Loader Mutt Continues...

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DaveKamp
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First and Last Name: Dave Kamp
Location: LeClaire, Ia

Re: Loader Mutt Continues...

Post by DaveKamp »

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:
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

TWheaton
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First and Last Name: Tim Wheaton
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Re: Loader Mutt Continues...

Post by TWheaton »

Glad to hear you are still among us in this sphere :beer:

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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...
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the other has been the reassembly and painting the bandsaw
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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:
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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:
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

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BigMike
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Location: Niles,Michigan

Re: Loader Mutt Continues...

Post by BigMike »

Dave, did that bandsaw come from Michigan?

NealC
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Re: Loader Mutt Continues...

Post by NealC »

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, ;)

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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:
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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...
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...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
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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.
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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.
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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.
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Now repeat that process from the other end of the line (same rules apply...)
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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.
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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.
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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.
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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.
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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:
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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...
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And use this to gauges how 'deep' into the plate you can chew, without going too far.
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Next, is to cut the OD clean and to basic size:
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Attachments
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

And cut away metal 'till it's the right size:
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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).
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

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dag1450
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Re: Loader Mutt Continues...

Post by dag1450 »

Thanks for the pics on the neat projects. What are you building the platform for? Do u have some renovation work planned?
127, 1650, 1572, 1872, 2072 . A mower, blower and blade for each.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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...
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

A little progress making pieces of parts today:
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Cutting axle flanges 'n stuff...
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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.
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Reversing the jaws on the chuck, I hold the plates by OD, and perform finishing cuts on other sides.
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Now I'm more-or-less repeating the same process to make spacer-sections to provide clearance over the bearing cups and bolts...
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

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...
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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!!!
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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"...
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Time for "Hot Glue"...
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To get a good, tight connection, it takes plenty of clamps. Start with small tack welds, to hold it in proper position tight...
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To minimize distortion, use small welds, allow time to cool between...
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Then finish them in, again, allowing cooling time between:
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And back to the lathe, to check and finish bolt clearance:
20190913_040356.jpg
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Okay, so a little delay while other projects and assignments take me aside...
but back for an update. I haven't done anything with the axle outers for a little bit, but...

I have this '53 Studebaker... it has three (of six) totally air-unretentive tires... well... now two... they're original, so one would think that 66 years of experience would make them capable, but apparently air has changed a bit since then...
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Anyway, the rims are rusted in some critical places, and they're multi-piece wheels of the type not-so-affectionately known as "widowmaker" two-piece rims, fitted by 7.00-20 bias-ply tires. They're tall and hefty, but so obsolete that replacements for the tires are ghastly expensive, and the rims... well... nobody really wants to have the liability of having 'sold' you one of these.

I need this thing to be capable of rolling in and out of my shop, so I can work on it at appropriate junctures, clean it at others, and roll it back in for storage. It needs something of similar size, but common, easy to find, etc., which means 19.5". It's a little shorter OD by about an inch-and-a-half, but my other option is a 22.5 rim, which is too tall... so 19.5 it is.
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These wheels came from the truck junkyard... they're from a railroad high-rail vehicle.

I don't need the centers... so I made a centerless trammel to hold the torch, and out they came...
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Then I repeated with the original wheel:
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Then ground them clean:
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Centered the new middle with a purpose-made trammel:
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Welded them outside:
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and inside:
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

Then mounted them up:
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and we're back to the land of the rolling.



Now... you may ask yourself what this has to do with the Loader-Mutt transaxle...

WELL... it just happens to be, that these railroad-spec wheels have really, really thick centers... they're about a half-inch thick...

and...

Not only do they have proper pilot hole and bolt pattern to fit the 1965 Ford F250 Dana 60 one-ton axle stubs...
They're 13" OD, which means there's enough there for me to use to make a new center for a 12" Cub Cadet wheel!!!
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Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

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dag1450
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Re: Loader Mutt Continues...

Post by dag1450 »

Wow. You are a mad scientist. :lol:
127, 1650, 1572, 1872, 2072 . A mower, blower and blade for each.

DaveKamp
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Re: Loader Mutt Continues...

Post by DaveKamp »

It's like this, Dave...

I like working on my projects... and I like working in dry conditions, on solid floor, with good lighting, and a cool breeze of fresh air is nice (as long as the breeze isn't blowing away my shielding gas). Night time is a perfect time, particularly in the fall.

I like music... I had four large speakers in the rafters of my prior garage. I have something similar, mebbie not as big... at this place... and I have a jukebox system of about 60,000 songs that plays randomly 24/7... and I have the audio piped to every building... the dairy barn, grainery, pole barn, old shop, garage, and basement. That collection includes everything from Sammy Hagar to INXS to Violent Femmes to Andres Segovia, David Parkening, Leo Kottke, and mebbie a hundred barbershop quartets, to opera, to John Prine to Allison Krause, Abba to ZZTop. When it's time to build something, the music is on loud enough that I can hear it through my earplugs.

Every so often, Toccatta and Fugue in D Minor comes on... and I'm grinding and welding... in the middle of the night. Sometimes, I'm resuscitating some great iron giant, frequently made from pieces of a half-dozen deceased other machines... What could be a better combination than adding the world's most well-known 'eerie organ music', along with man made lightning and thunder? A grey-haired guy wearing goggles, waving a magic wand throwing sparks everywhere, with hideous laughter... :lol:
Yes, I'm a Mad Scientist... but I'm usually happy, even when things ain't goin right.

mrbrown
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Re: Loader Mutt Continues...

Post by mrbrown »

Mad scientist, oh ya. And the music to go with it. Nothing better than making parts from parts. I'm building a rat rod garden tractor now from 100% misc junk. Hoping for the look of a small model A or T truck. Watching the scrap pile get smaller and listening to the music. Mike :)

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