Loader Mutt Continues...

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Re: Loader Mutt Continues...

Postby DaveKamp » Tue Aug 27, 2019 11:49 pm

Much to the chagrin of my wife, and other beneficiaries of my estate, I'm not dead yet...

I haven't been working on the Mutt's future transaxle on account of other outdoor-based projects, and lots of summer activities. At this moment, I have a for-purpose motorcycle transport trailer chassis that's about half-done in the driveway, awaiting some rather unusual suspension stuff, and a 1879ish J.A.Fay and Co 36" bandsaw that I reassembled over the weekend, waiting now for a coat of paint, some more steel added to the platform/pallet underneath, and axles and space-saver spare tires to wheel it in and out of the shop, and probably a 5hp Tecumseh gas engine to run it 'till I finally get it into a working position inside the new shop...

But I'll get back at it sometime in the next few weeks. I wanna have it ready, and get the current one swapped out before snow. :beer:
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Re: Loader Mutt Continues...

Postby TWheaton » Wed Aug 28, 2019 4:31 am

Glad to hear you are still among us in this sphere :beer:
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Re: Loader Mutt Continues...

Postby DaveKamp » Thu Sep 05, 2019 9:39 pm

Hey Tim! Great to hear from you too!

Okay, so I haven't gotten a whole lot done on the Mutt transaxle in the last few weeks, on account of... well... many reasons. One is that, the weather being more conducive, I've been working on some outdoor projects... one has been the process of converting a detassling machine into a combination mobile scaffold/workplatform/hoist/carry-crane...
20190905_190757.jpg
20190905_191130.jpg


the other has been the reassembly and painting the bandsaw
20190905_203636.jpg




But amidst doing some overhead welding in the driveway, I slapped two pieces of square metal on the cutting-bench, and made 'em into round pieces:
20190905_180155.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Thu Sep 05, 2019 9:43 pm

Looks like we've got a fair chance for rain on Sunday, so I'm getting parts pre-cut for machine work. A rainy day, is a great day to spend at the controls of machine-tools. :beer:
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Re: Loader Mutt Continues...

Postby BigMike » Fri Sep 06, 2019 2:55 pm

Dave, did that bandsaw come from Michigan?
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Re: Loader Mutt Continues...

Postby NealC » Fri Sep 06, 2019 4:11 pm

DaveKamp wrote:the other has been the reassembly and painting the bandsaw


That's too nice to be called a band-saw, must be an Orchestra-saw, ;)
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 10:28 pm

Dave, did that bandsaw come from Michigan?

No Mike... it's very ornate. If it was from Michigan, it would have to be substantially more Spartan. :twisted:

That's too nice to be called a band-saw, must be an Orchestra-saw, ;)


Neal, It's figure is NOT accidental - this machine was clearly built on a major scale... :lol:
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 10:44 pm

Okay, so today's operations are dedicated to the first steps of producing a completely new axle outer assembly for each side. This is a fabricated steel assembly using the Dana 60 outer tubes and spindles, but a plate steel flange with steel gussets.

I'm starting with two pieces of square plate that (as previous images show) I've cut into rough circles. I've not-particularly-carefully slapped 'em together such that they're on about the same exterior circle... the interior holes are clearly offset by a few...
20190906_151428.jpg

...then I took a measuring tape, and roughly centered a piece of scrap tubing, and welded it onto the plates, from the INSIDE (not the outside) of the tubing.

Then I chucked the plates, by the tube, in the 4-jaw independant chuck.

now, there's several basic types of lathe chucks, and a jaw-chuck has, just as the name says... jaws. Two typical styles of jaw chucks are 'independant' chucks and 'scroll' chucks. On an independant, you can adjust jaw position of any chuck independantly. On a scroll-chuck, all jaws move together at the same time. Scroll chucks are handy when you're working with material that's already round, and that you always want the workpiece installed concentric to the lathe axis. An independant chuck can be adjusted to center OR offset the workpiece however you desire. Many guys who start out on a lathe, buy a 3-jaw scroll chuck, and live in a world of grand frustration, because any part they try to put in for repair, winds up being off-center. In reality, the most important chuck that a machinist has, will be an independant chuck with at least three, but usually more jaws. For repairs, one-off building, or R&D type projects, a 4-jaw independant is the necessary must... because you can mount a part that isn't square or true, and MAKE it true... and if you need something that isn't easily obtainable, like a special camshaft, etc., then you can easily offset the workpiece WITH the jaws
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 10:54 pm

So I didn't take a photo of the raw plates and ring chucked in the lathe, so you'll hafta imagine it (like Whirl'd Peas). I centered it by just parking the tool holder out near the edge, off a little bit (not in contact) and observing the runout, and alternately loosening and tightening jaws to bring it into about-right-territory.

Now, I need to cut the OD of these plates to about same diameter as the original cast housings. I also need to cut an ID in them that will combine with the Dana 60 axle tube such that I can get a fairly precise, well-seated fitment that won't be all torqued-out-of-line as a result of assembly and welding. When done, it'll all need to be true and square, too.

First step, is to accurately mark the ID and OD of the surfaces I'll cut. To do that, I need to know some stuff. Here's the 'old school' way of rapidly solving geometric problems, with some very basic and practical tools and techniques. This includes caliper, sharp pencil, compass, straightedge, and sheet of paper.

20190906_152812.jpg


The ID holes:

Take a caliper, and get a snug measurement of the OD of the axle tubes. Place the caliper on paper, and trace the outer edge of the caliper's edges.
20190906_152917.jpg

Now draw a line from the nearest center of the drawing's tips.

Take the compas, set it to some arbitrary radius that's larger than half the line's length... I shoot more like 3/4 the distance... and draw an arc, originating from the point where the straight line hits the profile of one tip.
20190906_152946.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 11:02 pm

Now repeat that process from the other end of the line (same rules apply...)
20190906_152958.jpg


Using the straightedge, draw a line from where two arcs cross on one side, to where two cross on the other. This is the exact center.
20190906_153032.jpg


Now, place the center pivot of the compass on the crossing point of the two straight lines... and set the compass width to match the distance from center of intersection to the tip of one caliper-line... This is the tube's radius from center. I marked the radius through each caliper jaw point. This identifies the tube OD.
20190906_153108.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 11:08 pm

Now, I place this sheet of paper against my workpiece, and install a live center in the tailstock, advance it until it will hold a piece of paper in the lathe.
20190906_153404.jpg


Next (and it seems a little wonky, but it's not)... I put a sharp tool in the toolpost, and position it so that it will scratch a mark at the OD line of the workpiece. I just rotated the chuck by hand, and let it scrape a nice line. Once I did that, I removed the paper and repeated with a sharpie.
20190906_153738.jpg


Then I took a light pass just to make it obvious where I'd need to cut eventually, but just enough to mark it for now:
20190906_154512.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 11:12 pm

Next is to define the OD, and this one is simpler yet... Place a pair of ordinary dividers on the extreme OD of the old housing...
20190906_154525.jpg


And use this to gauges how 'deep' into the plate you can chew, without going too far.
20190906_154538.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 11:13 pm

Next, is to cut the OD clean and to basic size:
20190906_155308.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Fri Sep 06, 2019 11:18 pm

And cut away metal 'till it's the right size:
20190906_160747.jpg


20190906_154525.jpg


20190906_165112.jpg


And we're 2/3rds done here now. Gonna let it cool overnight, and when I come back, I'll finish cutting the ID hole through the first plate, and then follow into the second (which cuts the welds loose).
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Re: Loader Mutt Continues...

Postby dag1450 » Sat Sep 07, 2019 5:29 am

Thanks for the pics on the neat projects. What are you building the platform for? Do u have some renovation work planned?
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Re: Loader Mutt Continues...

Postby DaveKamp » Sat Sep 07, 2019 1:37 pm

It'll be used for a variety of purposes, working in elevated positions while maintaining and replacing my farm buildings, but also a mobile hoist, a transporter of tools, etc., and a mobile lighted shelter for outdoor work amidst inclement conditions...
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Re: Loader Mutt Continues...

Postby DaveKamp » Sun Sep 08, 2019 11:23 pm

A little progress making pieces of parts today:

20190908_170355.jpg

Cutting axle flanges 'n stuff...

20190908_132758.jpg

Once the roughing in is done, I cut through the welds keeping all the pieces on workholding... I have two plates tacked together, and a tube to hold 'em in the chuck for OD and ID cutting, and facing on one side.

20190908_132929.jpg

Reversing the jaws on the chuck, I hold the plates by OD, and perform finishing cuts on other sides.

20190908_170705.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Sun Sep 08, 2019 11:27 pm

20190908_174233.jpg


20190908_171902.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Sun Sep 08, 2019 11:33 pm

20190908_133016.jpg


20190908_173210.jpg


20190908_175416.jpg


20190908_185243.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Sun Sep 08, 2019 11:34 pm

20190908_191507.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Wed Sep 11, 2019 9:37 pm

Now I'm more-or-less repeating the same process to make spacer-sections to provide clearance over the bearing cups and bolts...
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Re: Loader Mutt Continues...

Postby DaveKamp » Thu Sep 12, 2019 1:54 am

So the spacer is simple- a half-inch piece of plate, cut into a ring, sandwiched 'tween the flanges and mounting surfaces. Building process is simple... rough cut the ring from 1/2" plate with torch, then chuck it in lathe and cut the OD and ID holes clean...
20190911_232739.jpg


And that happens to be one of my favorite tools for this kind of cut, because I'm actually piercing INTO the material, then cutting TOWARDS the torch-line. I make gradual cuts inward, and as I go, I'm getting in BEHIND the rough area, and cutting it free. If I don't, the cutter is subjected to 'interrupted cut' forces... shock from impact with blobby torch-cuts, which will shatter the carbide or crash the tooling. While it's simple, it's rather tedious. One of these days, I'll have the building up, and the CNC plasma gantry operational, and it'll make a 'cleaner' cut, but it'll still take gentle work with a machine tool to make a precision surface. Plaz don't cut like a laser!!!

20190912_002228.jpg

Now, in this photo, you see (starting in the forefront, and moving clockwise:
One spacer, sitting atop the left-hand side transaxle coverplate, with integral bearing cup.
Above it, is the flange that will have axle tube installed... it will sit flat on both of these, and be bolted to the housing.
To the right, transaxle housing, with cup installed, and spacer ring in general position.
To the front, is the right-side axle tube plate. Notice it has a slight recess- this is to clear the bearing cup bolts.

My intention with this assembly, is to have the spacers welded to the flanges, then flanges welded to the axle tubes, concentric with the axleshaft axis. Then I'll spin the whole works in lathe, then skim the transmission mounting face square, so it'll assure the operating alignment is correct.

Of course, to determine the axle tube mounted length, I need to determine where the wheel center WILL be, and then calculate how long the axle tube will HAVE to be. Now, I'll be doing some more crazy stuff with the wheels here, so be patient and don't fret it, you'll catch up once you see it...

But I'll hafta compensate for offset in the trans housing, make sure it fits th4e frame, AND to make sure that it doesn't end up putting the wheels/tires in the wrong place... so I start with measuring some basics. The stack of plates that'll be on each side... (left side 1.5", right side 1.0", and the original housing width is 8"...
20190912_002356.jpg

20190912_002419.jpg

20190912_002538.jpg
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Re: Loader Mutt Continues...

Postby DaveKamp » Sat Sep 14, 2019 6:56 am

Time for "Hot Glue"...
20190912_223513.jpg


To get a good, tight connection, it takes plenty of clamps. Start with small tack welds, to hold it in proper position tight...

20190912_223616.jpg



To minimize distortion, use small welds, allow time to cool between...
20190912_224031.jpg


Then finish them in, again, allowing cooling time between:
20190912_233750.jpg


And back to the lathe, to check and finish bolt clearance:
20190913_040356.jpg
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