Thursday, May 31, 2018

The Object Of My Desire

So I dismantled from the Cavalier a few objects today that answers the question, "Why do this? Why not just scrap the whole car?".

In addition to the 200+ lbs of good grade of aluminum, if I choose to break up and remelt the engine and transmission, I also mentioned a selection of different grades of steel.

The first picture below is the front end, suspension, power steering and wheel ball joints mounting assembly removed. This is quite heavy the thickest steel used is found in this assembly and the rear axle assembly. Notice the sway bar.

Here is the sway bar removed. This is probably the most useful piece of steel in the whole vehicle, not as brittle as shock spring steel (one of the shocks I removed from the front had a spring that was broken in three places) but it is just as tough (when you swerve hard a good portion of the weight of the car goes onto one or the other arms of the sway bar and prevents roll over). It's 3/4" round and about 4' long. Ideal material for forging various tools, turning chisels, knives, etc.

Also in the picture are the rubber bushings for mounting the sway bar. In the center of the picture is one of the many useful devices available in a dismantling like this. This is the steering column universal joint. Used to transfer rotary motion between two non planer points (the steering wheel and the power steering cylinder).

And as alluded to in the title of this post, this is the main object of my desire in this tear down. This is the rear axle and wheel assembly. My intention is to use this as the starting point for my bandsaw mill. In the position in the picture it is low to the ground, making it easier to load a log onto the cutting deck. Distance between the outside of the mount bushing eyes is 44", perfect for the small mill I am planing.

If I choose not to use it for the mill it is still a perfect axle and wheel assembly for a small trailer, either low to the ground or if you rotate the axle assembly 180*, a high deck. Thats a 4 or 5 hundred dollar value right there, tires are worn but hey, I got two more plus a mini spare plus wheels. lol.

So below is the back end hoisted up. Just a couple more items to remove, the fuel tank and accessories, and the rear shocks.

When that is done all that will be left is the bare unibody, a couple of added coats of paint but otherwise just as it was when it left the robot welding line.

Wednesday, May 30, 2018

Tight Squeeze But The Motors Out

So took a while but the motor and transmission are out. Talk about a tight squeeze, once it was half out I had contact with both sides of the frame, with a little coaxing, it left two scrapes in the paint but slipped out. So  much rust, I'm not sure it is worth trying to run it again, at the very least I got a couple of hundred pounds good quality silicon aluminum for remelting and lots of different grades of steel to play with.

It's amazing how tiring pulling a wrench all day can be, my lower arms and hands haven,t been so scrapped since I did this last time. Any weak or cheap tools usually show themselves on a job like this. I only lost one on this job, split the side out of a 13/16 Westward socket, maybe I should stop using cheaters. Ha ha.

So here is the interior of the unibody,  all stripped (lots of room now ha ha). Tomorrow I will hoist the unibody and remove the underside drive parts, the front end bottom suspension, and power steering assembly (you can see the end of the steering universal hanging just inside the firewall). The parking brake (red skirt on handle) bolts are removed but I left it in place  till I can disconnect  it, when I remove the rear axle and wheels.

So another day or two and then a couple of days of clean up and deciding what I want to keep and what gets hauled to the land fill. The unibody, door panels, and the few body panels will get loaded on my larger trailer and get hauled to the steel recycler.

Monday, May 28, 2018

Afternoon Chuckle

So mowing 7-8 acres can be a chore. If I change out the tractor seat for the one below and install a mini beer cooler on the back of the seat, I think I can learn to enjoy mowing the lawn. If I install that 142 hp motor under the hood, I'll never want to do anything else.

LOL not really. Some may not appreciate my brand of humor, but hey life can be a bitch without a good laugh once in a while. 

A couple of more days and I should get this Cavalier behind me.

Sunday, May 27, 2018

First Bears 2018

So I have been expecting visitors the last few days, this evening they showed up. Looks like the sow and her cub from last year liked the grass here and came back for more. Visited the local land fill this morning, they just started showing up there too. Timmins and Sudbury have had problems for a month already.

I couldn't get very close for these two pictures, the sow was keeping a close eye out, glancing around often. As soon as she sensed my presence, she dashed for that rock outcrop, the cub trying hard to keep up.

Saturday, May 26, 2018

Cavalier Strip Down Continued

So I got a couple of hours in on the Cavalier, slow day today, ha ha. I am now a little over half done. Here are a few pictures.

The first picture is the huge piece of back end plastic pulled off, the front piece is even larger. Living inside the foam and plastic is the steal bumpers. they are not very thick to begin with, even thinner with all the rust. The front not so bad, the rear (rustier one) was ready to fall off, one of the bolts that attach it to the unibody just pulled out, a second one sheared off when I put the wrench to it. I may find some use for the steal bumpers yet but I would have preferred  extruded aluminum.

Heres the small mountain of plastic, rubber, and foam accumulating in a corner of the shop, and I still have all the plastic and foam on the doors and interior to do. The seating is still like new, even the drivers seat with my fat butt sitting in it for close to 300,000 km. I may find some use for them yet.

It,s not all headed to the land fill and scrap yard. Pack rat that I am, here are a few items I have convinced myself that I can put to use in future projects. We keep dreaming, lol.

So I can be a bit of a night owl sometimes. Didn't get much done today, but the beauty of the new well lit shop is that I can get another 3 or 4 hours in tonight. "A wrench screams at midnight" lol.


Motors And Electrical Power

So, slow getting going today, figured a post would at least keep me active. " Step-By-Step Knifemaking" by David Boye has become a bit of a classic "must" for the novice pursuing the art of knifemaking. Everything is covered in this fine volume from setting up shop to etching designs into the steel. It may still be available as publisher remainders or in the used market. I had two a hardcover and a paperback. In a culling of my bookshelves to make more room, the paperback made it's way into the used market.

Below is a picture of the cover and an example of the many knife designs that Mr. Boye has produced. Many of these designs are covered in his step-by-step instructions.

In, setting up shop, is a basic but interesting article on motors and electrical requirements for setting up the small shop. Some of his comparisons rang a bell with me. Relating amps to the flow of water in a pipe and volts to the pressure pushing that water, helps to clarify, and is an analogy I was taught early on, obviously it stuck.

So it's basic, a little different, but interesting light reading on the subject.
If your new here click to expand, click again for best view.

Enjoy, Cheers

Thursday, May 24, 2018

Dismantling Rust

So I got the Cavalier into the ventilated shop this morning and got a start at dismantling it. I hate unibodies. I dismantled one back in the 80's, it was made shortly after unibodies were introduced and there was still a lot of extruded aluminum on them, like the bumpers. Now a days aside from the engine assembly, axles and wheel assemblies, most of what is snapped or bolted to that unibody is plastic (mountains of it), foam, and rubber. The few metal panels are thin as paper. I have driven a body on frame truck since I started driving. I got the Cavalier to save on gas, for a 100 mile return commute to work, that I did for 10 years. I'll hopefully never have to drive a unibody again. Ha ha. Don't get me wrong the unibody is actually designed to be safer in minor crashes. The unibody is designed to crumple in a step by step, more controlled fashion. My beef with the low end models, is that they are to much like the disposable society we have become. Difficult to repair with poor quality parts, after ten years up here with the salt on the road in the winter and rough roads everywhere, they are usually  done.

Here's a couple of pictures. It's going to take a while to get this all stripped down. 

I think it was on "The Big Bang Theory" that someone said "Your degree of white trash is measured by how many junked cars are in your yard." Ha, ha. I guess I am back to zero again. lol.


Tuesday, May 22, 2018

Fire Wood Or Lumber

So I got out this morning to clean up that downed spruce in "Sawmill Dreams". Cleaned up the saw, new bar and chain and we're ready to go.

There is a large poplar by the lane way near my power line I have been keeping an eye on. Looking up today 15-20 feet from the top I saw streaks of red sap running down the tree from holes in the trunk. The bugs and the woodpeckers going after them, were greatly weakening the trunk in that area. The next good wind storm is likely to snap the top off onto my power line, so down it comes.

Fresh woodpecker hole, going after the bugs.

Chances are a good wind storm would have snapped it off right here. Definitely weakened by the bugs and woodpeckers.

This pine was dead and dried out. I bumped it a few times with the tractor bucket when I did the cut and fill landscaping in this area 3 years ago. I had hoped it would survive, but no, so down it comes.

This is that spruce in the "Sawmill Dreams" post, delimbed and cut into 3-8 ft. lengths and a 18 ft. top.

All loaded up, haven't worked this hard in over 6 months, I'll feel it tomorrow. Working the springs on the old truck too, at 23 years old though, it just keeps on going. A very cold winter a decade ago, I froze the rad. and fried the bearings on it, half way to work one night. I traded the motor in on a rebuild and thats about the only problem I have ever had with it, and that was my fault, ha ha.

So getting to hot to stay out here, I'll finish cleaning up the limbs later when it cools down. It looks like climate change for us up here, means "weather extremes", we just went through a darn cold winter, now the forecast for this summer is blistering hot.

Sunday, May 20, 2018

Early PM Shop Notes Projects

So here is the third file I made up from those early (1905 - 1930) PM Shop Notes volumes. This file is not as large (41 pages) as the other two. Pickings were slim after pulling all the Romig plans for the other file. Never the less, some of these are more interesting than practical today, but thats an opinion,some may find many of them worth challenging, like the tool box below.

To complete this little collection, click Early PM Shop Notes Projects  to download. 11 MB - pdf

So as mentioned before their is enough content on this site now, that someone looking for projects to build, should have no trouble finding something of interest here.

There is a lot of work I need to do around the place and get my hands dirty on, and I want to fit in a few good road trips this summer, so I will be posting a lot less.

First on the list is dismantling my old Cavalier. It runs fine but the suspension and body have seen better days. I could repair and resell, but used Cavaliers, 15 years old, aren't worth much. I offered it to family for "FREE" but nobody bit. Ha ha. I guess I can use some parts for my sawmill build. The motor still runs great, not sure what I will use that for yet. Hows a 142 HP lawnmower sound? lol, lol not really.


Finger Joint Machine And Router Table

So here are a couple of nice plans from the 1987 Popular Science Supplement. The first is a finger joint cutting machine. There are many nice plans out there for finger joint cutting jigs. Most use the table saw to do the work with various blades, blade stacks, or dado stacks. Some are more complicated than they have to be and do not have much adjustment to compensate for things like, blades that run less than true.

If you have a bit of floor space and like to use finger joints for lots of joinery, this dedicated little machine might be for you. A 1/2 hp or larger motor, a ball bearing spindle available at most hardware stores, and a good quality 6" dado stack are the main parts needed. The rest can all be easily shop built. There is lots of adjustment, so once you have set up a snug fit, you can quickly start to produce stacks of finger jointed boards. As the author alludes to their are other applications this can be used for.

My feeling is that safety was a consideration in the design, the blade lives below the table, it is raised into the work with a simple foot pedal feed, and returns below the table, when the pedal is released. Additional guarding on the underside would insure nothing wanders near the blade from the underside.

The second project is a uncomplicated router table by R.J De Cristoforo. The table has nice built in storage and guards for the different functions, the top is solid looking. What more do you need? Some plans offer more in eye appeal but function no better for their intended purpose. A characteristic of R J's designs, I find, often omit unnecessary additions that don't contribute to tool function.

Saturday, May 19, 2018

Plans By J. V. Romig

During the early 1920's Joe V. Romig was one of the most prolific authors of plans and articles for the home diy'er, His plans and articles were published in both Popular Mechanics and Popular Science.

This 69 page file covers the majority of his work. I left some of it out, like a 8" jointer, the 2 knife square head is considered unsafe today, and a table saw, with limited adjustment (Joe was not a woodworker). I also left out some industrial sized cranes and farm equipment that were to far off topic here.

A few of his plans incorporate concrete for mass, a method developed during the first world war to get around material shortages. Since then their has been a bit of a revival with a few sites using this method to build mass in machine tools and avoid cast iron.

So I hope some will enjoy this collection of plans. Many of them are still very practical for the small hobby shop.

To download this file click Plans By J. V. Romig 15 MB - pdf

Short Plans From Pre 1930 Shop Notes

So as promised here is a 71 page collection of short plans and ideas from the pre 1930 PM Shop Notes. The 26 previous Shop Notes volumes (1905 - 1930) are widely distributed around the web and at least one company, Algrove Publishing, has reprinted them.  For this reason I did only the post 1930 uploads in my previous posts. For those who have not accessed these volumes but have some interest in what might be in them, here is a collection of short (less than 1 page) but more outstanding plans and ideas in these volumes. There are 2 more files coming with larger projects including one devoted to J. V. Romig and his plans.

To download click Short Plans From Pre 1930 Shop Notes 13 MB - pdf

Friday, May 18, 2018

Rescanned Belt Sander And Internal Wood Threading

So here is a better scan of a light belt sander I posted before. I can't find the belt length stated anywhere but a rough calculation puts it at a 48" belt. If you can find a larger double shaft motor you can double up on the belts similar to my 32" belt unit in another post.

Here is an interesting little jig for threading the nuts of wood vise screws. Size doesn't matter, if you have the screw this jig will cut the nuts for it ( no innuendo here, what can I say, thats the terminology). Ha ha.

So it's been a long haul, lots of workshop plans and info.posted on this site now. Enough that a person looking for a project can do a search and probably find something close. I have invested a lot of time with these posts and for a break I am going to back off for the next 3 summer months. If I get any interesting travel or wildlife pics, I will make the effort to get them up. If you like some of the older PM Shop Notes, check back this weekend, I just completed  3 files that might garner some interest. I'll get them up tomorrow and Sunday.


A Superior Sawhorse

Everybody needs a couple of good sawhorses, if you do any kind of outdoor work. Here is a very useful design from Mother Earth News's "The Home Hardware Handbook". It is a very useful design for cutting dimension lumber with the portable circular saw. On a conventional sawhorse this is usually a dodgy operation with respect to safety and the accuracy of your cuts. This design addresses both of those concerns.

Of course no one ever builds just one sawhorse, you need two, one to support the long end of the board you are cutting, right. When thinking of this it crossed my mind that nowadays when I build something outside or for framing, I use 2 X 6's as much as I use 2 X 4's especially for exterior framing and anything requiring superior strength. To this end, the second sawhorse should be made 2" wider than the above design so both sizes can be cut with the same degree of safety and accuracy and still have the long outboard end supported.

The design below has had the width measurements adjusted to accept 2 X 6's for safe crosscutting. I was too lazy to make a new drawing, ha ha.

Thursday, May 17, 2018

Sawmill Dreams

So I spent the afternoon cleaning up my trails, getting a start on my wood pile. As mentioned before, they weren't to bad, considering how bad that winter ice storm was, so pickings were slim.

A bad wind storm brought this one down, just off one of the trails. I have dreams of building a small band sawmill. This is a good candidate for some nice clear spruce boards, relatively straight and 16" diameter. I will have to cut it up into 8' lengths and bring it in, before the bugs get at it.

Right behind it, making it easier to eventually bring it out, is this fine example of a big birch. 22" diameter at the base, lots of fine birch boards in this one. Makes me want to start on that saw mill, ha ha.

An Inexpensive Panel Saw

So power is back on. I would like to think they replaced or repaired the piece of equipment that has caused some resent surprise outages, but more likely they were just reconnecting the cottagers for the season. The grid has been neglected for so long it's like an old car, when things start to break down, it's one thing after another.

So here is a plan for an inexpensive panel saw. Short of industrial equipment, its hard to find something easier to break down large panel material, than with a panel saw. Purchased units are quite expensive and many diy plans are built for heavy use. I have at least one for a future upload. This plan is inexpensive and relatively easy to build. For the home DIY'er who occasionally has need to break down sheet materials, this will simplify the process and save you lots of time.

This is another project from R.J. De Cristoforo published in the 1985 Popular Science DIY Yearbook.

R. J. is no spring chicken at this stage of life, but he makes it look easy to use the panel saw to break down full size panels.