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My friend Johns brother Dave owns a bar in Northern Michigan, which is an economically depressed area. He has an industrial pizza oven that was purchased in 1984. Over time the cross over tube has rusted out and the welds holding one of the two brackets have rusted off. The oven manufacturer is still in business, but doesnt sell the cross over tube as a replacement part. A new double oven similar to this one would cost $26K. Pizza ovens are very hot. The pilot light ignites flames in a cross over tube, which lights four burners. 1. Burner assembly
Before John retired, he owned a Fluid System Engineering company, so he asked one of his former technicians Harry bend up a replacement tube.2. Old and new tube assemblies
3. Rusted tube
The first step was to make the brackets. I like to scribe shape of the bracket as well as the hole and slot locations. I find that this gives me a second check on locations and dimensions. 4. Scribing bracket
5. Cutting out bracket
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:6. Sanding edges of bracket
7. Center drilling bracket
For non-critical slots I like to drill a hole in each end of the slot and then plunge the cutter into one hole, make a pass then increase the depth of cut on the other end before returning to the starting hole.8. Drilling bracket
9. Milling slot
I typically use the power of the mill using the back gear to reduce speed, to tap the holes, because I dont own a tapping head. For thru holes I use spiral point taps, which push the chips ahead of the tap and through the back side of the hole. For blind holes I use spiral fluted taps which pull the chips out of the hole.10. Tapping holes
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:11. Brackets done
I really like to use hog mills to square up stock, because they cut fast and leave a decent finish.12. Squaring up crimp tool
13. Drilling crimp tool
I chose to bore the hole in the tool for the tube and for the crimp area in the same setup to assure that they would be concentric. I had a 3/8 reamer which I used for the tube bore in the tool. I didnt have a .340 reamer, so I bored the hole for the crimp portion of the tool.14. Boring crimp tool
15. Reaming crimp tool
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:16. Crimp tool 1st op reamed
17. Installing dowel
18. Using center finder
19. Reaming crimping tool
20. Crimp tool done
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:The swivel fitting on the end of the cross over tube is actually just a standard barb fitting. The tube was crimped loosely to hold the barb fitting in place, but still allowing it to rotate for installation. The barbed fitting has an .040 orifice in the end, which acts as a jet which accelerates the air as it leaves the fitting. This creates a low-pressure area, which in turn creates a vacuum. The cross hole through the tube near the end of the barbed fitting allows air to suck into the tube. This means that gas doesnt leak out of the small space around the barbs, but instead sucks in air past the barbs.21. Crimped barb fitting
22. Crimp Mark on old tube
I drilled a larger hole most of the way thru the orifice and just drilled the .040 hole through the last 1/16. 23. Orifice pieces
I used my arbor press to install the orifice.24. Orifice press fit
25. Orifice installed
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:26. Arbor Press with crimping die in place
27. Crimping swivel fitting
28. Fitting crimped
I had to rotate the waist of the Bridgeport to allow the tube to pass the left end of the table.29. Setup for drilling holes
I installed tight fitting blocks in the Tee slot and then bumped the 1-2-3 blocks against them. (a red arrow points to one of the blocks.)30. End view of setup
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:I used a parallel against the back side of the 1-2-3 block to set the position of the tube.31. Parallel to set tube position
First I center drilled a drill point and then I drilled the 112 holes with a #76 (.020) drill.32. Drilling hole
33. Close up of hole
34. Crimping end of tube
35. Tube crimped
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:I used my Fireball Tool magnets to hold everything in place for welding.36. Setup for welding
Here is a picture of me welding the brackets.37. Welding brackets to tube
38. Brackets welded
39. All done
40. John holding the completed cross over tube
John plans on going to the Upper peninsula in two weeks to visit his brother and to install the new cross over tube.-DonSmith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP |
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发表于 2021-10-26 15:51:16