Thank you for the kind words
Thank you for the kind words
Got the frame off the table with the forklift so it could be flipped over.
Welded the web gussets into position:
Then clamped the outer plates and the frame to the table again to weld everything solid:
Then took the assembly off the table to get wire wheeled:
Then outside to get blown out with compressed air:
Then it came back inside and the casters were put on so it could be moved easily around the shop without the forklift:
Should be ready to start mounting the brake and the hydraulics soon!
Was debating adding some gusseting to the top crossbeam and finally decided to just do it. Cut some 4x4 square tubing:
And welded them into position:
Then mounted the top plates and eye bolts:
Drilled a couple holes into the base of the finger brake assembly to be used for mounting:
And mounted the base into the frame:
And assembled the brake:
Then got to work on the bottle jacks. They need to have the knobs added to them for ease of use. And to have the return springs and plates removed. The jacks as they come:
Pressed the roll pin out of the release valve:
Then added the new knob and pressed the pin back into position:
Installed the jacks:
Then quickly plumbed them together using the HF 3 way coupler to test the system. They worked! But were not in sync. We have a solution for that, stay tuned:
Knowing that the system will work was a relief. Reading up on what others do is great, but getting the same results isn't always likely. And since it works, the decision was made to plumb the air lines in a much cleaner fashion then using the bulky stock rubber air hoses and HF coupler. So it was plumbed using pex tubing and fittings, as well as uses the foot pedal that was mentioned earlier:
`looks great. I like the bare metal look. Did you do anything to keep it from rusting?
Time to get started on the mid plate. This piece will be crucial to making the press function correctly as well as making it easy to setup and operate. The mid plate will tie the bottom of the bottle jacks all together and keep them aligned. It will also act as a mount for the different press attachments, with the finger brake being the main attachment used. The assembly will be made up of a series of stacked plates in the center with sections of tubing on the outer edges. It will also feature a pair of removable guides that will straddle the vertical legs of the press frame, keeping the assembly aligned within the frame and parallel to the horizontal beams.
Start by cutting and cleaning up the pieces needed for the main assembly:
And since the brake press works, and are excited to try it out, the guides will be first to be made. Start with two pieces of 3/8" x 2" flat bar cut to the identical length:
Then bend them using the new brake:
Drilled some holes in the bottom of them:
Prepped the bent pieces and a set of 1/2" thick plates to be welded together. Clamped them to the fab table and welded them solid including filling the drilled holes by plug welding them for extra strength. Then cleaned them up:
The main body will be made up of stacked plates with tubing run along the edges. Cut a couple plates, one 1/2" thick and the other 1/4" thick, then drilled a couple holes in the 1/4" thick piece to use for plug welds, and welded them together:
Capped and sanded the ends of the tubing:
Clamped the pieces together and to the table using another piece of 1/4" thick material to help keep things aligned. Then welded the assembly together:
Then sanded the ends smooth and clamped the assembly back to the table in order to weld on the end pieces:
Finished sanding the assembly smooth then drilled a hole in each end and drilled and tapped the guides to match:
Placed the mid plate assembly into the press frame using some scrap tubing to keep it off the bottom beam:
Nice tight, but not too tight, fit:
Moved the assembly closer to the bottle jacks to begin layout of their mounting and the layout of the through holes needed for the different attachment mounts:
Machined a few hold down clamps to keep the bottle jack in position:
Positioned the clamps near the spring mounts since that area will see the most force:
Then used transfer punches to mark the centers. Also laid out the locations of the through holes. Then removed the assembly and drilled the holes:
Assembled everything back together:
Tested it and the mid plate worked well all round. The jacks do not release fully and start to recede until each knob is turned. And the jacks now work together as one can not move without the others. Happy with the results. Now just need to make the mount for the brake, fab a handle for the frame to help ease of moving, assemble the gooseneck and hemming dies, and then come up with a storage solution for the die sets.
Came to our attention that we forgot to show how we secured the top of the jacks to the top of the frame. The top mounts were drilled in the center and then countersunk.
Then the top of the jack was drilled and tapped in the center:
And the two were married:
Made an intermediate mount for the brake. Started with a piece of 3/8" thick flat bar, then drilled and tapped a series of holes in it to match the mid plate. Also included a couple holes to attach to the brake.
Then laid out the mounting holes on the top of the brake and drilled and tapped them:
And then assembled everything together:
Been slacking on the updates, though do have some. But to hold ya'll over, here is a short video of the brake press in action:
cnstaco (February 17th, 2020)