Monday, August 20, 2018

Started On The Drive Side Guard

So I worked all afternoon but don't seem to have accomplished much, when you look at the pictures. I started off by cutting up the mark up I did yesterday. I then went fishing in the old Delta parts box and found the cast iron sawdust fitting. It seemed more complicated than it had to be, they sure didn't skimp on material back then. Anyway, I fed it to the Startrite saw.

And after a little file work to refine the shape, this is what came out.

Next I cut an opening in the guard for the sawdust, welded a bolt in the bottom and a bracket on the bottom back edge to bolt the sawdust fitting to the guard, and finally welded the guard to the head slide.

Here is an outside view of the fitting.

And here is a view looking down into the fitting opening. Still needs a little cleaning up.

So will see about completing the blade guard tomorrow and installing a door on the guard.

Eye Candy From Miller Welding Gallery

So I started the mark up for the second guard this afternoon, when I got called away, I never did make it back into the shop. Looking through my welding folder this evening I came across a file I put together of some eye candy I found on the Miller Welding Idea Gallery. Most have probably seen some of these before but for those who haven't enjoy. It's a small file 900 KB and 29 pages, pdf.

There is a lot of talented people building a lot of nice projects out there. Some have sites where they document their builds some only share a few pictures on sites where it is safe to do so (like Millers). Forums are ideal for this kind of activity, but there are always a couple of characters who either insist they have the biggest dick and unless you are one of his chosen butt lickers he's going to whip you with it every chance he gets, or there is the character who wants to be a big dick and figures the way to get there is by dishing out backhanded praise comments to anyone who is willing to share his projects, probably in an effort to hide his own lac of production or imagination. If you call him on it, he will tell you he wasn't aware it was a backhanded comment. What a weasel, lol.

In a better environment I am sure many more great creations would be openly shared by creative people. Thats enough.

Sunday, August 19, 2018

Wood Turning Visualized Part 3

So a little late getting part 3 uploaded, spent the morning scanning, cleaning up, and assembling the pdf. Got it uploaded, but for some reason it didn't take, arrrrgggg, ha, ha. Had to upload it again.

This is the last part of this great little book. This part presents a large collection of turned shapes, face plate turned vessels, and various projects. Stools are great for practicing your turning skills, there are a few presented here.

I'll try to start on a new upload next week. Not sure on the subject matter yet.

To download Part 3 of Wood Turning Visualized go to my Books - Free Downloads page. # 56 - Part 3 - 5 MB - pdf

Saturday, August 18, 2018

Started On The Wheel And Blade Guards

So I spent yesterday working out details for the blade guards and hunting up materials. When I dismantled the old Delta saw I cut up the main frame to salvage what materials I could. I kept the door assemblies and after doing some serious cutting with half a dozen grinder cut off discs, yesterday, I decided I could make it work with most of what I had.

So this morning I started with the tension and tilt wheel side. After cutting away what I didn't need and adding the bottom piece you see in the picture, I welded the guard to the head slide.

The backside. Don't look that great but eventually a good scraping and paint job should improve the looks, ha,ha.

Well thats 2 boxes of weld rod so far. Loved these Hyundai weld rods, easy to strike an arc and hold it, even for this shaky old guy. Unfortunately Princess Auto doesn't carry them any more. 

I salvaged the hinges from the old doors, to reuse for the access doors. Here welded to the door and guard housing. I welded a nut to the inside lip and added a hand knob to keep it tightly closed.

Opened up to install wheel.

The wheel guard complete except for the make up to make it look pretty.

Hopefully get started on the second guard and blade enclosure tomorrow.

Friday, August 17, 2018

Seat Of My Pants Engineering - Corrections

So I started yesterday by reinstalling the carriage on the mill frame. I soon found out that my large blade guides were going to increase the minimum thickness of the last board without raising it off the bunks with a filler board. I proceeded to trim the bottom bearing mounts and modified the mounting bracket so that the bearing assembly was 1 1/2" lower than the rest of the bracket to prevent any possible hang-ups. The result the 2" bearing and 1" mount are the only thing lower than the blade. This increases my last cut to 2" thickness. A 1 1/2" filler board under the last cut will bring my minimum last cut to 1/2". Easy. I will need to raise the stops on the slide head to avoid running the bottom bearings into the carriage in a moment of inattention, ha' ha.

Here's how commercial mills get around this problem. There is no bottom bearing, instead there is a grooved flat surface. It is only right that they include lubrication and cooling engineered in. I suspect these produce more heat from friction and wear on the blade, without it.

So that was my morning yesterday. I spent the rest of the day making some finer adjustments and playing with the drives on the mill. Ideally this picture is the operating position. All operating functions, short of loading and turning the log, can be done from this location, even unloading a board is only a step away. When the electrical is done I hope to install extensions to the two winch controllers, so I can move around and observe the cuts as they progress.

So I made some fine adjustments to the sliding head, got the wheels perfectly parallel to each other and after setting the blade guides with good tension on the blade, I adjusted the lift cables so the blade was perfectly parallel to the carriage bunks. 

During this time I had both winches connected to the same battery I had used the previous day. I run the head slide up and down and the carriage end to end all afternoon, (I'm going to enjoy playing with this ha,ha.) without any noticeable loss of power. With 2 batteries and the small charging contribution from the engine system, a full day of sawing shouldn't be a problem.

Wednesday, August 15, 2018

Installed The Powered Height Adjustment

So productive day today, made a correction, got 5 band sawmill blades, got the chance to tell the norths worst delivery service where to go and how to get there, ha, ha. Long story, I'll not go there. Installed the height adjustment using another ATV winch and tested it out.

So the first picture is the extension and new hand wheel that I installed on the blade tension assembly, the previous installation was to short to extend beyond the future guard and I found this very heavy hand wheel. I had considered scrapping it a couple of times, because I couldn't find a use for such a heavy hand wheel, but turns out this is a perfect application for it. I threaded it 3/4" pipe thread and installed it with a 3/4" pipe extension.

In the same picture you can see one of the new blades. It is a 1 1/4" carbon silicon blade with 7/8" tooth spacing, and surgically sharp, (I drew blood just uncoiling it, ha ha.) made in Germany.

So on to the lift winch. This is another 1500 lb. ATV winch. A whole $40 about 10 years ago. To get it to work I had to make one modification. Since it is winding or unwinding two separate cables at the same time and rate, I had to drill a second retainer hole and set screw threading, at the opposite end and side of the winch drum. One cable feeds from the top and the other from the bottom so that when the winch operates, both cables are either winding or unwinding. The angle to the pulleys keeps the cable well spaced and top to bottom is less than one full rap on the drum, this keeps the speed consistent and even on both sides. I bolted the winch to the head, instead of welding, until I am certain this is going to work out.

Here is the pulley mounting, you can see the angle that keeps the cable well separated on the winch drum.

A wider picture of the winch and both pulleys. The cable passes through two 3/4" holes drilled through the head frame.

So we are ready to try it out. I pulled out one of the two marine batteries I recently got for this purpose, and connected up the winch.

So here we go ready to try it out. Here at the bottom slide locks still on and the cables just snugged up.

Released the slide locks and raised the cutting head to the half way point. Raised effortlessly, one side seemed to grab a bit occasionally. Checked the post and cleaned up a bit of weld spatter I found.

Continued to raise the cutting head to the top of its travel, traveled easy and steady. Lowering was faster and very steady. I have never seen this type of set up before, so I wasn't sure it was going to work. I have yet to see how battery life is going to hold up, but so far this works great.

When I put it into use a light greasing of the head posts will make it even smoother and less demanding on the batteries. This is another post where video would have been nice, maybe one day.

Tuesday, August 14, 2018

Head Slide Locks Installed

So you may recall, I was considering a linkage assembly for the head slide locks. However I would have been limited to a little more than a 1/4 turn. I decided a chain and sprocket assembly would work better and be less problematic.

Years ago I got a number of surplus double sprockets from Princess Auto, I cut one in half and welded each sprocket to 1/2" bolts. The bolt at the operator side is 4" long , I cut the head off after welding the sprocket to the bolt and installed a handle I got out of the old Delta parts box.

It was quite tight to start with, a couple squirts of thick gear oil helped a lot.

I started the remote bolt lock 1/2 a turn first, before I started the the handle lock. this to insure the remote side locks first, a good tug on the handle snugs up both sides.

Guides Complete

So it took a day and a half but I got the guides complete. As usual I overbuilt, in addition to the eccentric bearings the brackets are completely adjustable. I once read a forum discussion where one commenter stated that a properly set-up and running mill doesn't even need guides. That may be true in theory, but I doubt he ever run his mill without guides.

So here are some pictures of the completed guides. Here the guides and the brackets they fit into.

Another view.

Here installed in the brackets.

Another view. 

Here the brackets are installed on the guide arms and set to the maximum cut, 28" between guides. That will square up a 32" diameter log, not that I even have a log that big to square up, ha, ha.

Here a close up of one guide. I could gain another inch between guides by trimming the guide leading edge, but I have no need for more capacity and I would rather protect the bearings from getting run into the log.

Another picture of both guides pulled in.

Sunday, August 12, 2018

An Easy Positioner And Two Horses For The Metal Shop

So taking a break from the welding this weekend I thought it only right I upload a few quick welding projects. First is probably the worlds most easy positioner. I have had this file for a very long time, so I can,t remember where I found it. The positioner is designed for light work. Like the one I built a few years ago, it is fully adjustable, however this one mounts to a table.

Don't forget to click twice depending on your screen size for best view.

The next two projects are something I could have used in my current project. Light wood horses or roller stands are ok for woodworking or light shop work but for large welding projects and handling heavy steal sections these two heavy welded pipe and angle iron horses are just the thing.

The Lincoln Arc Welding Foundation published a book called "Welding Plans For Farm And School Shop". Couldn't find the publication date anywhere but it looks like it came from the 60's. There are a handful of other interesting projects in this book that I will try to remember to upload, in the future.

Wood Turning Visualized Part 2

So here is part 2 of "Wood Turning Visualized"  that I promised last week. As mentioned before, if you are new to wood turning or thinking of getting started in this satisfying hobby, this book is the practical, hands on, instructor you need.

The 48 pages in part 2 starts of with safety precautions while using the lathe, takes you through the basics of spindle and faceplate turning,  shows you some jigs and aids to make your turning more productive, and takes you into some practice turnings and projects. Enjoy.

To download "Wood Turning Visualized" Part 2 go to my Books - Free Downloads page. # 56 - Part 2 - 8 MB - pdf.

Look for Part 3 next weekend.