Assignment 3:
Tutorial 


How to make a Torus

Tools and Materials:

• Aluminium sheet
• Log with a rounded notch 
• Steel Planishing Hammer
• Nylon Mallet
• Steel pipe

Step 1

Mark and cut a strip of aluminium sheet 300mm x 100mm.

Step 2

Bend the strip of aluminium around the log to get the initial shape of the torus.

Align the notch in the log to the midline of the aluminium sheet to ensure the reverse curve is centred.

Step 3

Using the nylon mallet hammer softly to feel for the edges of the notch. Work hammering in a circular direction around the notch starting in the middle of the sheet. Once you have found the edges, begin to hammer harder working at the edges to form into the notch.

Note: Do not hit the middle of the circle. The shape must be formed from the outside in. 

Step 4
In the centre of the circle you will notice that the metal has been forced into a high spot as there is nowhere for it to go. Use the mallet to shrink this area into the form of the notch.

Tip: while doing this step make sure to hold the piece firmly to the log to ensure it stays centred over the notch.

Step 5

Move the piece around the log repeat steps 3-4.

Tip: Make sure the mid line of the sheet stays centred with the notch otherwise the reverse curve will form on an angle to the straight edges of the sheet. 

Step 6

Once you have formed the full length of the sheet it should look similar to the one pictured below (either with more or less of a curve).

To even out the larger bumps in the reverse curve, keep it in the notch and continue using the mallet to smooth out major ridges.

Tip: Be careful not to beat the ends to much as they will flare out.

Step 7

Using a steel pipe roughly the same diameter as the reverse curve, smooth out the remaining bumps with the mallet.

Step 8

Using the curved bar dolly and the flat face mallet, form the edges around the bar to achieve a finished and clean curved look.

  

Step 9

To clean up any bumps that are still noticeable repeat steps 6 - 8 where necessary.

Reflection

Discipline - Industrial Design

A spectrum of marine vessels and shapes that relate to my torus.

The flared shape (reverse curve) of the side sheets deflects spray away from passengers.

 

Streamline hull shape on a catamaran uses an inverted torus between and on the hulls for added integral strength in the structure.

My own work

Prop blades require scoop and thrust through a complex, twisted torus.

Hydrodynamic hull design with multiple connected tori providing a combination of streamline, strength and deflection.