perfectly smooth sinuous curves. These were checked with templates and found to be within a mm of the plans! I was astonished that “thinking” can trump “experience” to give apparent “skill” so that the steel workers thought I was a master, when I am actually totally learning!
Nothing was done twice to correct an error, but just to allow the old “workhorse” rolling machine to deliver the final force needed to meet the specified complex curves.
The various panels fitted together as perfectly as the bodywork on a luxury car!
The management of the steel fabrication house asked if I wanted to set up permanently in an area in their factory!
But then I would risk being exposed as a fraud!
Asher