New Correct Ace,Aceca,Greyhound & Cobra Fuel Caps

[BEX308]

Keith,
   I for one am very glad that you took up the gauntlet. While it may seem to many that this has been a VERY long process it is actually quite typical for this type of work. It is far more important to get it right than to get it quickly.
   Many Thanks
   Pete

[rsk289]

I absolutely agree - I have had to use a square-buttoned cap for the last 6 years, what's a few weeks wait for the right thing?  The quality of a classic car restoration lies entirely in the detail...
   
   Thanks, Keith

[AC Ace Bristol]

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   .
   
   
   Latest Update...  9th May 2012
   
   Good News & Bad News........ the light at the end of the tunnel, is / was a bloody train not daylight.
   
   Further to my latest exchange of phone calls, I made a visit to CEANDESS this morning and had meeting with Chris Smallman. (Quality Control).
   
   Good News..[;)]
   
   
   The Fuel Filler Cap castings have been cast and are in process of being polished in readiness for chrome plating...  I took a picture of a couple of rough / raw cast units and  three which had been tested for chrome plating, ( note,  these units were only lightly polished and not pre drilled, but just tested for chroming)  Picture from my Black berry to follow.
   
   
   The Bad News..[:(]
   
   
   The Lad..[?] Tasked with linishing the key hole shaped latches, Ruined not one but every bloody one, ( Consistant or what !! ).
    So a complete new batch have to be made,  copy of letter and explanation from Chris Smallman ( CEANDESS ):- as below:-
   
   
   Good morning Keith,
   
   
   Following your recent visit, here is a status update on the AC caps.
   
   Please take a look at the attached latch photographs. As you can see they are certainly not up to standard and have now caused yet another delay. I have spoken to the casting company regarding this.
   
   Apparently, what can only be referred to as damage, has been caused during the linishing operation. Following the casting of the parts a certain amount of flash would have been present. This would have then been Linished off on a belt sander type machine. It would appear that the job has been giving to an over enthusiastic employee who has just Linished them too much. Most notable issues are as follows-
   
   •   Large indentations from linishing on top face.
   •   Flats on the 'thumb diameter' from linishing.
   •   Several with flash/slag (?) inside the hook part of the    latch.
   •   Linished out of square.
   •   Excessive linishing on the top face leaving a feather edge around the 'thumb diameter'
   
   The casters are very embarrassed and apologetic with regards to this and have come up with a high quality but time consuming method to produce the latches. Usually casting boxes are packed with a ratio of reclaimed casting sand  to new sand. Using new sand alone is very difficult but they have a man who is very skilled in this art who will work continually on this batch until the full quantity is produced. Unfortunately he can only produce approx 60off latches per week! So we could be looking at 3 week production on these.
   
   The cap castings have been received and are in a suitable state to begin the production run (drilling prior to polishing). These should be completed tomorrow ready for sending for polishing.
   
   I can only apologies for these continued delays resulting in this long drawn  out saga. I hope you can bear with us.
   
   Personally I cannot wait to have the completed batch ready for despatch so I can return to a full night's sleep!
   
   Best Regards
   
   Chris Smallman
   Quality Engineer
   
   
   Likewise.....  I too wish to get a proper nights sleep, What started as a goodwill gesture in helping two Club Members in USA, snowballed and has now become a Avalanche!!
   
   Seriously,  Gerry & I would like to thank all who are patiently waiting and request they please hold on for a few more weeks,  We will get the quality finished product and Chris, Gerry & I get a good nights sleep.
   
   Keep you all posted , In the meantime I will get a few photos on line to complement this latest posting.
   
   Cheers for Now
   
   Keith..[:)]..[:)]

[nikbj68]

OK, let`s start with the good news!
   
   Here`s a selection of pre-production caps, in raw-metal and chromed, but not given final polish as they were solely to approve the plating process:
   
   
   
   
   
   And now the results of the poor linishing technique: [:(]
   
   
   
   
   
   Fishing weights, anyone? [xx(]
   
   
   
   What a shame. I would guess that the linishing lad is now the tea-boy and sweeper-upper!

[Robin A Woolmer]

This is all down to supervision & proper instruction, do not blame the hired hand!

[Migge]

I have no clue about the costs, but in these days ( and maybe 25 years ago)parts like this are may cheaper by CNC machines done. Once the program is written, you just need a block af alloy to get it done and every single one has the same quality. You just need a very good sample and it will be meassured by a laser as I know and all the important ankles, curves etc. will get into the program and then you can dubplicate as many as you want. Of course they need sanding, polishing, chromeing.
   Just my 2 pence or how is it said?

[aex125]

Keith, To echo what others have said, even though this has taken much time, thank you very much for taking this on. It is very much appreciated.
   
   Jay

[Gus Meyjes]

quote:Originally posted by aex125
   
Keith, To echo what others have said, even though this has taken much time, thank you very much for taking this on. It is very much appreciated.
   
   Jay
   

   
   I second that! Thanks Keith!
   
   Gus

[Migge]

Any news?
   
   Migge

[shep]

Welcome to the world of manufacturing! We have a pump manufacturing business and have all the skills in-house, R&D, CAD, Tool Room, CNC Machines, Plastic Injection Moulding, Assembly, Testing etc etc. We still have to buy in raw materials both metals and plastic, bearings, motors and elecrtic/ electronic components. It is frightening that we often have to go in to our suppliers to sort out their quality and production problems. The practical hands-on engineering knowledge is disappearing and the new intake of graduate managers often don't have a clue! What will happen in another 20 years when current 50 somethings have retired, I don't know. Keith you are doing a great job, and it is a shame about the temporary setback. Andy.

[AC Ace Bristol]

LATEST NEWS .
   
   Thursday  21st June 2012
   
   Just when I thought we had made serious progress and were on the home run !!.
   
   I receive the following email:-
   
   Good morning Keith,
   
   I've just returned to work following a week's holiday to find some major issues regarding the fuel caps.
   
   The polishing company phoned early last week to alert us to the fact that there were several of the caps showing large blow holes/pit marks in the surface that chroming would not cover. The casting company were made aware of this problem and they set about producing replacements immediately.
   
   The rest of the batch of caps were sent to the chroming company. As you know from previous trials the caps were showing small pit marks following polishing but the chrome covered these. The chrome hasn't been able to cover these marks on the balance of this batch. Regrettable these caps and latches are not fit for purpose so we will have to start production from scratch.
   
   It is now very obvious to me that sand casting is not the correct method of production for these caps. When I originally visited the casting company to ask their opinion on the production method they said there would be no problem. As they are the 'experts' on the subject I assumed they knew their trade and would be able to produce a satisfactory part.
   
   We are fully aware that this batch must be produced for you so we are in discussions with a die-casting firm to see if tooling can be produced. Matt Davies visited the die-casters on Thursday so I'll speak to them this afternoon to see how it is progressing. I doubt they will have a final price yet but this is likely to be the best route to go down so we will probably give the go-ahead to produce the tooling once all the dimensions are confirmed.
   
   This will obviously be quite an expense for Ceandess so , in the end,  this order will represent a considerable loss for the company. I can only apologise for these continued problems which mostly seem to fall at the feet of the casting company.
   
   I hope your customers can appreciate that we are doing all we can to produce a satisfactory product for them.
   
   Best Regards
   
   Chris Smallman
   Quality Engineer
   
   
   ACOC Members...
   
   Ceandess are being very professional and honouring our contract,  We will eventually receive a 100% correct and top quality fuel cap at no additional cost. It is just going to take a bit longer.
   
   Thank you for being so patient and understanding,  Jerry & I can assure you we will win, if we had known the task involved we would not have run with the project,  Too many hours of lost sleep and given up recording time spent visiting Ceandess Factory and answering phone calls and emails ....[:(]..[:(][:(]
   
   Keith..[;)]

[rsk289]

I greatly value the brave decision to start all this, and offer my wholehearted support to you for continuing to see it through.  Not easy, I'm sure - but speaking personally I'm extremely grateful!
   Roger

[Robin A Woolmer]

Die Casting tooling is very expensive,particularly for such a small production run, i see no reason why these cannot be investment cast & in fact i would cast them in Brass/Bronze, i had some parts (batch of ten) cast by an Art Metal Foundry who specialise in fine castings, this is not expensive in tooling terms & the castings will require less hand finishing, in addition if defect do exist they can be gas welded etc.
   Robin

[Mickmate]

How's these buttons looking [:D]
   

[Gus Meyjes]

Fuzzy?
   
   Gus