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Re: Build an Excavator from Scratch
Several times before, in some other projects, I've wished to be able to build my own little louvers.
A previous attempt to make a punch and die works but has imperfections to build a even row of identical louvers. Today i've started another attempt. the groove for the die was made with a radius mill and cut off one side. A sharp cutting edge was added. https://blog.rb-fotos.de/wp-content/...r/img_7218.jpg The die mounted on a piece of wood together with a stop and a ratched grip https://blog.rb-fotos.de/wp-content/...r/img_7219.jpg with a quadrant milling cutter i've made the punch. https://blog.rb-fotos.de/wp-content/...r/img_7220.jpg the punch guide https://blog.rb-fotos.de/wp-content/...r/img_7221.jpg all together clamped an read for the next louver you can use a hammer or a press. https://blog.rb-fotos.de/wp-content/...r/img_7223.jpg the result. I'm happy with it and look forward to make some of them for the hull of the excavator. https://blog.rb-fotos.de/wp-content/...r/img_7224.jpg |
Re: Build an Excavator from Scratch
WOW that took a lot of work but excellent results...
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Re: Build an Excavator from Scratch
Very nice piece of work there. May just have to copy that. Thanks for sharing.
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Re: Build an Excavator from Scratch
That louver punch is wild, they look great!
How do you register alignment between the base and punch holder? |
Re: Build an Excavator from Scratch
I've faced both parts sides together on the mill. Thereby they are absolutely even and a optical alignment was exact enough.
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Re: Build an Excavator from Scratch
A medium issue I've found was the unwanted contact between the superstructure and the undercarriage regardless all the ball-bearings.
https://blog.rb-fotos.de/wp-content/...r/img_7276.jpg So i've added another dedicated flat bearing from igus. called "iglidur" A .5mm thick plastic, easily cutable with a sciccor. Glued direct onto the stainless steel with a combination of loctite 770 and 401. https://blog.rb-fotos.de/wp-content/...r/img_7282.jpg After deburring and polishing the sprocket a first test https://blog.rb-fotos.de/wp-content/...r/img_7277.jpg Then the optical improvement of the undercarriage begins The front inner View is now this https://blog.rb-fotos.de/wp-content/...r/img_7266.jpg https://blog.rb-fotos.de/wp-content/...r/img_7267.jpg And the side view before https://blog.rb-fotos.de/wp-content/...r/img_7302.jpg and after the improvement https://blog.rb-fotos.de/wp-content/...r/img_7301.jpg |
Re: Build an Excavator from Scratch
Second side panel is done.
https://blog.rb-fotos.de/wp-content/...r/img_7309.jpg the first inner rear cover too https://blog.rb-fotos.de/wp-content/...r/img_7310.jpg a bit bored by all the cutting and bending I need a bit alternation. so i've milled the teeth for the bucket. https://blog.rb-fotos.de/wp-content/...img_7332-2.jpg https://blog.rb-fotos.de/wp-content/...img_7333-2.jpg |
Re: Build an Excavator from Scratch
Making the working lights. Modern squared style. 15x15x8mm.
each includes 8 smd leds. .3 mm stainless steel. https://blog.rb-fotos.de/wp-content/...r/img_7337.jpg https://blog.rb-fotos.de/wp-content/...r/img_7338.jpg https://blog.rb-fotos.de/wp-content/...r/img_7339.jpg https://blog.rb-fotos.de/wp-content/...r/img_7341.jpg https://blog.rb-fotos.de/wp-content/...r/img_7342.jpg https://blog.rb-fotos.de/wp-content/...r/img_7343.jpg https://blog.rb-fotos.de/wp-content/...r/img_7344.jpg https://blog.rb-fotos.de/wp-content/...r/img_7345.jpg https://blog.rb-fotos.de/wp-content/...r/img_7351.jpg https://blog.rb-fotos.de/wp-content/...r/img_7352.jpg https://blog.rb-fotos.de/wp-content/...r/img_7349.jpg |
Re: Build an Excavator from Scratch
the stick need some reinforcements.
copying the shapes https://blog.rb-fotos.de/wp-content/...r/img_7380.jpg apply to 1mm stainless https://blog.rb-fotos.de/wp-content/...r/img_7381.jpg saw https://blog.rb-fotos.de/wp-content/...r/img_7382.jpg sawed https://blog.rb-fotos.de/wp-content/...r/img_7383.jpg after welding these points https://blog.rb-fotos.de/wp-content/...r/img_7385.jpg turned into this https://blog.rb-fotos.de/wp-content/...r/img_7386.jpg with this little tool https://blog.rb-fotos.de/wp-content/...r/img_7384.jpg stick is finally finished and ready to use https://blog.rb-fotos.de/wp-content/...r/img_7387.jpg |
Re: Build an Excavator from Scratch
These parts are looking great, and it looks like you'll have a bulletproof model when its done.
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Re: Build an Excavator from Scratch
bulletroof? i hope so :)
----- the bucket links are done in a really quick and dirty way. they work but are very wobbly and a good portion of the hydraulic power goes not in the correct direction. https://blog.rb-fotos.de/wp-content/...r/img_7393.jpg for a proper working they need more guidance. Therefor i've turned some brass washers 10x15x1mm https://blog.rb-fotos.de/wp-content/...r/img_7397.jpg and fitting bolts and screws . ( sorry no pic) every joint is now backlash free and covered with brass bearings. https://blog.rb-fotos.de/wp-content/...r/img_7398.jpg https://blog.rb-fotos.de/wp-content/...r/img_7400.jpg https://blog.rb-fotos.de/wp-content/...r/img_7401.jpg https://blog.rb-fotos.de/wp-content/...r/img_7402.jpg |
Re: Build an Excavator from Scratch
finishing the parts was much more work than expected.
improvements, making more finger friendly, welding all the lines complete and not just some points. and at least put a brushed surface on it. https://blog.rb-fotos.de/wp-content/...r/img_7419.jpg https://blog.rb-fotos.de/wp-content/...r/img_7420.jpg |
Re: Build an Excavator from Scratch
I was going to ask how you were cutting your parts, then I saw your saw. You've got some fairly tight curves that you appear to be cutting. What are you using for a blade on that saw?
Don |
Re: Build an Excavator from Scratch
Quote:
the saw is a Proxxon MBS 240/E and the blade a proxxon 28 172 for stainless steel. The shown curves are the limit for this blade. Narrower curves are possible only with little steps side by side. |
Re: Build an Excavator from Scratch
This is looking great. The beauty panels pulled it all together so well. The metalwork shows your high standards.
The hard pipes on the boom are a great detail. |
Re: Build an Excavator from Scratch
thank you.
Next thing to improve is the motor mount of the rotary drive. first attempt. principally working but too weak for the complete weight of the upper construct. https://blog.rb-fotos.de/wp-content/...r/img_7422.jpg https://blog.rb-fotos.de/wp-content/...r/img_7423.jpg The motor is strong enough, so i need just a better adjustment technic and a more stable mount. First part is the combined clamping and movement thing a plan https://blog.rb-fotos.de/wp-content/...r/img_7424.jpg and the real thing https://blog.rb-fotos.de/wp-content/...r/img_7426.jpg https://blog.rb-fotos.de/wp-content/...r/img_7427.jpg https://blog.rb-fotos.de/wp-content/...r/img_7428.jpg https://blog.rb-fotos.de/wp-content/...r/img_7429.jpg https://blog.rb-fotos.de/wp-content/...r/img_7425.jpg more to come.... |
Re: Build an Excavator from Scratch
the wedge bar is done. cutted from a stainless steel bar.
https://blog.rb-fotos.de/wp-content/...r/img_7442.jpg fits well https://blog.rb-fotos.de/wp-content/...r/img_7441.jpg |
Re: Build an Excavator from Scratch
Still working on the rotary drive.
Today the outer clamps and their flanges to the platform were built. Befroe that, the old flanges have to remove from the platform. i've used the little 35 mm cuttings discs from proxxon. https://blog.rb-fotos.de/wp-content/...r/img_7445.jpg The outer clamps get some recesses for the weldable flanges with m4 threads. https://blog.rb-fotos.de/wp-content/...r/img_7446.jpg After this a first setup of the mechanism happens https://blog.rb-fotos.de/wp-content/...r/img_7447.jpg https://blog.rb-fotos.de/wp-content/...r/img_7448.jpg works fine but needs some more details before completed.... |
Re: Build an Excavator from Scratch
Last part of the rotary drive.
clamp screws with stainless bolts to avoid damaged threads https://blog.rb-fotos.de/wp-content/...r/img_7456.jpg adjustment with a simple block on the maximum position and an offset of 1/10 mm with a feeler gauge https://blog.rb-fotos.de/wp-content/...r/img_7461.jpg clamps very well, no more wobble even if i simulate lateral forces like when the bucket is digging https://blog.rb-fotos.de/wp-content/...r/img_7458.jpg |
Re: Build an Excavator from Scratch
The work on the cabin begins.
Some angle-guides... https://blog.rb-fotos.de/wp-content/...r/img_7472.jpg for this little micro belt sander,... https://blog.rb-fotos.de/wp-content/...r/img_7473.jpg together with a 90 |
Re: Build an Excavator from Scratch
Nice machining! That slew motor clamp with dovetailed adjustment is really slick!
I'm not sure if adjusting your feed speeds for the material might help with edges on breakout, or if i'm just used to seeing parts after a deburr tool has done a little chamfer. The micro bench sander could be its own write up over in the Tools section. |
Re: Build an Excavator from Scratch
some impression from the cabin
https://blog.rb-fotos.de/wp-content/...r/img_7510.jpg https://blog.rb-fotos.de/wp-content/...r/img_7511.jpg https://blog.rb-fotos.de/wp-content/...r/img_7512.jpg The stick are display holders https://blog.rb-fotos.de/wp-content/...r/img_7513.jpg https://blog.rb-fotos.de/wp-content/...r/img_7515.jpg |
Re: Build an Excavator from Scratch
cabins upper guard
3mm stainless rods https://blog.rb-fotos.de/wp-content/...r/img_7516.jpg welding setup https://blog.rb-fotos.de/wp-content/...r/img_7517.jpg https://blog.rb-fotos.de/wp-content/...r/img_7518.jpg https://blog.rb-fotos.de/wp-content/...r/img_7519.jpg operators joystick. freehand cutted from some stock aluminium using a ball vise and a foredom hanging motor. https://blog.rb-fotos.de/wp-content/...r/img_7524.jpg looks similar enough as little details on the chair. https://blog.rb-fotos.de/wp-content/...7a12449ef2.jpg |
Re: Build an Excavator from Scratch
I think you've already told us, but what do you use for a welder?
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Re: Build an Excavator from Scratch
Quote:
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Re: Build an Excavator from Scratch
Very nice craftsmanship. Really like your 'whittled out' control handle.
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Re: Build an Excavator from Scratch
thank you, zabco.
---- The cabin gets a bit more interieur and a fire extinguisher. All windows are in and the cabin is installed on the under construction. https://blog.rb-fotos.de/wp-content/...r/img_7548.jpg https://blog.rb-fotos.de/wp-content/...r/img_7549.jpg https://blog.rb-fotos.de/wp-content/...r/img_7551.jpg The complete ensemble is dismountable in seconds to reach on the ballast sections. https://blog.rb-fotos.de/wp-content/...r/img_7552.jpg The cabin is done :bounce: |
Re: Build an Excavator from Scratch
I really am amazed at how quickly you complete all this fabrication! Very nice!
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Re: Build an Excavator from Scratch
Thank you.
Fast? This build is running since eight Months. But the end is nigh :D The Cabin is done and the work on the Hull has started. Unfortunately I'm not able to "metal shaping" with a shrinker/stretcher/english wheel in a proper way. So I've decided to make the back not really round but in five parts. https://blog.rb-fotos.de/wp-content/...r/img_7579.jpg After two hull panels (the back and the small part behing the cabin) I've mocked up all the parts to check the proportions. I like it so far :) https://blog.rb-fotos.de/wp-content/...r/img_7580.jpg https://blog.rb-fotos.de/wp-content/...r/img_7581.jpg https://blog.rb-fotos.de/wp-content/...r/img_7582.jpg |
Re: Build an Excavator from Scratch
The superstructure and the undercarriage are now connected.
The electro block has moved from vertical https://blog.rb-fotos.de/wp-content/...r/img_7584.jpg to horizontal https://blog.rb-fotos.de/wp-content/...r/img_7586.jpg to get room for ballast, if i need some https://blog.rb-fotos.de/wp-content/...r/img_7585.jpg |
Re: Build an Excavator from Scratch
Pufferfish:
I've been watching a youtube channel called Fitzee's Fabrications. He does bodywork including fabricating some very complex replacement panels using simple hand tools, including some tools that he has built himself. Check out his videos if you haven't already seen them. While his go to welder is a 120V MIG, and your go to welder is NOT - they might still give you some ideas. 40+ years ago I was trained as an autobody repairman, and Fitzee is an education in how much you can do with simple tools. Don |
Re: Build an Excavator from Scratch
Hi Don,
thank you. I'll will give him a look. Machining is easy for me. Make an approach, measure, finishing, ready. Metal shaping is a thing for wich I need more "feeling" for sculpting than I have.:o |
Re: Build an Excavator from Scratch
The first side of the Hull is done. All brushed stainless steel.
No color is planned. https://blog.rb-fotos.de/wp-content/...r/img_7608.jpg https://blog.rb-fotos.de/wp-content/...r/img_7607.jpg |
Re: Build an Excavator from Scratch
Awesome workmanship!
Love all the detailing going on with the cab. Each update is pretty epic |
Re: Build an Excavator from Scratch
Using two old smd led stripes
https://blog.rb-fotos.de/wp-content/...r/img_7626.jpg to make the working lights (just mocked up. some shaping still needed) https://blog.rb-fotos.de/wp-content/...r/img_7629.jpg https://blog.rb-fotos.de/wp-content/...r/img_7628.jpg works https://blog.rb-fotos.de/wp-content/...r/img_7627.jpg |
Re: Build an Excavator from Scratch
Most of the time my mantra is "keep it as simple as possible" also for my strategy in making things. The earlier shown second version of the rotary drive was build in three parts some of them from brass because it's easier to handle on the mill.
The drive works well under lab conditions but not if some cross forces comes up. If I increase the clamping to handle the forces this happens https://blog.rb-fotos.de/wp-content/...r/img_7651.jpg Major problem was the lack of a baseplate. To build the complete lower part from a massive block would be too expensive. Thereby I've decided to build it from stainless parts and weld them together. https://blog.rb-fotos.de/wp-content/...r/img_7661.jpg Works now perfect with all forces up to a stalled motor. |
Re: Build an Excavator from Scratch
Working lights done :)
overall 18 smd leds. The illumination of the working area fits good. (completely dark room) https://blog.rb-fotos.de/wp-content/...r/img_7675.jpg Also the space in Front of the excavator is bright. https://blog.rb-fotos.de/wp-content/...r/img_7677.jpg |
Re: Build an Excavator from Scratch
Very nice build. Impressive skills!
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Re: Build an Excavator from Scratch
Thank you.
I'm a fan of functional gimmicks. So i've spend the last two days in the shop to make a remote controlled ladder for the operator. https://blog.rb-fotos.de/wp-content/...r/img_7698.jpg https://blog.rb-fotos.de/wp-content/...r/img_7699.jpg https://blog.rb-fotos.de/wp-content/...r/img_7700.jpg I think, the operator needs some handrails https://blog.rb-fotos.de/wp-content/...r/img_7703.jpg |
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