Birth Of Gustav

[H.I. Gosses]

Here some pic's of robot fabrication.

The first is a picture of the layout of the face, with the eyes already punched out

and the mouth stamped out.

If you make a "One-off" you make one part fit the next.

The problem with a series is that all parts should fit all others. The ubiquitous

computor came to the rescue. I "CAM-med" the layout and glued it to the tin.

In the middle are to plates with the die for a "pressed" nose. This whole sandwich

goes into the hydraulic press. The guides are to keep the positive and the negative die

in line (hopefully)

Syringe is not a secretive habit but to apply superglue.

[H.I. Gosses]

Here you see a small handpress (3 metric tons) used to make the mouth.

This is done with two oblong stamps; one smaller than the other.

The tin is pressed into a layer of lead (-not a contra-die), so you get a nice smooth edge.

As it is difficult to guide this process, the two stamps must be concentric, it is done first.

When it goes wrong, not too much work is lost.

[H.I. Gosses]

Here we see "The cutting of the Noses".

The glue on paper was a good idea, it saves on scribing,

but the puches do not like it at all. They refuse to cut through first

a soft layer, which deflects them. I made a specially ground punch.

Easier than scribing out 25 noses.

This is a very precise spindlepress, which started life a a tailstock of a large lathe.

[H.I. Gosses]

Another little press, that started life as a $5.- drillpress, used to press out

the "Rivets" in the body. The pair of plyers is used for the riviets that

can not be reached by the press, i.e. 'round the corner.

The plyers are harder to use as they have no guide and the stroke and

pressure is not limited.

[H.I. Gosses]

And now for the ONE picture, others besides John might enjoy.

Gustav in his constituent parts.

[H.I. Gosses]

Gus #00 looks on at his descendants.

-At least their faces.

There are two nose variations: the mounted nose, which gives a

more austere and severe impression and the pressed nose, this gives

the toy more "Toy-ness" and makes the face much, much softer. (la Gustava?)

[robert]

Thanks for the tour Henk! It helps me to appreciate the incredible amount of work that goes into your production. I like the fact that the "human" element is introduced enough to make each robot slightly different. I can see that the mouths and rivet pattern will have some variation, and the fact that so many of the pieces are hand punched, hand cut and handpressed should also add to the uniqueness of each robot. Fantastic!

[robobob]

Henk,

Now THATS a garage !!

Thanks for the wonderful tour, and photos

of some of the hardware involved...It gives

me something to aspire to !

(although it looks like I might have to sell my bike,

and expand the workshop into the extra space!)