Saturday, July 21, 2018

Carriage Ready For Power

Standing in the shop this morning, looking at the hoist on the mill, I realized I had not added a triangulated strengthening strap to the main boom. Probably not needed for it's intended purpose but for the amount of extra weight added it does stiffen the boom and takes some of the bounce out of it. It was a quick job to add the 1 1/2" X 1/8" strap.

So back to the carriage, I first prepared the sockets and 2 dogs for the back of the bunks. I cut the sockets from 2 1/2" tubing 3" long. I then drilled 3/8" holes and welded 3/8 nuts to line up with the holes, these accepted 1 1/2" X 3/8" bolts to lock the dogs in place.

Here I have 2 dogs installed in the socket. I will be making 2 more of theses 6" dogs and 4 more 12" dogs for handling larger logs. For now these 2 will do.

Here I have the sockets welded to the bunks and the bunks welded to the carriage, but the main focus is the two eye bolts near the bottom of the picture. I cut two lengths of 1 1/2" X 3/16" angle iron, and center drilled them to accept the 1/2" eye bolts. I welded the angle 2.5' from both ends of the carriage, at the bottom edge of the carriage. The cable feed for the carriage will be attached to these 2 eye bolts.

So I pulled back and got this picture. The carriage is pretty well complete. It still needs front dogs, but these need to be depth and height adjustable for different diameter logs. I'll visit that later. The bunk spacing will allow a log as short as 2' to be sawed, without any special jigs.

So I'm ready to start on the carriage feed.

Friday, July 20, 2018

The Carriage It Rolls

So we got started on the carriage this morning. I first cut and mitered the frame members and 4 bunks. The carriage frame is 2" X 1/4" angle, The 4 bunks are 2" X 3/16" angle.

 I then welded up the frame, taking care to keep the carriage square. I put the bunks aside for more work later.

Next I pulled out a 1 ton trolley I had purchased on sale for this purpose, many years ago. I cut the frames to separate the four wheels and leave enough mounting plate to solidly weld to the carriage frame.

Here the wheels, all separated. The bent tabs will be used to hit stops at the ends of the tracks.

 After carefully locating and clamping each wheel on the carriage, they were welded in place.

Here is the carriage siting in its track.

Here rolled to the opposite end. A light push did it, without the stops welded in yet, I had to stop it from rolling off the end.

Here I loosely placed the 4 bunks on top of the carriage. I still need to add sockets to accept the rear fence dogs, before I can weld them in place. Maybe tomorrow.

Thursday, July 19, 2018

Handlebars And Holster Are On

So stepped out to the shop to clean the floor and move the sawmill back in the shop. One look at the hoist and I couldn't resist. Removed the hoist and brought it inside to install the jack bar holster and handlebars for turning. The holster was quick just a 2" piece of 1" pipe welded to the side of the mast.

The handlebars are a 2' length of 3/4" pipe. I had a couple of plastic rubber handles from when I modified my seed spreader in a earlier post. They came off  1/2" tubing so I heated them up in a toaster oven until soft and stretched them on the 3/4" pipe. Cooled to a very tight fit.  After determining a comfortable height to operate the handlebars, I welded them to the back of the mast with a couple of heavy welds. Here's a few pictures.

OK ready for paint, we have a long ways to go before we get there though, ha, ha.

Another Odds And Ends

So getting in some clean-up and a little summer reading. Heres a picture I should have posted in the last post. A pulled back picture of the sawmill so far, to get an idea of the proportions so far.

Don't go away, their's more. Here are a few short, reader submitted articles, from early 60's Popular Science. The first one is a different and interesting take on the common sanding block. This one allows you to not just sand edges, but also different curved, and circular work. The resolution is not that great, but usable if you expand for best view.

I have uploaded a number of articles before on speed reducers for bandsaws and other equipment. Here are a couple more. The first one is an easy one for the bandsaw. It uses the original pulleys and adds a relatively simple jack shaft.

You don't often see lathe speed reduced this low (12 rpm for slowest speed) but the author, Manly Banister, makes a good argument for these low speeds in special work. Interesting read.

For those following the sawmill build, stay tuned , hopefully get back in the shop tomorrow.

Tuesday, July 17, 2018

Hoist Completed And Tested Out

So the first job I did this morning was make up, and weld, the mast to boom connection bracket. Here it is welded to the top of the mast.

Next I cut the main boom section using 2 1/2" X 3/16" tubing, 48" long. I cut a 3" length of the same material and drilled it 3/4", and welded it 1" from the end of the main boom. This will connect to the bracket at the top of the mast.

Next I drilled four 5/8" holes spaced 10" apart in the main boom. I then temporarily installed the main boom on the mast to determine the bracket position for the top jack connection. Next I made up and welded the bracket to the boom, seen here below the second hole on the boom. The boom extension is 2" X 3/16" square tubing. I drilled 2 - 5/8" holes 3" from the ends, one will register with the four different main boom holes to change the boom length. The other will take a bolt to lock the chain and hook assembly. One of the links in the hook assembly passes through a slot cut in the bottom to engage the bolt. OK we are ready to assemble.

Here is the hoist fully assembled. I dug out a set of log tongs I had, and rolled it outside for some pictures and to test it out.

I loaded two of the larger logs in the back of my truck, back at the end of May, where they have been ever since. I figured this would be an acceptable test. The first is a little less than 8', around 200 lbs. Popular log. With the boom in the third position, a little over 6', it reached right in the back and pulled it out.

Their's one more little item to do and that is weld a set of handle bars on the back of the mast for turning the hoist. As it was, it turned easily, with a light push on the boom and pull on the mast. Here ready to drop the log on the carriage, if their was one, the frame deck will have to do.

Here I went back and got the second log. This one is a little less than 7', Spruce and a little over 150 lbs.

OK that was easy, how does it handle both logs. I changed out the log tongs for a strap, and raised both logs for a total of over 350 lbs. No problem, lifted easy and everything remained stable. The jacks give good support without any side to side movement of the frame. The only wood I have on my property that might come in over 400 lbs. in a 8' log, is Birch, and I can see this handling much more than that. It should be noted that when the boom is extended it will handle less weight, retracted much more. Fully extended I would limit myself to around 4 to 500 lbs., fully retracted your probably good up to 3 tons, on the boom and mast, however the hoist receiver and trailer are not designed for that kind of weight.

Here ready to drop both logs back into the truck. Took a little more effort to turn with both logs , but not bad, the handlebars will fix that ha, ha.

Here the hoist is folded up in it's storage position. There are 3 mating pairs of holes in the flanges, so the hoist can be locked in 3 positions with a pin and retainer.

So next is the carriage, but its break time for me again, to do some clean up of the shops and take a breather.


Monday, July 16, 2018

Started On The Sawmill Hoist

So I spent the morning finishing up the welding on the hoist receiver. Managed to flip the trailer on both sides to do the underside welds, and turn the vertical welds into flat welds, My skill level and equipment don't do well with vertical welds, ha, ha.

Here's the receiver complete, doesn't look pretty but it's solid.

So after lunch we made a start on the hoist. I started by deciding on a angle for the mast, measured to length and cut the angles on my chop saw. Set up the receiver insert on a vise and welded the mast to the flange. The mast is 3" X 3/16" square tubing. It's overkill but I wanted a large weld surface at the flange, since there will be no strengthening struts. I'll go smaller, 2 1/2", for the boom, with a 2" extension.

Here is a close up of the bottom bracket for the long stroke jack that will power the hoist. The jack is rated 8 ton, which is overkill again, but it was on sale and the regular price of a 4 ton was quite a bit more.

The next two pictures are front and back views of the mast with jack in place, just waiting for me to install the boom.

Not that fast though, there are a couple of brackets I have to make first and some heavy drilling to do. Hopefully get it done tomorrow.

Here's an idea I will be adding to my to-do list. I have two trailers an 8' and a 12'. Loading and unloading heavy equipment is always a problem, if there's no hoist or loading equipment around. Since I have this removable hoist now, it would be simple enough to beef up my trailer A frames, and install similar receivers to accept the the hoist when needed.

Sunday, July 15, 2018

Hoist Mounting Socket

So picking up where I left off, last post. I cut the hoist mounting socket pipe lengths to 10" lengths. I want the hoist height comfortable to operate, but not so high that I overload the socket with leverage pressure and introduce height capacity I will never need. I beveled the end of the inside pipe and welded the turned insert in the end, nice tight fit.

Here both the inside pipe and outside pipe are done, ready to install. The 1/2" machine bolt will not be accessible once the hoist is welded in place, so I welded the head permanently to the removable mount.

Metal cutting band saws are nice but they can be overrated. They are great for what they are designed for, crosscutting, but for odd shaped work, diagonals, or circular work, they fall short. I often abuse my 4 X 6 in the vertical position but the 4" throat makes it very limited. Where precise measurements are not top priority, the lowly grinder is the best tool in your shop. With a good selection of disc thicknesses all manner of work can be done, and with guide jigs even precise cuts can be accomplished. For straight cut offs, for welding use, I prefer the cut off disc, its faster than the band saw and with practice even free hand cuts can be quite satisfactory. The cut below was done free hand in half the time the 4 X 6 would have taken, if the throat was deep enough, which it isn't.

Here the strengthening ribs are all tacked in place, ready to do the weld-up. 

Here I have inserted the hoist base into the receiver. The insert spins easily, without to much play, I don't imagine it will spin as easily with a 500 lb. log hanging from the hoist, ha ha.

So hopefully finish all the welding tomorrow morning, and get started on the actual hoist.

Hoist Rotating Socket Flanges Prepared

So the hoist will rotate and be easily removable, to move logs onto the carriage and for storage when not in use. The bottom of the hoist will be welded 2 1/2" pipe, It will slide into a 3" pipe, welded to the A frame. The rotating mating surfaces will be 2 nice chrome steel flanges I have had tucked away for years waiting for a project. One can be used as is, the other had to have the center cut out, it will be welded to the top of the 3" pipe and the 2 1/2" will pass through it.

Fortunately the largest hole saw I had was the right size to cut the center out of the one flange. None of my drill presses has the power to do this job, this is where my mill/drill comes in handy.

The two flanges mated together for rotation of the hoist.

I took the center cut out and turned a socket to fit into the end of the 2 1/2" pipe. This should result in a very solid connection when welded.

All the parts required for rotation and solid socket installation of the hoist.

So hopefully I can prepare the pipe, and strengthening ribs, for the hoist base tomorrow, and get it assembled.

Saturday, July 14, 2018

Beefing Up The A Frame

So still not up to par this morning, but got an early start anyway. As mentioned before I wanted to strengthen the A frame to accept the small hoist, by adding stiffening ribs. In the first picture are the ribs and the hoist base plate, cut, and bent.

Looks like this bug was still having it's effects. My brain was off in never never land when I ground the bending slot on the wrong side of the bottom triangular piece.

Below, not a problem I had intended to weld over the slots anyway.

Wood moves when it drys, and metal moves when you weld it. Before clamping up the ribs and base plate, I retracted the A frame jack and then placed a 200 lb. piece of rail on the front to weigh it down I then raised the two front frame jacks and leveled the frame. Only then did I place the ribs and base plate and clamped them tightly in place. Ready to weld. This is done to compensate for the inevitable up tilt to the A frame when the welding is done.

After the welding was done, I removed the weight and cleaned up the welds.

There are a few more welds to do when I tilt the trailer on its sides, but otherwise I am ready to start on the hoist. It will be placed in the center of the base plate where I placed the white dot.

Maybe there is something to be said about the old saying that you have to sweat out a bug. I feel better after a good sweat, than I did when I started. If the energy is there, I'll get started on the hoist this evening after it cools down a bit.

Friday, July 13, 2018

When It Hits The Fan, It Hits The Fan

Sorry no update today, I picked up a nasty bug a couple of days ago and it's been sweats and chills for two days. I think I am on the mend but it didn't help that in the middle of all this heat and humidity, smoke rolled in yesterday morning and its even worse this morning.

There are many fires burning in the North but the largest is 30,000 acres in Lady Evelyn-Smooth Water Park near Temagami. The park is one of the few old growth forests left in Ontario. The preservationists won the fight against the loggers a few years ago, but it looks like fire is going to get some of it. The park is 100 miles south but when the wind changed it blew the smoke all the way up here. Nasty.

That haze you see in the picture is not haze, its smoke. 

So I did drag myself into the shop yesterday, but it was all I could do to get it cleaned up ready for the next stage. 10 lbs of weld rod ends, slag, and grinding dust off the floor and at least it looks more inviting.

I think I'm on the mend now, hopefully get back in the shop tomorrow.