

Micheal Leath Inner circle 1046 Posts 
Could someone explain how they make an expanded shell?

Stanyon Inner circle Landrum, S.C. by way of Chicago 3407 Posts 
Let's see...
Take a real coin...put it on a milling machine and take out all of one side (Heads or Tails)of the coin, excluding the thickness required to retain the opposite facing and the milled edge...the edge is then worked outward, from center, far enough to allow a like coin to nest within. That's the bare bones! Cheers!
Stanyon
aka Steve Taylor "Every move a move!" "If you've enjoyed my performance half as much as I've enjoyed performing for you, then you've enjoyed it twice as much as me!" 
Bobcape Elite user Rapid City, SD 470 Posts 
I think you have those two actions reversed. You start by expanding the coin in a press. Then you move to the lathe. You need a step collet that fits the expanded coin. Then using a cutting tool ground for inside cutting you begin making cuts from the center out until you approach the correct depth and diameter. Make the final cuts very light to account for tool "pushoff". Deburr the shell edge and you're done.
Bob
Be Amazed! + Enjoy The Magic!

Stanyon Inner circle Landrum, S.C. by way of Chicago 3407 Posts 
Quote:
Wouldn't be the first time Bob! This could be a tomatoes / tomatos thing. I'm sure our resident gaffers will check in soon! Cheers!
Stanyon
aka Steve Taylor "Every move a move!" "If you've enjoyed my performance half as much as I've enjoyed performing for you, then you've enjoyed it twice as much as me!" 
kaytracy Inner circle Central California 1793 Posts 
Okay that helps me! I was getting ugly face deformities form the cutting tool in my shop! Perhaps a smaller collet, instead of the single size! and i will try the press part first, my cutter fits the coin
e x a c t l y, so little room for error there! Mwua ha haaaa!
Kay and Tory
www.Bizarremagick.com 
Bill Palmer Eternal Order Only Jonathan Townsend has more than 24260 Posts 
Actually, he had the order right. I have a friend who makes expanded shells. You start off by milling out the inside of a regular nongaffed coin. This requires a special fixture that has an inset plunger to pop the coin out of the holder, which is basically a collar. The coin is held in he collar with dopping wax.
Next, you have a series of slightly larger collars, each of which allows you to expand the coin a little more. The first is about .020 inch larger than the OD of the coin. The second is about .020 inch larger than the first one, etc. You gradually expand the coin by pushing the metal outward from the inside of the coin. When you finally have it almost ready, you knurl the outside edge of the coin and then do the final milling on the inside. If you start by using pressure to expand the coin and stretch it out, it flattens the face of the coin. There may be some makers who do this, but it's not the recommended method.
"The Swatter"
Founder of CODBAMMC My Chickasaw name is "Throws Money at Cups." www.cupsandballsmuseum.com 
Stanyon Inner circle Landrum, S.C. by way of Chicago 3407 Posts 
Thanks for the vindication Bill!
Cheers!
Stanyon
aka Steve Taylor "Every move a move!" "If you've enjoyed my performance half as much as I've enjoyed performing for you, then you've enjoyed it twice as much as me!" 
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