coping machine and railings

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Been a while since I posted, thought some people may find this interesting ?    I went on a search for a tube notcher/coping machine, after much research I decided that I would put in a few extra hours (on top of the 80 or so I normally put in) and build it myself. Most of  the truely industrial 6-7", 5+ H.P. were in the $7-8,000.00 range. This cost me about $600.00 to build, I did have the X-Y table already. It will cope miter's, offsets,straight copes, you name it, I havent tried it, but I suspect I can do 4" pipe if I make the mandral to do so. We dont just weld in my shop, so I have the ability and tooling to cut crowned drive rollers,mandrals,ect... along with a being able to machine the frame on a CNC mill, but I am sure a guy with a manual mill and small lathe could pull this off too. It took me a total of 26 hours to design and build but has run very many hours (most of which off of one of our trailblazers) with out a single problem. The railing is one of the jobs we just finished, doing 95% of the work on site. Attached ImagesDan.Repair Specialties LLC
Reply:NICE!!!! Whoa, that's pretty dang creative.  I'll be coming by with a few ideas as soon as I can!!!! Paul.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Super-giant industrial belt sander with replaceable nose rollers for the desired diameter of pipe/tube you are coping?Where's the drive motor hiding?  I can't see it.And that must be -ahem- interesting when a belt rips or lets loose!Nice tensioning cam and handle idea.Let's see:- 4 pillowblocks and two shafts and two rubber rollers,- two bearings and custom shaft/nose-roller,- 200 pounds of miscellaneous steel plate,- a whole bunch of socket-head and button-head cap screws,- a long abrasive belt,- miscellaneous pins, bolts, screws, washers,- some grease (got to have some grease),- other stuff (like a drive motor?)That machine is just screaming for a H-U-G-E  red emergency shut-off button.  Sort of like the Staples (store) "easy" button, only bigger and redder and marked "OFF".  The best laid schemes ... Gang oft agley ...
Reply:Very nice shop built machine!I'm also interested how the motor & drive is done, can you post a few more detail photos?Thanks,Mike
Reply:pic #2..... See the dual capacitors sticking up over the green rollers on the far side at the left side of the picture?"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Pic 3 is better to see the motor"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by DanMBeen a while since I posted, thought some people may find this interesting ?    I went on a search for a tube notcher/coping machine, after much research I decided that I would put in a few extra hours (on top of the 80 or so I normally put in) and build it myself. Most of  the truely industrial 6-7", 5+ H.P. were in the $7-8,000.00 range. This cost me about $600.00 to build, I did have the X-Y table already. It will cope miter's, offsets,straight copes, you name it, I havent tried it, but I suspect I can do 4" pipe if I make the mandral to do so. We dont just weld in my shop, so I have the ability and tooling to cut crowned drive rollers,mandrals,ect... along with a being able to machine the frame on a CNC mill, but I am sure a guy with a manual mill and small lathe could pull this off too. It took me a total of 26 hours to design and build but has run very many hours (most of which off of one of our trailblazers) with out a single problem. The railing is one of the jobs we just finished, doing 95% of the work on site.
Reply:Couple things, first off.  It will do a striaght (90degree) cope on 1-1/2" schedule 40 in about 25 seconds, same size cope on 1" sch 40 in about 15 seconds- yes really. The belt is hauling arse pretty good, thats a 3450 rpm motor with 5" drive rollers, not into the math right now but there is some serious surface speed here. It literally shreads the ends of the pipe-its like a steel wool making machine. The last post mentioned static build up- very smart person ! yes you do get static buld up, but with the machine is grounded along with the drive and it isnt enough to do anything but make the steel into a rug on the floor. At the end of a big job you just roll up the shavings and blow the rest out. It is a very dirty method of coping,but about as fast as it gets.  the motor as mentioned is back there I have a filter over it thats why its hard to see. Anyhow it is a direct drive to the drive shaft using a coupler. The drive rollers are urathane with aluminum hubs.believe it or not, they are albion caster rollers. The bore was really true so I just bored them, then cut the drive shaft so I could press 3 of them on,then after they were assembled I turned a single crown across the three. I was winging it at about three in the morning so I cant tell you the degree of crown, but i can tell you there is atleast .060-.070" of difference between the center and the ends. The idlers are flat, and the nose roller (mandral) does have a very slight crown, only about .012" from ends to center. That one you dont want too much crown on because you are trying to have a consistant cope, but I believe it is very important to have some crown or the belt is going to get pushed over too easy when dragging the material across it.  Hope that answers a few of the questions, I appreciate the compliments.  Ohh ya, the ends of the railings were made partially in the shop then on site using pre-fabbed bends welded into place, I use those split sleeves with wedges to line them up when doing them onsite.Dan.Repair Specialties LLC
Reply:one more thing, the handle over the top operates a cam (you can see it) on each side to push the end back evenly after changing the belt, works pretty good, changed the belt and it tracked almost perfect right off the bat.Dan.Repair Specialties LLC
Reply:Nice job on the notcher/coping machine and rail.  Thanks for sharing.Why was it necessary to build so much on site?  What method did you use to weld the rail?  Did you have to grind joints?
Reply:The neatest thing about this machine is that it is a result of a mind thinking about a problem, and solving it.It's something that's unique to this country.  No one else on the planet has our ability to solve problems in different ways.  More than one way to skin a cat.Free thinking people, living in a free thinking country.  That's America.From what I understand, this is an unusual way to notch tubing.  Seems like a good way to do it.  The machine work is beyond reproach.  A tribute to generations of builders.Our nation is losing those bulders.  No oppurtunity for them to flourish anymore."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Hey farmersamm, dont be so depressed; they are still around, look at the racing industry...Airco 300 squarewaveMig welding center...Powcon sm300/LN 25Powcon sm200/PD lHypertherm PM 1100Miller AEAD 200LE W/LN25 FCand now another sm200 pd l combo.
Reply:Originally Posted by sunlineHey farmersamm, dont be so depressed; they are still around, look at the racing industry...