At Hess Engineering Lab, we began fabricating the crutches in the machine shop. We cut the crutches to fit the modifications, and created the new parts that will comprise the shock absorber (spring).
First, the PVC pipe was cut into four 10" lengths using the multi-angle bandsaw. This machine uses a floating bandsaw that lowers into the pipe, using its weight to cut.
Cutting PVC pipe on the multi-angle bandsaw.
Next, the cutches were cut on the bandsaw. A 4" section was removed from each piece of the crutch, allowing room for the 6" long spring. This will make the new crutch a total of 2" longer than the origional. The additional 2" length will account for the commpression of the springs during use.
Cutting the aluminum crutches on the band saw.
The sharp, cut edges of the aluminum crutch were then ground down using an orbital sander.
Rounding the edges with the Orbital Sander.
Next, four 1.5" slots were cut into the ends of the PVC pipes using the band saw. The slots will allow the pipe to deform when a hose clamp is applied. This is necessary because the diameter of the crutch tube is slightly smaller than the inner diameter of the PVC pipe. The hose clamp will compress the PVC pipe to connect it to the crutch.
Cutting The PVC slots on the Bandsaw.
Hose Clamp
Design of Shock Absorber
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