MadModder

The Shop => Metal Stuff => Topic started by: Rob.Wilson on April 02, 2011, 03:49:13 PM

Title: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 02, 2011, 03:49:13 PM
Hi Lads


This afternoon i thought it was about time i made a start on building a cupola furnace  :dremel:  , the build will use what i have at hand around the shop  and the bits and bobs i have managed to scrounge up for the project   ::),,,, so the build  should come in under budget at 10 quid  :lol: :lol:

I am not working to any real plan ,just working it out as i go and to make best use of  the materials at hand  :med:


So may as well work from the ground up starting with the stand and a bit of welding  :zap:
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030172.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030173.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030175.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030177.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030178.jpg)
the furnace barrel on for size
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030179.jpg)
found a bit of plate just the right size to make the drop bottom from
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030181.jpg)
this was cut to size and a hinge made from bit out of the that may come in handy one day draw
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030184.jpg)
next a few bit of tube were welded to the bottom so a bar could be fed through them to keep the furnace bottom up in place when the furnace is in operation .
At the end of the casting session , this bar will be pulled out and the content dumped on the floor.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030185.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030188.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030187.jpg)

Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on April 02, 2011, 04:03:24 PM
Rob

I was just sitting here wondering what Rob was up to in his shop now that the weather is getting a bit nicer. Suddenly this pops up and now I know. I can see by the way that this is starting out that it is going to be another excellent thread. :) :)

My only concern is, do you really think that those welds will pass muster with Mr. Stevenson?  :lol: :lol: :lol:
I'll be enjoying the rest of this build as it comes.  :coffee:

Cheers  :beer:

Don

Title: Re: New Furnace Build ,,, Cupola
Post by: CallMeAl on April 02, 2011, 04:34:15 PM
Nice start, Rob.  This is going to be very interesting!
Title: Re: New Furnace Build ,,, Cupola
Post by: Stilldrillin on April 02, 2011, 04:35:28 PM
Looking good Rob!   :clap: :clap:

Watching, quietly.......  :thumbup:

David D
Title: Re: New Furnace Build ,,, Cupola
Post by: DaveH on April 02, 2011, 04:46:30 PM
Hi

Nice welding  :clap:

Dave
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 02, 2011, 04:57:40 PM
Hi Rob

Most impressive  :thumbup: 

So. Next question ..

Why is a Cupola Furnace different from the one you have ??

Kindly explain for the benefit of doombrains such as myself .. who have lived sheltered lives .. blowing the heads of transistors ...  :scratch:

( Yes, today ...    :doh: :zap:  :zap: ... back to Krakatoa electronics .. )
 
Dave BC
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 02, 2011, 05:27:27 PM
Cheers Lads  :beer:


Rob
My only concern is, do you really think that those welds will pass muster with Mr. Stevenson?  :lol: :lol: :lol:
Cheers  :beer:
Don
:lol: :lol: :lol: :lol: :lol: probably not Don  :lol: :lol: :lol: :lol:
Hi Rob

Most impressive  :thumbup: 

So. Next question ..

Why is a Cupola Furnace different from the one you have ??

Kindly explain for the benefit of doombrains such as myself .. who have lived sheltered lives .. blowing the heads of transistors ...  :scratch:

( Yes, today ...    :doh: :zap:  :zap: ... back to Krakatoa electronics .. )
 
Dave BC

Cheers Dave ,,,,,,,,,,,,,,,,, you could zap more things if you dug out that welded you use as a seat  :lol: :lol: :lol:

The reason for building a cupola furnace is ,,, cheaper fuel (coke)  and its a better type of furnace to melt iron with ,(will also melt bronze), made for the job  :dremel:  only down side is i will have to use it outdoors ,, but when up and running it should  melt continuously  about 350 lbs of iron  an hour if i needed  and will hold about 70 lbs of molten iron in the well . So its a summer job  :ddb: :ddb:

The other furnace will be used just for ally and bronze ,, that i can do indoors  :med:

Cheers lads


Rob
 



Title: Re: New Furnace Build ,,, Cupola
Post by: saw on April 02, 2011, 05:38:13 PM
Nice work Rob.  :clap: :clap:
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 02, 2011, 06:07:05 PM
Hi Rob

Oh! Coke .. never thought of that.   :palm: Assumed it was a bigger gas wotsit  ..

Welder is fine as it is. Not wearing it out at the moment. It's resting. Could do with a cushion for it though ... a bit parky around the nether regions ..

Dave BC

Title: Re: New Furnace Build ,,, Cupola
Post by: John Hill on April 03, 2011, 07:23:25 PM
I wonder if I could buy coke around here. :scratch:

The gas works are long gone so what other industries would be making coke?
Title: Re: New Furnace Build ,,, Cupola
Post by: John Stevenson on April 03, 2011, 07:28:20 PM
Crap welding  :poke:
I was going to say looks like pigeon $hit but knowing that lot up norf they have probably ate them all.

John S.
Title: Re: New Furnace Build ,,, Cupola
Post by: Bernd on April 03, 2011, 08:50:28 PM
I wonder if I could buy coke around here. :scratch:

The gas works are long gone so what other industries would be making coke?

Since you probably don't have any steel mills in New Zealand, I'd say make your own. That leads to the next question. Can you get coal? The lumps should be bigger than your hand.

Bernd
Title: Re: New Furnace Build ,,, Cupola
Post by: John Hill on April 04, 2011, 02:05:43 AM
I wonder if I could buy coke around here. :scratch:

The gas works are long gone so what other industries would be making coke?

Since you probably don't have any steel mills in New Zealand, I'd say make your own. That leads to the next question. Can you get coal? The lumps should be bigger than your hand.

Bernd

One steel mill at the other end of the country.  Plenty of coal but I dont know if I can buy it as it is probably outlawed in this 'green' town. :scratch:
Title: Re: New Furnace Build ,,, Cupola
Post by: lordedmond on April 04, 2011, 03:48:24 AM
Rob

Having been around molten metal for the first ten years of my working life I used to work at Stanton ,part of Stanton and Staveley ( I am a sparks )

we had blast furnaces x6 and more small cupola's than I can count , plus in the latter years induction furnaces from 750kw to 1.5 mw

My point consider a few vent holes in the drop base to vent the refractory

are you going to use lime stone as a flux along with two level taping holes.

as you can guess seeing iron casting inc ductile ( with the magnesium flare ) was common place , the finest casting was to cast nuts and bolts that screwed together without any machining

good luck with the project , bet it will have a 20 foot flame on blow down before the bottom is dropped


Stuart
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 04, 2011, 05:55:07 AM
Crap welding  :poke:
I was going to say looks like pigeon $hit but knowing that lot up norf they have probably ate them all.

John S.
:lol: :lol: :lol: :lol: :lol: :lol:  we have ,mmmmmmmmmmm

Rob

Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 04, 2011, 06:07:33 AM
Rob

Having been around molten metal for the first ten years of my working life I used to work at Stanton ,part of Stanton and Staveley ( I am a sparks )

we had blast furnaces x6 and more small cupola's than I can count , plus in the latter years induction furnaces from 750kw to 1.5 mw

My point consider a few vent holes in the drop base to vent the refractory

are you going to use lime stone as a flux along with two level taping holes.

as you can guess seeing iron casting inc ductile ( with the magnesium flare ) was common place , the finest casting was to cast nuts and bolts that screwed together without any machining

good luck with the project , bet it will have a 20 foot flame on blow down before the bottom is dropped


Stuart


Hi Stuart  

Thanks for the input  :med:  ,,, i had not considered putting holes in the base to vent the refractory  as i had planed to just sit the furnace on the base ,, is it beneficial to have a few holes in the base ?

I am still undecided weather to use limestone as a flux ,,,,,,,,i will have ago without at first  and see how things go ,,, as it is a small furnace it may not (i hope ) have too much problems with slag .

I probably will still add a slag tapping point  .


Rob

  
Title: Re: New Furnace Build ,,, Cupola
Post by: lordedmond on April 04, 2011, 07:55:53 AM
Rob all I can say all the ones at Stanton had vent holes in the base ,they were a bit cruder than your project with just two half circle doors held up with a prop , a chain was attached at the end on the shift , this was then fastened to a Lansing Bagnel Tractor , then away we go prop away and bottom dropped if you were lucky  :D

the best bit or worst was if there was water in the pit  :)

the day end process was to blow down the cupola to get rid of most of the remaining coke the drop the bottom


FYI the blast furnaces had 4000 hp steam turbine blowers with coopers stove to heat the blast the pipes before the tuyere's glowed red hot , the cupola's had 50 hp to 150 hp blowers , most of the equipment when I was there before 1972 ( 10 years ) was DC  
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 04, 2011, 05:23:27 PM
Sounds a fun place to work Stuart  :dremel:

Was that a Lansing Bagnel Tractor  a TUG electric ?   


Here is one of the places have the pleasure  of working in   :ddb: :ddb: :ddb: :ddb:
 


The crucibles are over 6 foot tall and the moulding flasks ,,,,,,,,,well i could park my van in them  :bugeye:


Well i got a wee bit more done tonight ,,, not allot ,but moving forward  :dremel:

Drilled the four radial blast  holes in the barrel ,,,,, i used my handy doodad tool to mark the position of the holes ,,, great tool made in the USA .

i  marked a line around the barrel some 11" up from the bottom ,,, stick the tool on with the point touching the line and mark that position .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030196.jpg)
rotate barrel 90 degrees and make sure it cant move 
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030197.jpg)
remove tool and reset it back on the barrel with the pointer at zero
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030196.jpg)

repeat until all four positions are marked out ,,,,,,,,,,,,,,,,,,Nice and easy ,,,,,,,,,just right for a Geordie bloke  :D

then i burnt out a couple of large washes from some 3mm plate  for the wind belt
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030199.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: John Stevenson on April 04, 2011, 06:14:49 PM

repeat until all four positions are marked out ,,,,,,,,,,,,,,,,,,Nice and easy ,,,,,,,,,just right for a Geordie bloke  :D



Rob

Is there still 360 degree's in a circle up there ?
Just wondered because some thieving tyke is liable to have nicked a few   :scratch:

John S.
Title: Re: New Furnace Build ,,, Cupola
Post by: lordedmond on April 05, 2011, 03:08:52 AM
Rob
by hek they did not use this new fangled lecky thing

the older ones were petrol then the went modern and got a diesel one or two

yes it was very interesting but very old I was there 1962 - 1972, they were still casting pipes vertically in a pipe pit using hydraulic king post cranes , lot of hydraulic accumulators  around the place.
It was a common site to see a Lansing Bagnal towing a truck with a five ton ladle on molten iron trundling out to a casting plant sloping everywhere  :)

the biggest sand casting was for slag ladles they were built up moulds bricks held together with sand ,straw and hoarse dung then struck off with a strickle to get the shape ( one of my uncles did that type of moulding )
another one did brass casting using the crucible in the pit method

of course the large volume runs ,for tubing plates were done with sand slingers on a rotary roundabout track ( they were still using the same plant that used to make bombs during WW2 ) that plant used a different type of furnace to melt the iron called a Cessey SP. I never saw those but they had stainless steel pipe it the very top that pre heated coal dust which was blown in at the bottom

What I ddi see was the time they were doing a huge order for the tubbing plates ,they brought down from the blast furnaces the iron in 75 ton ladles ( just to speed thing up a bit )

the of course was the pipe spinning plants that was a sight to behold iron spraying out like cathereen wheels  :) when the socket end failed


sorry to go OT in your thread but seeing the word cupola invoked many old memories , but at the time it was just normal part of my working life ( it was no fun though to have to mend the cranes that had the 75 ton ladle stuck on the hook it was hot )

Stuart
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 05, 2011, 05:36:08 PM
Hi Stuart


"sorry to go OT in your thread "      ,,,,,,,,,,,,,,,,No worries you go for it  :thumbup:  ,, i am all up for hearing about how things were cast and how things were done and i am sure others are .

I have seen pipes centrifugally cast at another foundry i used to go to ,,, as you say it is worth watching ,,, they were making short lengths of thick wall, high spec nickel alloy tubes ,, the mould was spun up and the alloy pored in until the excess metal  and any slag flew out all over  ,,, the gaffa explained that centrifugal casting gave a much finer grain structure to the metal   :smart:  i think they use the same method to produce piston rings .


 :lol: :lol: :lol: :lol: :lol: John ,,,, nope there seams to be more after i have had a few  :beer: :lol: :lol: :lol: :lol:


Rob

   
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 05, 2011, 06:12:07 PM
and any slag flew out all over    

Hmmmmmm  ... now that's an idea for getting shot of the Chuckle Scrubbers ...  :lol:

BC
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 06, 2011, 01:57:18 PM
and any slag flew out all over    

Hmmmmmm  ... now that's an idea for getting shot of the Chuckle Scrubbers ...  :lol:

BC
:lol: :lol: :lol: :lol:  what diameter would you say the two of them are  :smart:  :lol: :lol: :lol:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 06, 2011, 02:07:37 PM
and any slag flew out all over    

Hmmmmmm  ... now that's an idea for getting shot of the Chuckle Scrubbers ...  :lol:

BC
:lol: :lol: :lol: :lol:  what diameter would you say the two of them are  :smart:  :lol: :lol: :lol:


Rob



Diameter ???? Dunno ... one's short and fat, seriously over-square. T'others sort of skinny ... both gormless and noisy.

Try THICK ... that'll be a good approximation..  :lol:

Dave BC
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 07, 2011, 01:45:52 PM
and a bit more , :dremel:,,,,,,,not allot but moving forward ,,, welded the rings to the barrel then rolled  up a bit 3mm plate for the outer .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030200.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030202.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030204.jpg)
a bit more plate required  :dremel:
 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030203.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on April 07, 2011, 03:29:14 PM
Its a propper job :bow: :bow: :bow: :bow:
Title: Re: New Furnace Build ,,, Cupola
Post by: saw on April 07, 2011, 03:34:25 PM
Looking good Rob  :clap:
Title: Re: New Furnace Build ,,, Cupola
Post by: lordedmond on April 08, 2011, 04:19:41 AM
Rob

Thats a big wedding ring you have on there , are you going to water cool the tuyere's in the full size they were fitted in a cooler ( water cooled ) and then the tuyere was inserted into that at a down angle of about 20 deg. boy was it a job when the cooler or tuyere failed on the furnaces as they had to be changed hot , they just removed the blast.

Build is looking good , but will look evan better with flames out of the top  :D

you may know this but in an induction furnace the lining was put in dry the base was rammed up to refusal then a steel pre form place in and the gap slowly fill with dry refractory this was rammed with air powered peening hammers held on jig and raised with the crane ,hell of a din but the lining was rock hard, the pre from was melted out as the first charge

Stuart

Title: Re: New Furnace Build ,,, Cupola
Post by: Brass_Machine on April 08, 2011, 01:36:35 PM
Holy crap Rob! You don't do things half assed do you?

Shaping up pretty nice!

Eric
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 24, 2011, 04:50:19 PM
Cheers lads  :beer: :beer: :beer:

just a bit of an up date ,,, progress has been slow  ::)   ,,,,,,,,,,,,,i have made up the formers and pored the castable refractory and added some handles ,,, the formers were just like the ones i used for my other furnace build ,,, i forgot to take photos of the ones for this furnace  :doh:
 (http://www.nam-engineering.com/cm/albums/userpics/10002/Centre%20Form.JPG)
(http://www.nam-engineering.com/cm/albums/userpics/10002/Center%20form%20covered.JPG)

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030287.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030288.jpg)


I will be leaving this project for a wile as i need a change of pace  :coffee:


Rob

Title: Re: New Furnace Build ,,, Cupola
Post by: Brass_Machine on April 24, 2011, 05:02:08 PM
I will be leaving this project for a wile as i need a change of pace  :coffee:

Eh? Whatcha gonna do?
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 24, 2011, 05:23:40 PM
Hi Rob

Most impressive. Far, far beyond my ancient capabilities ...  :(

Change of pace ???

It would look really cute if it were decorated ... here's a thought - wall paper......  :thumbup:
Nice bit of Laura Ashley with possibly  er ... Paeonies   ????
Yes, I think paeonies would be sweet   .....

 :lol:  :lol:  :lol:  :lol:

Dave BC


Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 24, 2011, 05:38:25 PM
Hi Eric


I just need a bit of a change  :)  ,,, the past couple of  years i have been fixing up my machines , making tooling and building the foundry   ,all good stuff,,,,,  but i need a break ,,, so i plan to build a small IC engine from bar stock   :med:


 :lol: :lol: :lol: :lol: :lol: Dave i hate decorating ,,,,,,,,,,,,,  :bang: :bang: spent the last three days doing it ,,,,,,,,,,,may be thats why i am so de-motivated  :lol: :lol:

"Nice bit of Laura Ashley with possibly  er ... Paeonies   ????" sounds like your in touch with your feminine side Dave  :poke: :poke: :lol: :lol: :lol:   or have you been spending time  listening to the chuck ell scrubbers    :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol:




Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 24, 2011, 05:48:01 PM
Hi Rob

The Chuckle Scrubbers are notable by their absence .. for which I am most grateful   :thumbup:

Long may they remain so ...  :lol:  :lol:

BC
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 24, 2011, 05:55:08 PM
Dam i love to see a grown man squirm   :lol: :lol: :lol: :lol: :lol: :lol:


Rob 
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on April 24, 2011, 06:05:34 PM
Dam i love to see a grown man squirm   :lol: :lol: :lol: :lol: :lol: :lol:


Rob  

What a dreadful thing to say. Have you no feelings for a fellow male in his torment??  :(  :(

I decline to do any squirming, or any thing else for that matter, with that pair ..

Might I suggest they take a trip to see you ??? See how you get on ..   :lol:

Mind you, one of 'em is pretty hefty. Make a good job of ramming your flasks, I bet.

BC
 

Title: Re: New Furnace Build ,,, Cupola
Post by: Brass_Machine on April 24, 2011, 10:56:42 PM
...
 so i plan to build a small IC engine from bar stock   :med:
...

Soooo... Radial? V-Twin? Boxer?
Title: Re: New Furnace Build ,,, Cupola
Post by: sbwhart on April 25, 2011, 01:35:54 AM
...
 so i plan to build a small IC engine from bar stock   :med:
...

Soooo... Radial? V-Twin? Boxer?

I bet it's a big-un.  :headbang:

looking forward to it.

Stew
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 25, 2011, 04:07:09 AM
hi lads


I have been mulling over lots of engines the past few days and fancy doing something small for a change ,something that i could maybe get some practice using my small CNC mill ,as it just sits there doing nowt  :whip: ,,,,  thought about doing a Webster then remembered Chris is building one ,so i knocked that idea on the head ,,,,,,,,,,,,,,,,,,so it will be a hit and miss engine by Mr D Kerzel ,,,,,,,,,,,,,i seam to have all the materials for this engine at hand ,,,except some stuff called
corian  :scratch:  for the spark plug insulator .

Cheers Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Jasonb on April 25, 2011, 04:20:54 AM
Let me know if you want a bit of Corian, think I could spare a bit of pink :)

Jason
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 25, 2011, 04:26:44 AM
Let me know if you want a bit of Corian, think I could spare a bit of pink :)

Jason
:lol: :lol: :lol: :lol: :lol: just my colour Jason  :lol: :lol: :lol: :lol: :lol:

What is Corian   :scratch:  ,,,, not in the RS catalogue


Rob  


Edit ,, Googled it ,,,,,,,,,,,stuff for worktops  ::)              ,,,,,,,,,you live in a pink house Jason  :poke: :poke: :lol: :lol: :lol:
Title: Re: New Furnace Build ,,, Cupola
Post by: Jasonb on April 25, 2011, 04:38:28 AM
Its a hard plastic for want of a better description. Mostly used for kitchen worktops, the Americans call it "solid surface material". Generally comes in 12mm sheets and is bonded with a colour matched epoxy, can be worked with woodworking power tools like a router but also mills well, can also be thermo formed into curves. The lid on this box (http://img.photobucket.com/albums/v156/jasonballamy/z22.jpg) I made by heating and then vacuum pressing (http://img.photobucket.com/albums/v156/jasonballamy/corian.jpg) over a former having first used a router to thin it from 12mm at the hinge down to 6mm at the front. Also makes a good former for flanging (http://img.photobucket.com/albums/v156/jasonballamy/Fowler%20construction/PICT0084.jpg) over. This (http://www.bespokefabrications.co.uk/assets/images/seat_c.jpg) is something else I did in conjunction with teh corian fabricator I use

I've got quite a few old discontinued samples which are 50x50x12, you are welcome to some. PM me where to send it
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 25, 2011, 04:54:53 AM
 :bugeye:  now thats a very nice box Jason ,,, interesting stuff how you formed the lid  :med: :dremel:  ,, it the wood spelted ? think thats what it called .

Thank you very much  for the offer PM sent ,,,,,,,,,,,,i am now doubly in your debt  :bow:

nice bit off flange work on the traction engine gear cover too  :clap: :clap: :clap: :clap:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Brass_Machine on April 25, 2011, 12:32:37 PM
That's some neat stuff Jason. Had to look up the pump you have... I do a lot of vacuum bagging of CF. Tired of my vacuum pumps.

What else you hiding??


Rob... After you do the Hit or Miss, then you will do a radial??
Title: Re: New Furnace Build ,,, Cupola
Post by: Jasonb on April 25, 2011, 01:32:47 PM
This (http://www.homeworkshop.org.uk/index.php?option=com_adsmanager&view=show_ad&adid=7070&catid=2) could be a nice radial project for you Rob, would make a good blower for the new furnace :bugeye:

J
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on April 25, 2011, 03:21:48 PM
Rob... After you do the Hit or Miss, then you will do a radial??


One day Eric ,,,,,,,,,, i have the drawings for the Bentley rotary aero engine  ,,just have to get in the mood for all those repetitious parts  :med:



Now thats an engine Jason  :lol: :lol:



Rob 
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on July 10, 2012, 10:40:31 AM
So Rob - what happened with the cupola build?
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on July 10, 2012, 11:22:04 AM
So Rob - what happened with the cupola build?

Next on the list , just need to finish the CNC , hope to have it fired up in September  :thumbup:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: RotarySMP on September 25, 2012, 05:28:43 AM
Great fabrication.

What will you use for a blower?
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on September 28, 2012, 10:46:07 AM
Great fabrication.

What will you use for a blower?

cheers  :beer:  RotarySMP  ,,, I will probably just use the blower from my other furnace ,
(http://i1066.photobucket.com/albums/u410/RobWilson100/Foundry/BLOWER.jpg)

or then again i may just knock up another blower  for this furnace .


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: RotarySMP on September 28, 2012, 05:01:39 PM
Call me a stalker, but madmodder.net has a search function - all post by user. I looked at all the pictures you have ever posted to MadModder Rob, and am truely impressed at the quality of your work.

Thanks for sharing your skill and knowledge.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on September 29, 2012, 03:52:04 AM
BLUSH Thanks RotarySMP

Do you do any casting ? 


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: RotarySMP on September 29, 2012, 06:54:51 AM
A little. Started about a year ago. I have a little A5 furnace built to Anon (www.alloyavenue.com mpderator) design.

My casting so far are here: http://s1124.photobucket.com/albums/l579/rotarysmp/

Just a raw beginner.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on September 29, 2012, 04:35:24 PM
Looks like your off to a good start , motor mount looks good and solid  :thumbup:

(http://i1124.photobucket.com/albums/l579/rotarysmp/L1011091.jpg)




Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: RotarySMP on September 30, 2012, 03:56:01 AM
Hi Rob,

Not sure it is a good idea posting photos of my work in your threads. The casual oberver might think its from you, and that you have lost your touch.   Your reputation is at stake :)

People already suspect you have issues milling out square...
(http://madmodder.net/Smileys/default/kranke_200-1.gif)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1050443.jpg)

I don't mean to highjack your cupola thread, but when I machined my two motor castings, I drilled through the hinge axis with a long (~200mm long 6mm drill). Even with center drilling, I ended up with the axis alittle squewed off. You can see in the tensioning widget, that things didn't line up very well.

How would you have gone about that?
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on September 30, 2012, 04:55:40 AM
No worries , the cupola build has stalled for now due to other jobs  :proj:

I would have marked each lug out and drilled them individually ,from either side .



Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: RotarySMP on September 30, 2012, 06:03:48 AM
Thanks. I was trying to avoid that, guess it would have been the better of two unattractive options.
Title: Re: New Furnace Build ,,, Cupola
Post by: ironman on October 01, 2012, 12:51:48 AM
Good to see that someone is going to build a cupola. I have had years of experence in running one (9" dia). they can be very temperamental furnace to run so If you need help I can help.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on October 01, 2012, 12:00:53 PM
Good to see that someone is going to build a cupola. I have had years of experence in running one (9" dia). they can be very temperamental furnace to run so If you need help I can help.

I probably will not get this project finished until next  year ,so many other shop jobs  :palm: , when i get stuck and i probably will , I will give you a shout .


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on May 01, 2013, 08:12:08 AM
Bugger - I only joined up to see this build  :lol:
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 01, 2013, 01:00:52 PM
Bugger - I only joined up to see this build  :lol:

 :lol: :lol:  I was actually looking at the furnace last night  ,,,,,,thinking I may do a bit work on it now that the weather has improved a bit , have a break from the 626 project .

Just looked its been two years since I started the build ,,,,,,,,,fook me I am slow  :lol: :lol: :lol:

Rob

Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on May 01, 2013, 01:54:24 PM
Never mind Rob, my 100kW Induction Furnace and my Propane Furnace are still not unpacked from moving here 5 1/2 years ago I'm ashamed to say !
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 23, 2013, 09:25:05 PM
It  has been raining here for 3 days but there was enough of a pause late today for me to cut up some 1/2" rebar and make up 2 botting irons and 2 tapping bars.

Better hurry Rob or I'll be the first to watch slag dripping out of my cupola into a pouring ladle! 

Puttin on the pressure, uhhuh, uhuh :headbang:
Title: Re: New Furnace Build ,,, Cupola
Post by: tekfab on May 24, 2013, 04:31:58 AM
,,fook me I am slow  :lol: :lol: :lol:

Rob

Thats not what your wife told me  :D   :D                                                       
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 24, 2013, 12:39:32 PM
It  has been raining here for 3 days but there was enough of a pause late today for me to cut up some 1/2" rebar and make up 2 botting irons and 2 tapping bars.

Better hurry Rob or I'll be the first to watch slag dripping out of my cupola into a pouring ladle! 

Puttin on the pressure, uhhuh, uhuh :headbang:

 :lol:  Steve you win  :lol: 

I still have bott sticks , pokey stick  :poke: , blower , crucible poring shank and the furnace to finish  :Doh:

Better go and look for a motor for the blower ,,,,,,,or I will be hand cranking   :(


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 24, 2013, 07:16:53 PM
Ah, well Rob, I've got the drop door to do, the lid to line, lid lift and swivel mechanism, pouring shank, ladle, pig molds to weld, as well as make up some iron sand. So false bravado, here!  :lol:
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on May 24, 2013, 08:34:34 PM
c'mon you two - less talking and more action (with pics - lots of pics)!
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 27, 2013, 11:04:22 AM
Here we go  :)

After spending most of the weekend sorting out my workshops , had to take advantage of the good weather , I managed to drag  the furnace into the fab shop , it was a bit of a fight , big spiders and the ivy had grown over it  :palm:

First job was to remove the centre form .

before.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1030288.jpg)

After ,
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060680.jpg)

then a bit work to the stand ,I noticed this had a fare bit of spring in the legs when I was dragging it into the shop and the corners of the box section were also digging into the flags .
So some tubing was added to brace the legs , nice a stiff now . Some 4 inch bar was sliced up to make feet .I rounded the edge so they would slide easier.

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060666.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060675.jpg)

these were then welded to the bottom of the legs .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060677.jpg)

still a bit work to do to the stand .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060683.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060682.jpg)

I better move my arse as Steve has had fire in his furnace  :D

Rob

 
 
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 27, 2013, 01:57:10 PM
Woohoo!

That is one impressive cupola.  :bow: :bow: :thumbup:

Mine did come along a little faster.

Just like a fire in a dustbin is faster to prepare for than constructing a convection oven for a pastry chef.

Any time you want to trade, Rob, just let me know!
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on May 27, 2013, 02:14:26 PM
Looking good Rob
The legs wont be flexing now  :lol: :lol: :lol: :lol: :lol: :lol:
John
Title: Re: New Furnace Build ,,, Cupola
Post by: krv3000 on May 27, 2013, 03:28:08 PM
can rost sum nuts with that rob well dun
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 27, 2013, 05:50:04 PM
can rost sum nuts with that rob well dun

LOL, LOL!

Lets hope not....
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 28, 2013, 03:58:29 PM
Thanks Lads  :beer:

Only had an hour in the shop tonight so I decided to make the shoot ,were hopefully molten iron will flow from .

So I grabbed an off cut of 100mm box .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060687.jpg)

Set it at an angle I was happy with and marked both sides with chalk .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060689.jpg)

A couple of minutes with an angle grinder .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060690.jpg)

so I now had a shoot shape .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060692.jpg)

I decided to bend out the sides using a 2ft adjustable.

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060694.jpg)

Once I was happy with the angle , mark one eye ball .

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060693.jpg)

I needed to bend the other side the same , the original measurement between the walls was 90mm

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060696.jpg)

I had bent the first side out 20 mm

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060697.jpg)

so all i had too do was bend the other out until the gap was 130mm

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060699.jpg)

then both would be bent equal , well close enough for this job.

the bit scrap that was cut from the box previous was re welded in at the front for the shoot to form a lip.

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060700.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060701.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060702.jpg)


The shoot was then welded to the drop bottom .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060704.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060706.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060711.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060708.jpg)


would have took me 40 minutes if I did not stop to take photos  :lol: :lol: :lol:


Cheers Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: hermetic on May 28, 2013, 04:26:56 PM
Superb piece of work, Get yersen a broon!
Phil.
Title: Re: New Furnace Build ,,, Cupola
Post by: tekfab on May 28, 2013, 06:13:14 PM
Is this an Australian Cupola ?   :D
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 28, 2013, 07:53:19 PM
Rob, beautiful work as usual.  :bow:   Just a little concerned about welding the tapping spout to the drop door. I know Terry Aspin shows that on his little 5 gallon can cupola, but I'm concerned on a larger furnace with a long spout, the drop will hang up on the spout, and/or the extended door will throw the drop forward. I think straight down is best, and I'm guessing the reason for double doors on larger furnaces is to clear the drop instantly and shunt it straight down To do that there is as little door overhang as possible.

Maybe I'm wrong. apologies if so.  :bow:
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 29, 2013, 11:23:09 AM
Thanks for the comments Lads  :beer:

Hi Steve

I was going to weld the spout to the main body but decided not to for a couple of reasons , the first being I have to be able to move this 190 kg lump around myself as I have nowhere to have it setup permanent, with the main body off the stand I can roll it on its edge ,the same way one rolls a gas cylinder   ,if I had the shout welded on it would hinder doing that .

Secondly its much easier to mod the spout if needs be welded to the drop bottom than it is welded to the body .   

Hope fully all will be well  :palm:


Cheers Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 29, 2013, 11:42:28 AM
I have a similar problem Rob. I want to attach the spout to the shell, but that is thin stainless and has little stiffness. Now also backed by refractory.

I also need to ditch the wheels and raise it on legs. So trying to think how to do it all.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 29, 2013, 02:51:42 PM
Hi Steve ,

Welding the spout on with the refractory in place should not hinder you , just welded three lugs to mine tonight so that the stand can be bolted to the body.

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060716.jpg)

With it now bolted together I flipped the furnace up onto its feet .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060713.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060719.jpg)

Not allot done tonight , but every little helps  :med:


Cheers Rob   
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on May 29, 2013, 03:10:43 PM
Very nice Rob
It looks like the start of a time travel machine
(you sure those welds have plenty penetration) :lol: :lol: :lol: :lol: :lol: :lol:
John
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on May 29, 2013, 03:45:09 PM
Is this an Australian Cupola ?   :D

Might have been.  :doh:

 :update: 
Now it can be used in both hemispheres!  :lol: :lol: :lol:

Cheers  :beer:

Don

Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 29, 2013, 07:27:45 PM
Looks great Rob!  :clap: :clap:

Title: Re: New Furnace Build ,,, Cupola
Post by: NeoTech on May 30, 2013, 02:07:59 AM
This is damn neat.. if you would need to extend it, could you just pop another section onto the top there or what? =)

When this comes into play, can we look forward to a operations video? =)
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on May 30, 2013, 08:56:15 AM
Looking good Rob - what is the purpose of the lip on the front of the shoot?  Also, does the refractory run the full length of the cupola?
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on May 30, 2013, 03:27:12 PM
Cheers Lads  :beer:

Looking good Rob - what is the purpose of the lip on the front of the shoot?  Also, does the refractory run the full length of the cupola?

Hi Mayhem , the lip is there to give some  support the end of the clay spout , Yes the refractory runs the  full length , basically its a concrete pipe .

This is damn neat.. if you would need to extend it, could you just pop another section onto the top there or what? =)

When this comes into play, can we look forward to a operations video? =)
 


Hi Andreas ,  yes extensions can be added if needed  :thumbup:  I may make one 2ft extension .  I will take a few photos not into doing video  :palm:



Marching on , I dugout from the loft at the weekend the only usable motor I have for this job , a Brooks 2.2Kw /3hp, 2800 rpm ,240v  single phase , its a bit crusty but should do nicely .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060724.jpg)

So I made a start on the blower , machined up the rotor discs , going for a 10" fan .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060663.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060726.jpg)

I better get moving as Steve,s furnace is growing legs  :)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: krv3000 on May 30, 2013, 04:29:44 PM
cuming a long nicely
Title: Re: New Furnace Build ,,, Cupola
Post by: micktoon on May 30, 2013, 06:29:03 PM
Looking good Rob  :bow: :bow: , I had been wondering about the lip on the bottom of the spout too but makes sense now, its looking like some sort of robot as John says , you will have to give a name  :D

Cheers Mick.
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on May 30, 2013, 09:03:42 PM
...I will take a few photos not into doing video  :palm:...

You should have a chat with Geordie John Bastard Doubleboost productions - He'll sort you out with a video Rob  :thumbup:
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on May 31, 2013, 09:29:05 AM
That motor should do the job, Rob!
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 01, 2013, 03:48:07 AM
That motor should do the job, Rob!


 :lol: :lol: aye Steve its a tad on the large side  , but hey were use what we have at hand  :med:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: John Rudd on June 01, 2013, 06:44:39 AM
Nice job on the fan discs Rob.... :bow:

Any chance of an explanation on how you did them please? :scratch:
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 01, 2013, 07:15:20 AM
That motor should do the job, Rob!

 :lol: :lol: aye Steve its a tad on the large side  , but hey were use what we have at hand  :med:

Rob

Definitely Rob! My missus is glad to see me reducing the size of the outdoor treasure pile now that I'm making things with a bit of it. And the shop/storage shed seems to get larger when I do that too for some reason. I can actually crawl in there, now! Hmmm wonder when the next flea market is....

ps. I've read of a few first cupolas which didn't have enough blast to start with, and you may have a cupola extension, too some day, so that bad boy seems like a wise Plan A.

Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 01, 2013, 08:06:30 AM
Nice job on the fan discs Rob.... :bow:

Any chance of an explanation on how you did them please? :scratch:

Hi John , I screwed the discs to a bit plywood that was fixed to the face plate , turned OD , bored hole , not allot to it  :dremel:

 

Quote
ps. I've read of a few first cupolas which didn't have enough blast to start with, and you may have a cupola extension, too some day, so that bad boy seems like a wise Plan A.
 

If in doubt give it more clout Steve  :)  I can always throttle it back  :palm:



Made a start on the tuyere  inspection ports this morning , first off I need to make some flanges ,so I burnt a strip of some 10mm plate , this was cut into three and the burnt edges milled up , one 3mm pass each side sorted that .

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060723.jpg)

I made a sheet steel template for marking out and the saw was set over and the lengths of plate were then cut into diamond shapes , the template was then used to mark out the radius's

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060730.jpg)

Then the plate was used as a drill jig to mark the hole centers.

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060728.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060729.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060732.jpg)

The four on the left have temp holes drilled into them for fixing to a fixture for boring , they will be drilled and tapped after welding to tubes .

Time for some lunch me thinks .

Rob

 
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 01, 2013, 08:53:35 AM
Wow, nice!
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 01, 2013, 02:48:24 PM
A bit more progress  :dremel: 

Flanges were bored in the lathe .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060734.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060735.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060736.jpg)

Then the tubes were welded to the flanges , three washers were used to give some offset for welding.
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060740.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060739.jpg)

Tacked
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060742.jpg)

welded
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060744.jpg)

These will be welded to the wind belt after I finish the machining them .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060747.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060748~0.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 01, 2013, 10:16:44 PM
Oh so that's how you do that! Learning a lot.  :bow:
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 02, 2013, 06:11:02 AM
Time for a tea break  :coffee: so I may as well do a quick post .

First job this morning was to skim the flange bolt faces  to get rid of the distortion caused by the welding .

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060749.jpg)

That done the holes were then drilled and tapped , if I had drilled and tapped these before welding the studs would not have been perpendicular to the flange face .

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060753.jpg)

M12 SS studs.

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060755.jpg)

 With that done they were welded to the wind belt .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060759.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060760.jpg)

Suppose I better finish the covers now , Deciding weather or not to fit glass viewing windows , may splash out  even though it would take me over my 10 quid budget for this build  :lol: :lol:


Rob 
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 02, 2013, 08:08:09 AM
Well thats the covers done for now  :dremel:  , filed a slot on the RH side so they can be swung clear .


(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060765.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060767.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060768.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060769.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on June 02, 2013, 12:56:49 PM
Very nice. I hope that you are going to nickle plate them to stop them rusting !

btw thin mica sheet is good for viewing windows
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 02, 2013, 01:05:46 PM
 :lol: :lol: :lol:  Nope going for oh natural look Andrew

Quote
btw thin mica sheet is good for viewing windows
 

I will looking to that  :thumbup: , I was thinking of cutting circles from the front glass of a log burner (John DB )  idea .

Rob   
Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on June 02, 2013, 03:52:42 PM
I do have a few sheets, but they are only 35mm wide by 125mm long. PM me an address if they are any use to you.

Title: Re: New Furnace Build ,,, Cupola
Post by: micktoon on June 02, 2013, 05:02:30 PM
Hi Rob , its coming along really well now , I look forward to seeing the first cast getting done :thumbup:  :clap:

 Cheers Mick
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 02, 2013, 07:27:58 PM
Great to watch how you do things, Rob. Are you putting in a slagging door, too?

That furnace is a work of art.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 03, 2013, 11:47:49 AM
Thanks Lads  :beer:

Hi Steve ,   I am in two minds about fitting a slag hole , I think maybe if I were to run the furnace all day slag build up could be a problem . What do you think ?  you fitting one ?


Rob 
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 03, 2013, 01:42:47 PM
I don't think I am going to, Rob because my well will be so shallow @ 10 lbs iron. But I was thinking that it might make one man operation somewhat easier -- re skimming before the pour.

I guess the ideal for one person might be a teapot type ladle.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 07, 2013, 05:20:19 PM
Well my fan motor EXPLODED!  :lol: :lol: :lol: :lol:

 (http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060780.jpg)

Tested insulation with mega  :zap: thats OK , ran up motor , bearings sound a tad dry , checked shaft  :palm:

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060782.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060783.jpg)

Looks like it has had an ill fitting pulley on it  some time in its life ,,,,,,, the price you pay for using salvaged parts  :coffee: and the centrifugal switch contacts could do with a clean .


So its repair motor first job tomorrow  :dremel:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 07, 2013, 08:12:58 PM
Yikes!


Wait a minute......

It didn't really explode,  you just took it apart to make sure it was in perfect running order.

Why I oughta....
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 09, 2013, 02:29:11 PM
Evening Lads  :beer:

A wee bit done to the motor , pressed off the bearings .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060795.jpg)

Ground the shaft end parallel with the good old tool post grinder  :dremel:

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060801.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060802.jpg)

And pressed one of the new bearings back on the shaft .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060805.jpg)


Now when I removed the motor fan cover one of the wee screw heads sheared off .
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060808.jpg)

Well corroded in as per with ally and steel . A bit of heat needed ,for jobs like this I use a heat gun .waist of time trying to use penetrating oil at this point .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060809.jpg)

File a couple of flats on the screw if poss  , don't cut a slot for a screwdriver or you will be getting the drill out ,  warm the ally part up , just wiggle the screw back and forth to crack the bond once its loose a bit then spay some penetrating oil on . been using this method for yonks on motor bike and outboard engines .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060812.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on June 09, 2013, 03:15:04 PM
Nice repair on the shaft rob
Be careful with the grinding dust on your lathe bed  :lol: :lol: :lol: :lol: :lol: :lol:
"plus gas" is good for snapped studs (oxygen plus acetylene) :) :) :) :) :) :) :) :)
John
Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on June 09, 2013, 03:48:33 PM
Conventional advice is if you must use a tool post grinder, cover the ways in damp newspaper first, then after use, a good clean up and re-oil. Grinding grit trapped under a way wipe can cause no end of damage.
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 10, 2013, 11:58:14 AM
Conventional advice is if you must use a tool post grinder, cover the ways in damp newspaper first, then after use, a good clean up and re-oil. Grinding grit trapped under a way wipe can cause no end of damage.

Sound advice Andrew  :thumbup: 

I had the shop vac stuffed between the ways  :dremel:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on June 13, 2013, 09:02:04 AM
Better pull your finger out Rob - Steve is talking about mixing mould sand in his build  :whip:
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 13, 2013, 10:46:50 AM
Talk is cheap.   :zap:   Raining again today can't even mix the stuff. Rain through to weekend predicted  :bang:

Last two years: drought. Can't complain.



Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 16, 2013, 03:48:36 AM
Better pull your finger out Rob - Steve is talking about mixing mould sand in his build  :whip:

 :lol: :lol: Aye Steve is kicking my butt  , I have been rather distracted this week , work , new shop toys , just picked up a load of blacksmiths gear yesterday  :hammer:  I am fighting the urge to knock up a forge  :lol: :lol:


Rob   
Title: Re: New Furnace Build ,,, Cupola
Post by: Mayhem on June 16, 2013, 07:01:31 AM
Better pull your finger out Rob - Steve is talking about mixing mould sand in his build  :whip:

 :lol: :lol: Aye Steve is kicking my butt  , I have been rather distracted this week , work , new shop toys , just picked up a load of blacksmiths gear yesterday  :hammer:  I am fighting the urge to knock up a forge  :lol: :lol:


Rob

New shop toys you say?  Do show  :drool:

Did you see the forge I made from an old Landcruiser rim? (http://madmodder.net/index.php/topic,8640.0.html)
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 16, 2013, 10:56:59 AM
Hi Darren

Just some more rust old gear to add to my distractions  :Doh:

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060822.jpg)

Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 16, 2013, 02:28:18 PM
Wow, look at that!! :drool:

I'd be knocking up a forge if I had that trove, Rob ...... that is beautiful!

In fact, I've been resisting doing the same thing, And that might get unsuccessful if I keep tripping over the #$@! brake drum and 2" tee and pipe nipples just sitting in front of my shed door where I'm storing the torch. .....no, no, must complete the honey-do list ...... :coffee:
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 16, 2013, 03:06:21 PM
Hi Steve

 :lol: :lol: Its easy to get distracted  :Doh:  , My anvil is actually on a swage block stand .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060823.jpg)

So i will need to make a stand for the anvil as I will be putting the swage block in the stand , anvil is too low as is . I also have a pile of fire bricks to use up .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060824.jpg)

Thinking I could use some of them  on the forge hearth  , It would also give me some were to silver solder /braze if i clean the coke from the hearth .

Forge would also be  cheaper than using acetylene for hot work .   


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on June 16, 2013, 03:29:48 PM
Hi
Mate
You have gone from a CNC build to Blacksmithing  :jaw: :jaw: :jaw: :jaw: :jaw: :bugeye: :bugeye: :bugeye: :bugeye:
They say that variety is the spice of life  :lol: :lol: :lol: :lol: :lol:
John
Title: Re: New Furnace Build ,,, Cupola
Post by: micktoon on June 16, 2013, 06:31:18 PM
 Hi Rob .......................Go with the mood I say  :D ...... nowt wrong with combining CNC with blacksmithing lol. It looks like you have a canny selection of tongs etc there and the bick iron is a good handy bit of kit too.
I look forward to seeing the anvil stand and forge projects  :thumbup:

 cheers Mick
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 16, 2013, 07:53:31 PM
A CNC drop hammer, bellows and automated coal scuttle would show the 3D printer boys a thing or two, wouldn't it?
Title: Re: New Furnace Build ,,, Cupola
Post by: Pete. on June 16, 2013, 08:36:04 PM
I hope you don't have any close neighbours - coz you won't be on speaking terms after you start using that lot :D
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 21, 2013, 04:27:05 PM
Hi Lads

Done a bit tonight , made the fan rotor boss ,

Cutting key way on the shaper .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060831.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060827.jpg)

Drilling the clamping screw holes , I did this in the lathe with my ye-oldey shop made dividing head .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060836.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060843.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060839.jpg)

That the boss finished

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060846.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060844.jpg)


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on June 21, 2013, 04:42:43 PM
Very nice Rob :bow: :bow: :bow: :bow: :bow:
That key way is a beauty
John
Title: Re: New Furnace Build ,,, Cupola
Post by: micktoon on June 21, 2013, 05:40:48 PM
 Shiny as usual Rob  :thumbup: , I like the dividing head for the lathe, just shows there is always more than one way to skin a cat , as John says  nice crisp keyway too. Hope you have a bsuy weekend in the shop and the project gets one step closer to being done  :clap:

 Cheers Mick.
Title: Re: New Furnace Build ,,, Cupola
Post by: Stilldrillin on June 21, 2013, 05:50:41 PM
Quality kit Rob!  :thumbup:

Well done.  :clap: :clap:

David D
Title: Re: New Furnace Build ,,, Cupola
Post by: krv3000 on June 21, 2013, 06:32:08 PM
well thats a nuther tool on me to do list well dun as per rob
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on June 21, 2013, 07:07:09 PM
Beautiful workmanship, Rob!  :bow:

Title: Re: New Furnace Build ,,, Cupola
Post by: mattinker on June 22, 2013, 01:57:19 AM
Rob,

I've clearly understood,

"I DO NOT SUPPLY DRAWINGS/PLANS OR CASTINGS !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! THIS IS JUST A HOBBY FOR ME ."

but could you post a couple of photos of your
" ye-oldey shop made dividing head."?

I'm on the scrounge for ideas!

Regards, Matthew
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 22, 2013, 02:39:30 AM
Cheers Lads  :beer:

Hi Matthew ,

Not a problem ,I will take a few photos later today , I am off up to Scotland this morning to pick up more rusty iron .

The dividing head is L H Sparey  design  and the plans for it can be found in his book  "The Amateur's Lathe "  A cracking book by the way .


The new addition to my tag line is due to getting bugged with PMs from people who just join here to ask me "can they have" , I have no problems helping members that contribute to the forum .


Cheers Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: mattinker on June 22, 2013, 03:21:18 AM
Thanks Rob,

I'm looking forward to the pictures.

I've ordered the book, but it will take some time to cross the channel!


Thanks in advance, Matthew
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 22, 2013, 12:57:24 PM
Hi Matthew

Its a canny book  :thumbup: , I have posted the dividing head photos in its own thread.  http://madmodder.net/index.php/topic,8656.0.html


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on June 22, 2013, 01:49:25 PM
Cheers Lads  :beer:

snip... I am off up to Scotland this morning to pick up more rusty iron . snip...


Cheers Rob

How long are you going to keep us in suspense?  :lol: :lol:

Cheers  :beer:

Don
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 22, 2013, 02:06:52 PM
 :lol: :lol: its still in my van Don .


It just an old blacksmiths leg vice , it still has a very large RSJ and a lump of concert attached   :palm:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Bluechip on June 22, 2013, 03:27:59 PM

It just an old blacksmiths leg vice , it still has a very large RSJ and a lump of concert attached   :palm:


Rob

That is no way to treat an Old Blacksmith's leg, or indeed any other body part ....
 
Shame on you ....  :lol:
 
Dave BC
 
 
Title: Re: New Furnace Build ,,, Cupola
Post by: Stilldrillin on June 22, 2013, 03:40:25 PM

It just an old blacksmiths leg vice , it still has a very large RSJ and a lump of concert attached   :palm:


Rob

That is no way to treat an Old Blacksmith's leg, or indeed any other body part ....
 
Shame on you ....  :lol:
 
Dave BC

Still wearing greaspaint, from the concert?  :scratch:         :D

David D

Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 22, 2013, 04:22:53 PM
 :lol: :lol: :lol: oops



Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 24, 2013, 08:23:26 AM
Here you go Don  :Doh:

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060876.jpg)

I was going to get the sledge hammer out ,,,,,,,,,,,,, but me being a fat lazy git I borrowed a breaker from Mick  :)

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060879.jpg)

And the distraction continue   ,,,,,,,,new machine coming  :ddb: :ddb: :ddb:


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: Pete. on June 24, 2013, 10:31:15 AM
Nice vice - I have it's twin :)
Title: Re: New Furnace Build ,,, Cupola
Post by: doubleboost on June 24, 2013, 10:37:01 AM
Hi
Rob
Will the vice jaws you built fit this one as well :lol: :lol: :lol: :lol: :lol:
John
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on June 24, 2013, 10:47:08 AM
Nice vice Pete  :thumbup:   ,,,,,,,,,,,,,,,, have you used yours ? 

 :lol: :lol: :lol: Dont thinks so John .


Rob
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on June 24, 2013, 12:10:54 PM
Rob

Nice one. And now you say there is another new machine coming. It seems that you love to keep us in suspense.  :lol: :lol: :lol:

Cheers  :beer:

Don

Title: Re: New Furnace Build ,,, Cupola
Post by: Pete. on June 24, 2013, 01:27:37 PM
Nice vice Pete  :thumbup:   ,,,,,,,,,,,,,,,, have you used yours ? 

Nope, not yet. I'm building new benched in my workshop and it will be bolted to one of those.
Title: Re: New Furnace Build ,,, Cupola
Post by: krv3000 on June 25, 2013, 05:43:03 PM
well if only you sed i gave one to the scrap man a bawt a fortnight a go
Title: Re: New Furnace Build ,,, Cupola
Post by: Rob.Wilson on July 26, 2013, 01:40:33 PM
A bit more done  :dremel: , finished off the fan rotor .

(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060896.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060897.jpg)
(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060900.jpg)(http://www.nam-engineering.com/cm/albums/userpics/10002/normal_P1060901.jpg)


Rob 
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on July 26, 2013, 02:19:04 PM
Rob

That fan rotor looks very impressive. It looks as good or better than any you would buy in any parts store. Your usual high standards at work again.  :clap: :D :D

Cheers  :beer:

Don
Title: Re: New Furnace Build ,,, Cupola
Post by: micktoon on July 26, 2013, 02:47:47 PM
Looking good Rob  :thumbup: :clap:, as Don says better than what you would be able to buy, should give you years of service without falling to bits like most bought stuff these days too.

 cheers Mick.
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on July 26, 2013, 03:12:22 PM
All right!  :thumbup:
Title: Re: New Furnace Build ,,, Cupola
Post by: unc1esteve on November 02, 2013, 11:27:16 PM
Rob,
I have been reviewing the posts on metal casting furnaces.
The pictures on your posts are not available.
How do I view them?
Thanks.
Title: Re: New Furnace Build ,,, Cupola
Post by: dsquire on November 03, 2013, 02:18:55 AM
Rob,
I have been reviewing the posts on metal casting furnaces.
The pictures on your posts are not available.
How do I view them?
Thanks.

unclesteve

I am sure that it is just a temporary thing that the photo's on Rob Wilsons post's are not available. I'll try and keep an eye on them for you.  :D :D

Cheers  :beer:

Don

Title: Re: New Furnace Build ,,, Cupola
Post by: unc1esteve on November 04, 2013, 10:39:44 AM
Thanks.  They are still not available.
Title: Re: New Furnace Build ,,, Cupola
Post by: NeoTech on November 04, 2013, 10:49:54 AM
Seems like all images of Robs is gone from the nam-engineering website.
Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on November 04, 2013, 11:22:04 AM
Rob's not been active for a couple of weeks - perhaps he's on holiday and his server has gone down?

Andrew
Title: Re: New Furnace Build ,,, Cupola
Post by: vtsteam on November 04, 2013, 11:25:22 AM
Looks like the host, www.nam-engineering.com is "under construction" at present.
Title: Re: New Furnace Build ,,, Cupola
Post by: NeoTech on November 05, 2013, 01:43:23 PM
Yeah Rob had a new job last time i messaged that was taking most of his time. I guess he be back someday.. =)
Title: Re: New Furnace Build ,,, Cupola
Post by: Pete. on November 05, 2013, 03:08:05 PM
Damn that work stuff. Always getting in the way of real life :D
Title: Re: New Furnace Build ,,, Cupola
Post by: awemawson on November 05, 2013, 04:04:29 PM
Total waste of time working - glad I've given it up for good and only have to jump to my own orders  :ddb:

I took a definite decision to retire early even though it had a big impact on the finances - I saw my father die before he retired and hence had no time for himself, and I was determined that wasn't going to happen to me. I needed my second childhood  :lol: