More homemade shop equipment.

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It has been a while since I posted anything so here goes.Welding positioner with a 1/2" x 12" platen. It is basically a beefed up version of the Atlas® brand that is used at work.The frame is 1" sq. 16 ga. wall along with 1/4" x 4" and 1/4" x 6" flat skinned with 20 gauge. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:more. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Will add more details and pics after work.Pics.1) propane smelter2) small roller3) big roller4) 12" disk 6"x48" belt sanderhttp://www.youtube.com/user/CARDAN531?feature=mhee#g/uhttp://s159.photobucket.com/albums/t150/robg_010/ Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:That is some beautiful workmanship! It must be great to watch your ideas take shape and be useful.
Reply:Forgive my ignorance, welding positioned? what is it?www.thefusionsolution.com
Reply:It's a lathe or turntable that slowly rotates the work piece for you. Some of them have a mig or tig torch mounted on them such that they become somewhat automatic.Notice in the pics above how he has the ground lead attached below with a brush assembly riding against the shaft.Lincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:ahhh.. I should have known that..  thank you.www.thefusionsolution.com
Reply:Where did you get those small gear reduction motor drives?Thanks
Reply:Originally Posted by CHINAMANWhere did you get those small gear reduction motor drives?
Reply:Hello Rob, I have thoroughly enjoyed viewing your projects, the attention to detail and functionality, and the craftsmanship that you have displayed. Many could take note of and emulate your techniques to have success on their own projects, myself included. I will continue to look for additional projects that you are willing to share here. Great work! Best regards, Allanaevald
Reply:Originally Posted by CHINAMANWhere did you get those small gear reduction motor drives?Thanks
Reply:The furnace... this was the biggest sheet metal project I have taken on to date. Have always liked the look of the old riveted boilers so that is the style I went with. The shell is 15 1/2" Ø as well as tall and is made mostly of 20 gauge with a little 1/8 " thrown in. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:more. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:The slip roll:Don't have many build pics for some reason. The frame is all 1/4" wall tube and the rolls (which are temporary) are 1 3/4" Ø. They were found at the scrap yard and are hardened about a 1/4" deep. The wheel is 1" square with 1/2" Ø spokes and is 48" Ø. The drive chain is #40 iirc. The jack is a 12 ton air/hydro from H.F. Pillow blocks are 1".I am hoping to run across a good deal on either some 3"-5" solid round or tubing/pipe to make new rollers out of. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:two more.Will post more tomorrow night. Attached ImagesLast edited by Rob Garner; 09-16-2011 at 01:45 AM.Darwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:how did you turn the roller to roll the wheel that turns the roller?
Reply:Originally Posted by weldbeadhow did you turn the roller to roll the wheel that turns the roller?
Reply:that pic is lighter than original  post  ..there it is! cool roller..
Reply:Very nice. I'm book marking this for future reference. A furnace is on my list for one day. It's been years since I did any sand casting alum. I've got any number of projects that could use that ability right now. I take it you just cast refractory cement in the shell you made for the furnace? Are you using one of the mig tip burners like they use for forges to heat it?The positioner is another around to project at some point when funds allow. Right now I just make do with a small manual one I built to get by.Very nice work. The attention to detail shows in things like the cover for the chain drive. I doubt many would have bothered, and it really helps show the time and thought that went into that project..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Hi I have a ring gear and spur gear with a reducer setup attached.  If anybody want to build a positioner PM me I will give you a very good price.the ring gear is made to bolted at the center circle and the outer rotates being driven by the spur gear.  They are pretty heavy 2-1/4" thick 88 teeth on the ring and 18 teeth on the spur.  The ring is 16" diameter and spur is 3-1/2"  Maybe 40 pounds total.have funTom Attached Images
Reply:Rob,On the positioner you built, do you think you'd be able to give us a good couple of close up pictures of how it's grounded to the central shaft?  I could kinda see something that looked like a spring loaded copper rod in the pictures but not clearly enough to be sure.  I'm thinking of building one of these and honestly, your design is what I'm gonna go off of Thanks in advance.--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Here you go. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Awsome   Thanks Rob, I appreciate it.--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Tom, I sent you a pm.Thanks, David Originally Posted by acourtjesterHi I have a ring gear and spur gear with a reducer setup attached.  If anybody want to build a positioner PM me I will give you a very good price.the ring gear is made to bolted at the center circle and the outer rotates being driven by the spur gear.  They are pretty heavy 2-1/4" thick 88 teeth on the ring and 18 teeth on the spur.  The ring is 16" diameter and spur is 3-1/2"  Maybe 40 pounds total.have funTom
Reply:Word of caution on your ground clamp setup, I don't know what kind of amps you'll be putting through that, but my positioner at work used to have that same style of setup.  The spring lost it's tension and the weld started grounding through the postioners electrical and fried like 30 feet of wiring through the buzz bar.  They switched it to a type of clamp style, I'll try and get a picture of it for you.I saw a post where the guy used a flat braided cable around the shaft so he had no spring. The old car battery type cable
Reply:Originally Posted by AntiblingWord of caution on your ground clamp setup, I don't know what kind of amps you'll be putting through that, but my positioner at work used to have that same style of setup.  The spring lost it's tension and the weld started grounding through the postioners electrical and fried like 30 feet of wiring through the buzz bar.  They switched it to a type of clamp style, I'll try and get a picture of it for you.
Reply:Originally Posted by acourtjesterI saw a post where the guy used a flat braided cable around the shaft so he had no spring. The old car battery type cable
Reply:DuaneThat is very similar Great post.  But the one I remember the braded cable was like spiral wrapped and did not have a spring.  I guess with more contact coverage he did not think he needed a spring.have funTom
Reply:Time for an update. Been working on the belt/disc sander quite a bit.pics:1) The stand. 1 1/2" x 16 ga. wall square tube with various bits of 1/8" and 3/16" flat and angle.2) Because the tubing has such a light wall I sleeved the top plate mounting holes to prevent crushing it.3) The belt sander mount/pivot. It's a piece of 1"x6" hot rolled. 4) Started out with boring the shaft hole to 1 1/2". Since I do not have a rotary table for the mill I chain drilled the holes for the pivot slots.5) Then it was time to get up close and personal with the die grinders. Lets just say I felt like a pin cushion for about a week after this. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:more.6) Pivot done.7) The top plate. It is a piece of 1/2" x 12" x 12". Here it is getting all of the mounting holes drilled.8) All holes drilled and the slot for the belt to pass through torched out.9) Since I had the torch out, went ahead and cut out the sanding disc from a piece of 3/8" x 12".10)  Bored the hole for and welded in the mounting hub. My lathe is not big enough to turn it so I used one of the lathes at work to turn it to size and face it. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:still more.11) Front 12) Back13) Belt sander arms. Material is 1/2" x 4"14) Torched out the profile.15) Cleaning up the torch cut. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:More again.16) Upper roller slot cut out.17) Checking to see if it all fits right.18) Checking fit again. Also upper roller carrier bushings installed.19) Upper roller carrier.20) Checking fit still. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Again.21-22) tacked up.23-24) welded up.25) checking belt fit. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Does it ever stop!26-27) Belt tracking adjuster.28-29) Belt tension release lever.30) Horizontal stop. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Awesome.  I like it.  Those are some pretty clean curved slots with the die grinder.
Reply:Still more? Wtf31-35) disc guard. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:How many is that now?The belt rollers. 3 1/2" o.d. 1/2" wall tube.36) Boring. (literally)37) Bottom roller hubs.38) Good fit. (got lucky)39) Upper roller hubs.40) Got lucky again. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Almost done!41-45) Disc table (still in progress) Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Last ones for tonight.46-48) motor mount49) How it sits as of tonight50) Yours truly compliments of my nine year old. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:So are you wishing you just bought one yet? #36 made me chuckle. Last week I made a buddy a 4" to 3.5" aluminum reducer for a supercharger kit, not having any type of aluminum tube at hand, I made it out of a chunk of 4" round stock. The largest drill I have is 1" so I had to bore out the rest of the ID with the boring bar. Luckily the part was only 2" long.When he stopped by to check on it I tried to see how many times I could use the word "boring" before he caught on.....I got 4 If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:I wish I could afford a good quality unit. Just can't lay out that kind of money all at once. It never fails, when a good deal comes along the money isn't there or if it is there are no good deals to be found. As for the "boring" comment, the lathe is only a 9"x17" with a 4" chuck. Lets just say that doing that was interesting. Back gear and as slow as it would go seeing as the chuck jaws are only holding it by a 1/2". I wasn't standing any where in front of it! Darwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Question about crowning the rollers. Does it need to be a radius or can they be tapered from the center out? The reason I ask is, the one this is based on looks to have a straight taper of a little less than 1 degree from the center out to the end. Of course it could just be that it is wore pretty good being that it is aluminum. See pic. As for the rollers not being machined yet, I am saving up for a bigger bull nose center. Biggest one I have is 1" od but need one that is a min. of 2 1/2" to fit the upper roller.Should be able to crown them my self. I think there will be just enough travel on the compound slide. Attached ImagesDarwinian evolution used to fix stupid. Now that humans have mostly removed themselves from the process of natural selection the survival rate of idiots has skyrocketed.
Reply:Rob-You do really good work.  I enjoy reading your thread and have learned some good ideas aswell, I look forward to seeing the finished project.  I grew up in Galesburg Il, we used to go to Milan Surplus and get all kinds of good stuff!!!!  I havent been there in years dont even know if they are still open.  Stuk4x4
Reply:I'm impressed. There's a lot of thought that went into that so far, even if you had an original to copy. The attention to detail I see is superb. Also you have done an excellent job documenting what has gone into this.Someone here recently wanted to know what they could do to show "experience", and I made a comment on documenting personal projects and doing them with an attention to detail. Your work on this was exactly the kind of project and documentation I was thinking about when I wrote that. A project like this in a portfolio would show any potential employer what sorts of skills you have at your disposal.Again very well done sir. I look forward to seeing more of this project..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:When you machine your roller a slight taper will hold the belts to the center.I did a belt grinder with 2" wide wheels and machined a small flat at the center and a slight taper to each side and it has held the belts fine.Very nice looking work.have funTom
Reply:Originally Posted by acourtjesterWhen you machine your roller a slight taper will hold the belts to the center.I did a belt grinder with 2" wide wheels and machined a small flat at the center and a slight taper to each side and it has held the belts fine.
Reply:Holy crap, That belt sander is awesome, I bet it weighs about 500 pounds.....Lincoln pro mig 180Lincoln Square Wave Tig 300/wp 20/home built water cooler Victor, Purox, Harris, O/A welding/cutting setupsVintage Craftsman drill pressVintage Craftsman/Atlas 12"x 36'' lathe7''x 12'' w/c band saw Everlast 140 st
Reply:that sander will outlast the need for sanders to exist.miller syncrowave 250hobart handler 140home made 400 amp engine driven in progress...
Reply:MADE IN USA!  Great Job, on all of your projects.