18 SERVO 05.2016
fixture and the liberal
application of fire, the
chain guard was able to be
bent into shape easily.
The top and bottom
armor needed to be
shaped as well, but to a
shallower angle. To do this,
a similar fixture was used
and the side frame rails
were kept handy to check
the bends to ensure they
were a bit past the ideal angle
without going too far.
This was done so that when
everything’s bolted down tight, the
bent panels will have a bit of pre-load
keeping them flush with the frame.
In addition to the bending
required, there was a significant
amount of welding needed to
assemble the weapons for Morrigan.
Initial prep consisted of cutting the
chain segments to length and
grinding weld grooves into the half-links that would attach the chain to
the weapon shaft.
The flail teeth were designed as
two pieces so that they
could be wrapped around
a solid link. This minimizes
the strength loss in the
chain itself, and allowed
the weld locations to be
moved out of axis with the
expected forces on the
teeth. The hope is that by
orienting the welds this
way, they’ll be able to
easily survive the loading
they’ll see in action.
The orientation of the thresher
impactors was always a bit up in the
air. I’d gone back and forth between
aligned and offset several times
during the design process, and finally
settled on aligned impactors.
The downside of this setup is the
Thresher blades tacked in place to lock their orientation. With the chains welded to the shaft, the flail weapon was
Halfway through the welding process
on one of the flail teeth. Pile of parts prior to welding.
All eight flails ready for welding
to the weapon shaft.