[TheForge] Little Giant frame repair

[Andrew Vida]

Dragons Watch Forge wrote:
> 
> Hi Andy,
>     To be honest, I have not looked at the parts he was referring to.
> However, I did notice the hammer we were looking at while discussing
> this problem had a separate sow block from the rest of the frame.  How
> it was attached I did not notice.

	Tapers in a dovetail, just like the die blocks.

	So, are you saying the place where the sow block mounts is
	broken?  If so, then you may have a far more serious problem,
	though if you have enough meat there to cut another dovetail
	you could do that an then just make a taller sow block.  You
	would have to carefully consider the design of the frame to
	make sure you're not cutting into anything vital such as
	where the 'C' portion is meets the base.  That will be
	an area of some stress concentration and you don't want to
	remove any material in the immediate vicinity.  It's hard to
	say anything intelligent without seeing the actual hammer.

	Last, if you're out of material, then the drill and tap
	solution might be your only real avenue.  As I think of 
	it more I see that if it is done right it should not pose
	any serious troubles.  It is, after all, a comparatively
	small hammer.  A few aircraft grade bolts should do.  
	Perhaps you could find some in a whitworth thread to minimize
	stress risers in the casting.  One way you could ensure
	they don't loosen would be to cut square counter bores
	where the bolt heads would seat and then pour some babbit
	metal over them after assembly to lock the heads in place.
	It would provide a very strong lock on the bolt, yet be
	comparatively easy to remove if needed.  That might actually
	be your ticket.  Simplifies the machining, lowers that cost,
	leaves more meat on the hammer, is strong, and allows for
	good maintainability.  It also eliminates the inordinate
	stress of wedges in the cast frame.  They can and do cause
	breakage.  It could well be the reason your hammer broke.
> 
> Larry