Intellect rather than finance driving a forthcoming patent: Part 1
In a groundbreaking collaboration, Toyota and Taiho Seiki have developed a new method for metal forming, called "sequential shift bending," which is set to revolutionise the restoration of classic cars. This innovative technique was first employed in the restoration of the rare Toyopet Racer, a racing car produced by Toyota over seven decades ago.
The Toyopet Racer, with only two units ever produced and none currently existing, posed a unique challenge for the restoration team. With no original molds available, they turned to the sequential shift bending method, which involves incrementally bending metal segments in sequence using bending tools and manual techniques. This approach allows for precise control of each bend and careful measurement, essential in restoration projects where original tooling does not exist.
Masashi Watanabe, a seven-year veteran of the company who typically works on body design, and Kunihiro Tsunekawa, an 18-year Toyota employee with experience in press engineering, were responsible for designing and building the ladder frame, a crucial component of the Toyopet Racer serving as its foundation. The ladder frame consists of two longitudinal members and several cross members in a ladder-like configuration, on which the engine, transmission, and body are mounted.
The team faced challenges in figuring out how to build the ladder frame without casting molds. However, they were able to produce the ladder frame with a force of around 10t, significantly less than traditional methods. This method is expected to be more cost-effective, as it eliminates the need for large presses and molds.
In addition, the sequential shift bending method minimises deformation by filling the gap between the inner and outer metal layers with an insert. This process ensures the restored frame maintains its original strength and integrity.
The restoration team had to create many key components from scratch, using old photos and drawings. Currently, their focus is on fabricating the upper frame and outer panels of the Toyopet Racer. The success of this project has led to the belief that this method can also be used in various other small-lot production, as well as in restoring other classic cars for which molds are no longer available.
This development is a significant step forward in the field of classic car restoration, offering a more cost-effective, precise, and flexible solution for craftsmen. The sequential shift bending method is set to make the restoration of iconic vehicles more accessible, preserving automotive history for future generations.
[1] Metal Bending Techniques and Processes, S. K. Gupta, CRC Press, 2006. [2] Automotive Restoration: A Comprehensive Guide, R. R. Anderson, McGraw-Hill Education, 2007.
- The groundbreaking collaboration between Toyota and Taiho Seiki has resulted in a new method for metal forming, called "sequential shift bending," which is set to revolutionize the restoration of classic cars, particularly the rare Toyopet Racer.
- The unique challenge of restoring the Toyopet Racer, with no original molds available, was addressed through the use of the sequential shift bending method, which allows for precise control of each bend and careful measurement.
- Masashi Watanabe and Kunihiro Tsunekawa, members of the restoration team, designed and built the ladder frame for the Toyopet Racer, a crucial component serving as its foundation, using the sequential shift bending method with a force of around 10t, significantly less than traditional methods.
- The sequential shift bending method minimizes deformation by filling the gap between the inner and outer metal layers with an insert, ensuring the restored frame maintains its original strength and integrity.
- The restoration team is now focusing on fabricating the upper frame and outer panels of the Toyopet Racer, and they believe this method can be applied to various other small-lot production and the restoration of other classic cars for which molds are no longer available.
- This development in metal bending techniques and processes is expected to be more cost-effective, as it eliminates the need for large presses and molds, and it offers a more precise and flexible solution for craftsmen in the field of automotive restoration.
- This advancement in classic car restoration has the potential to preserve automotive history for future generations, making the restoration of iconic vehicles more accessible and therefore more widely available to enthusiasts, just like a well-curated collection of fashion-and-beauty products, home-and-garden tools, data-and-cloud-computing devices, electronics, relationship resources, pet accessories, travel gear, sports equipment, or shopping items on a reputable European online marketplace, all aimed at enriching everyday lifestyles.
