[TheForge] Re: OT Threads ?

Sun Feb 5 07:45:30 EST 2006

Hi Mike,  Sounds like we're in kind of the same mode ......(winter).

I'm fixing three projects for contractors(welding with forge bending
assist).......... (Is that a meta-smithing Project?)

Also I've been doing some small forging projects.

1) Series of 8 door pulls for sliding barn doors - which I made up better
tooling and documented the entire process on PowerPoint like I've been doing
with many of my metal projects.  I'm finding that program is a great way to
not only document and save how you did it last time - but you've got
speaker's notes you can put the materials lists into, notes on sequence and
methods used - and an outline can be printed  in case you decide to do a
class or workshop on it........and basicly with the new "create and album"
feature - it's a smoking way to enter a whole file of pictures into a
documentation in one feld swoop.  I really like it.

2) Making locking/aligning/hook arrangements for sliding barn doors so it
looks "somewhat traditonal" and gives a level of security to the barn so
someone doesn't just walk in and take sheep, jeeps, cedar canoes, etc.  Two
customers have requested this - so I'm making something that fits different
thickness doors - good head scratcher, but I'm gaining.

3) Finished 10 fire pokers that look like whimsical swords for christmas
presents and the extras are heading to a gallery close by for consignment.

4) Also eight of my coat racks are headed to the same gallery/outlet.

5) An interesting set of "entrance Trellises" a customer requested are in
progress - and I really like the pattern the customer sketched out.  I've
made extra elements to put together a garden gate - and that will head to
the gallery/outlet as well to see how others like it.

Shop projects with hopes of using winter as an excuse to get them done:

1) Glad to hear your making progress on the A&O - motor running is a good
sign.  On this end the machining for the Nazel 3B is continuing at a snails
pace (Frosty calm yourself)...... and the main shaft bushings are complete
and installed back into the hammer with the crank & flywheel assembly.  I
felt this was a major advancement towards completion - and now I'm machining
the lower compressor rod bushing, reboring the rod true to round after
making new side shims for it, and also just fit the TGP shafting to the
wrist pin bose in the piston, and now have to fit a bushing that pin and the
top of the rod as well.  Chatting with Bob Bergman and Terry Suthers made me
aware that the shims (gasket paper) in mine weren't an "after manufacture
repair" - Nazel made two style rods and did it continuously thru the range
of manufacture.  I'm still trying to figure why they did this - as the shims
add an extra step to making the shims to within .001, and pining them to the
lower rod cap.  Fun repair all in all and I'm getting lots of lathe and
milling machine time evenings and weekends.

2) Wiring the Nazel has taken a giant leap forward now as well.  All the #2
copper cable has been run thru conduits to the knife switch I sent you
pictures of, then on thru the 20 HP phase converter, and into the three
phase breaker box.  I'm headed to the electric outlet tommorrow to pick up
the few small items to complete the wiring main runs and box locations -
then it's connect it up and spin the motor time!!!   I think once I see this
happen I believe the rebuild will take on a whole new drive forward.  A
running motor and spinning flywheel is more than half way as far as I'm
concerned.

3) More power tooling fixtures - I've had two workshops in the past month
with tool and die making friends and we're coming up with new ways to make:
	a) Firescreen chamfered frames in the power hammer
	b) Large steel discs cut in the punch press from 1/8 sheet.
	c) Faster lathe tools for tenons and radius turnings for swage positives
	d) Power slitting in a punch press
	e) Ball swages for pipe and hollow form forging
	f) "Bread Boards" as one fellow called them for fences and strippers on the
punch press -it acts as a method of free cutting in a punch press instead of
fixed placement dies.  Can be used for texturing and veining.

	*still have not gotten to perfecting the hot - slit/drift process for the
hydraulic press - but an upcoming job may throw that into warp speed with 80
feet of balisters to place.

	I can't offer any suggestions on the air compressor - other than what your
doing with a test sample on the smaller motor to see what results are seen.
Send me a picture of the compressor if you have a chance - maybe that'll
help the imagry.

	The machinst that comes by to check up on me during Nazel madness is
talking of making an electric truck with me.  I just sold the heavy pickup
bed off the back of an old toyota - and we're gonna pull the motor and make
an "around town chore wagon".  That's 95% of my driving - and what better
way to avoid all those crash tests, and registration delemas than to take
something we already have approved (and sitting in my back field) and make a
useful golf cart on steroids.    :-)
	We're also putting lots of effort into greenhouse, rootcellar, and water
supply here on the farm - I'm going away from supporting corporate america
and going to do more right here - for less..........which is what it will
take to survive the next three years of this current adminstration.  What my
retirement ends up as doesn't really matter at this point - I've got to make
it to 2010 first!

	Low tech is the answer to the problem.  Stock up on what you need while you
can afford it - and try to have fun!

Ralph

-----Original Message-----
From: theforge-bounces at mailman.qth.net
[mailto:theforge-bounces at mailman.qth.net]On Behalf Of Mike Spencer
Sent: Saturday, February 04, 2006 9:02 PM
To: theforge at mailman.qth.net
Subject: [TheForge] Re: OT Threads ?

> I take it no one has done any work worth talking about lately?

Just to get back on topic....

I've only had a fire in the forge a few times recently, to make some
small parts or free up some stuff balled with rust.  That's because I
have three meta-smithing projects going at once and all are stumbling
along more or less as usual:

+ A&O air hammer.  Have an industrial engine running, jack shaft,
  gear, pillow blocks, pulleys and supports for same.  Hammer was
  buried in snow yesterday.  Have to drag the engine back inside and
  re-position it on its trailer, only the engine is still snowed in,
  can't get to it even with the 4x4 truck.  Getting close, though.

+ Post drill.  Finally got a bag of 3/16" bearing ballsm got
  everything assembled and turning nicely.  I think I now have to do
  some careful filing of the keyway in the advance screw where I
  brazed it, make a thumb screw and get a Jacobs chuck for it
  somewhere.

+ Old compressor, Atlas Copco 427 PSI 10 HP.  Can I get 100 PSI by
  cobbling up various pulleys and belts and a smaller motor?  Gotta
  wire up and mount an old pump motor for a trial, modify the
  compressor's old-fashioned air cleaner etc.

Parts of all these projects are scattered around the shop.  I'm at the
computer now because I broke a cast flange into three pieces and
decided it was time for a coffee and some liver & onions.

> I can run a length of pipe from my cable modem to the tuyere.

If we go much further, you won't even need to light a fire, just use
the flames emitted by the modem.  :-)

- Mike

--
Michael Spencer                  Nova Scotia, Canada       .~.
                                                           /V\
mspencer at tallships.ca                                     /( )\
http://home.tallships.ca/mspencer/                        ^^-^^

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