ROTJ Darth Vader Graflex Stunt (MoM)(a.k.a. DV6) – by WannaWanga

[thd9791]

I’ve had success (after heating with a torch but not for very long) using flat pliers to bend the tabs slowly until the tabs/pliers bump into eachother. I then lay it in a vise and close the vise so there is constant pressure along the whole thing. I do this with D rings too.

 

[Poikilotherm]

Thank you all for your help and input (more welcome). I think I have a plan. The interwebs say that the bend(blue arrow in pic below), has become work hardened. To be able to bend this area again, the material must be softened with an anneal. 800 degrees F min. for brass(but also the brass will still soften some if that temp isn't reached.) We have these tweezers at work that pass current between the tips to heat metal for things like soldering. I am going to put the tabs between the tips and activate to pass the current(green line representation in pic below). With an IR heat gun, I will aim it at the blue arrow area and try to get this to 800 degrees F, hold it for a bit and then let it cool to room temp naturally.(repeat on other tab) The red line, I figure, is my oxidization line. If the oxidation gets too close, I will need to stop. Once they have cooled to room temp, I will use a heat gun to get the tab area warm-hot and start bending the tabs with pliers to greater than 45 degrees and then finish with a vise. Does anyone see any flaws with this plan?
I really hope this plan yields flatten tabs on this piece but also helps others from cracking their tabs!
View attachment 1919312

Heat the area as much as you like and don't worry, even if the lack of heat causes it to break, you can weld it back together with a welding tool, but it will eventually be covered with paint.
Previously recorded a video and pictures of the process of welding to repair after a break.

 

[Darthmagpie]

Thanks all for the feedback. Using the heated tweezer plan, I was able to get the bend up to 750 degrees F. I ve been under the weather so haven't tried the bend yet, but will let you know how it goes.

 

[Darthmagpie]

SUCCESS!

Now I need a nap...

 

[Darthmagpie]

This thing is like Swiss cheese. I have to believe some prop assistant was having a bad day and after the blade loosened up for the 10th time, he said to the machinist-PUT 50 SCREWS IN THE DAM THING AND LETS BE DONE WITH IT.