Re: Volvo G990 Grader
 

Stefan, Just how many bucks does it take to have that printed? I was thinking about using that method to make some other parts I have planned some day.
Maybe when that day comes,it will cost less than it does now.

Re: Volvo G990 Grader
 

Nice parts Stefan, do you need to compensate size on drawings to get part correct size after printing (like when making a mold)??
/Dan

Re: Volvo G990 Grader
 

John, I was thinking of a 400 W bl outrunner or a low rpm brushed motor and a three or four gear transmission. A problem is that the gear spread between the lowest and highest gear on the real 11 gear transmission is 15 times, i.e at 2100 rpm the ground speed is 2.1 mph in gear F1 and 30.8 mph in gear F11, so I have to find out how much of that spread can be taken up by the better low rpm torque capability of an electric motor.

Steve, the "large" part, which is 14.3 mm high, cost 12.50 euros (they actually quote the price in euros when you give a "Euroland" address). There are also different grades of plastic starting at one fifth that price. The small part is 10 mm across, 3 mm thick and went for € 6.27. For each item there is a 6 $ (yes, dollar) handling fee included, so in some cases it would pay of to upload drawings of suitably connected parts. Maybe increased competition will lower the price in the future.

Dan, a German forum colleague found out that you should enlarge your drawing by 1.8 percent to get it right at the end. I did that and 14.3 mm turned out to be 14.34 mm, not bad, and the 0.34 mm will be machined away, anyway.

Re: Volvo G990 Grader
 

so your squeezing all that under the hood? with full hydraulic system with tank and then batteries to boot? wow, ya first gear in forward range is a creeper gear loads of torque in the 970. so will you have the hood open ? and i got to ask if your having a rad and fan set up? i believe the fans are set up to reverse to blow the dust backwards threw the rads to help keep them cleaner. if your need engine pics or interior give me a shout and ill be able to get them within a day if i can figure out how to send then on here lol good luck keep up with the pics and great building techniques everybody from what i've read loves hearing about it!!

Re: Volvo G990 Grader
 

Wait can you 3d print rad an intercoolers? Hmm

Re: Volvo G990 Grader
 

Have been thinking of rad and fan but on the other hand, and as you indicate, it will get crowded enough under the hood and the hydraulic system is not at all used as much as e.g. in an excavator and there are a lot of excavator models without rad and fan. So much for operational rad and fan. Still, there has to be at least a fan and something locking like radiators since they are clearly visible from the outside. Sure the hood will open as on the real thing. 3D printability is a bit dependent on how delicate the parts must be, have a look at shapeways.com. Thanks a lot for the picture offer! Nice to know someone having access to a 970, and a bit envy, too... :o:D

Re: Volvo G990 Grader
 

Stefan: May i ask you about the tires of your grader? Do you already have them, or have a place to buy, or you will make it yourself (molding)? The machine i plan to build, would needs tires with almost the same size.

Re: Volvo G990 Grader
 

The optional 20.5x25 tires of the original machine in scale 1:8 (D=186 mm, W=69 mm) do not seem to be commercially available. Consequently I´d have to make them, too. What size would you need, exactly?

Re: Volvo G990 Grader
 

Mine is (in scale 1:14.5) D=184 mm, W=72 mm, inner D=70mm. But the hardest part of this challenge is to figure out how soft the tire should be to looks like the real at 1:1...

Re: Volvo G990 Grader
 

OK, I forgot to mention that my tires would have an inner D=55 mm. Despite the difference from your 70 mm I'd be very interested in hearing from you if you find some tires or start making them. I fear it will be hard to figure out the appropriate softness without actually making some tires to experiment with.

Re: Volvo G990 Grader
 

I just talked to someone who seems to be able to mold the tires, he will also make some test concerning the softness of the material. As i have any more info, maybe the finished tires, i will post it.

( The previous dimensions i mentionned was from a plan, which was not correct. The correct size of my tires 41.25/70-39 -> W=74 mm, D=172 mm, inner D=68 mm. Just for correct myself )

Re: Volvo G990 Grader
 

I too have to correct myself since 20.5R25 (a wide base size) evidently relates to a 25" rim, so the scale diameter would be 79 mm or 3"1/8.

Re: Volvo G990 Grader
 

I managed to finish the circle turn cylinders. Here´s a video from the first test under pressure.

http://youtu.be/qKv85_feX5Y

Stefan

Re: Volvo G990 Grader
 

Just WOW:) 54 bar, nice...

Re: Volvo G990 Grader
 

I'm searching for a while, and all i could find were pumps with max 10-12 bar. Are your's a commercial one, or you built it yourself? I would need 20-25 bar

Re: Volvo G990 Grader
 

Try Jung Fluid.

Re: Volvo G990 Grader
 

Yeah, Reg, you nailed it. My particular setup is a Jung 4001 (type designation IPZ1-HR-3) driven by a Flyware powerREX 430-300 motor. The pump delivers 0,5 liter/min @ 40 bar and 3000 rpm and is good for 120 bar. Here some pics from the build of the coupling block.

https://drive.google.com/uc?id=0B_yT...WFsaU5TY21iLVU

https://drive.google.com/uc?id=0B_yT...mMxTW1Eb1B0bzA

https://drive.google.com/uc?id=0B_yT...3hTSzZpa1VyWmM

https://drive.google.com/uc?id=0B_yT...EEyaWZIdlpsa2M

https://drive.google.com/uc?id=0B_yT...VNkOHBibUNyckE

Stefan

Re: Volvo G990 Grader
 

Thanks for the tips... As always i just found something myself after posting the question: http://www.123modellbau.de/modules/w...7&cat_id=51774 (it looks like yours)

Re: Volvo G990 Grader
 

That´s a Jung pump, alright. They have a whole range looking the same. The one in your link has a higher flow than mine. You might get a better price if you order directly from the manufacturer, Jung Fluid. As far as I know, they sell to private, too. Also Premacon sells them.

Re: Volvo G990 Grader
 

Converted some rod ends from RC4WD to more scale like ones. To make it simple, I used the original balls and the bronze inserts, which were put into a new housing. That´s why they are not quite as small as the scale would have required.

https://drive.google.com/uc?id=0B_yT...mJJdVZBbmhPQTg

https://drive.google.com/uc?id=0B_yT...HhGNTRaNzAya3M

https://drive.google.com/uc?id=0B_yT...kNWR0NEb0h4VXM

Stefan

Re: Volvo G990 Grader
 

You my friend are incredible:)

Re: Volvo G990 Grader
 

OUTSTANDING!:popcorn:

Re: Volvo G990 Grader
 

Wow, exact detail, right down to the ball joint! Nice!

Re: Volvo G990 Grader
 

beautiful work :drool:

Volvo G990 Grader
 

Thanks fellows! Have some "making of" pics to add:

https://drive.google.com/uc?id=0B_yT...VV0d3ZtMFpJMTg

https://drive.google.com/uc?id=0B_yT...k5NaUE4VTdXdUE

https://drive.google.com/uc?id=0B_yT...VlfemlGYnJXOHM

https://drive.google.com/uc?id=0B_yT...TFjdlRhNDlZWlE

https://drive.google.com/uc?id=0B_yT...mdxNjBwSlZkQnc

https://drive.google.com/uc?id=0B_yT...i1qSk1vR1NwVlk

https://drive.google.com/uc?id=0B_yT...nBCNm11MHUxMXM

Re: Volvo G990 Grader
 

Wow.....the workmanship on this is exceptional!!! Remarkable amount of work and skill going into this build, the attention to details is inspiring!!

Re: Volvo G990 Grader
 

Hello guys, I see an update is more than overdue, had to go to the fifth page to find the thread again.

Having spent a long time making some as-much-scale-as-seems-possible 45 degree angled fittings I couldn´t wait finishing the 90 degrees ones, and finally had the circle drive tested without them only last week, although I finished the valve already last April. With the glide bearings still missing, the tooth wheels jam in one direction, but funny enough hardly in the other, as you can see in this video.

https://drive.google.com/uc?id=0B_yT...GJvVFBmcm1pX1k

https://drive.google.com/uc?id=0B_yT...FBYUnV6dm9fYjA

Re: Volvo G990 Grader
 

Absolutely fantastic work Stefan:drool:, GREAT VIDEO:drool::drool: now I see why you RC Para is not flying yet.:D I am sure the grader will be finished before I am 60 :D

Re: Volvo G990 Grader
 

That is just amazing!

Re: Volvo G990 Grader
 

:jaw::jaw::jaw: very nice Work Sir

Re: Volvo G990 Grader
 

@ Paul, Ap, Pontiacmann: Thanks! Glad you like it.

Now to the moldboard. Started from a stainless tube with 3 mm wall thickness. The radius of the tube was only slightly smaller than needed and to my luck it widened up to almost exact scale radius when the cut released the inner tensions.

https://drive.google.com/uc?id=0B_yT...lZHTTRKZjZiNUU

The upper edge has a non-radiused portion, so a 10 mm by 3 mm strip was added.
https://drive.google.com/uc?id=0B_yT...0JOX2dubUlIS28

https://drive.google.com/uc?id=0B_yT...1NTWlloT2EtSXM

https://drive.google.com/uc?id=0B_yT...nlfOWpRTzdReTQ

The real moldboard is recessed along three sides for the cutting edges as you can see here.
https://drive.google.com/uc?id=0B_yT...1NLS1hZdFhIVDQ

https://drive.google.com/uc?id=0B_yT...mtna2ZhRnZYX28

The recesses are apparently forged in a big press, so forging was one of the build options considered, but in the end I opted for a combination of adding parts to the edges and milling and grinding out the final shape. First, the ends were bevelled.

https://drive.google.com/uc?id=0B_yT...EtldGl4QzZVT3c

https://drive.google.com/uc?id=0B_yT...Wd6UXE1WndHV2c

https://drive.google.com/uc?id=0B_yT...19OQjJYcFFsNFE

https://drive.google.com/uc?id=0B_yT...UlSdjV1dkllWGs
Stefan

Re: Volvo G990 Grader
 

WOW!!!:jaw: It looks like I will have to watch this build a lot closer than normal builds. Your machining and thinking outside of the box makes me want to stop trying to make anything :eek::eek: You just keep setting the bar higher and higher.

Absolutely one of the best builds to date on the forum.

Re: Volvo G990 Grader
 

I have to agree with tc1cat you are so skilled it's un real. Wish I had just 1/10 of the skill you have been watching very close. Keep up the good I am sure many will be watching also

Re: Volvo G990 Grader
 

Man you definitely are disciplined in your work!! I have a hard time when I have to change drill bits!!! Skill and dedication are paying off, build looks awesome. Looks like you got a 1:1 to keep the details in sight!!

Re: Volvo G990 Grader
 

Stefan your skills and thought of how to preform the operation are very impressive. Thank you for sharing you skills and thoughts with us. Ed

Re: Volvo G990 Grader
 

Thanks for the great comments! Think I´ll be able to post some more pictures the coming weeks.

Thanks a lot Lynn, but I really hope you don´t stop building, hate it to be the cause of that :o. However, now when the circle turn valve is finished I don´t think the bar can come much higher in this build (maybe except for the swivel valve, where there is very limited space for the hydraulic fittings).

Thanks! But don´t underestimate yourself. With some time and thorough planning you can achieve a lot. But sure, you need the tools.

Thanks! I really wish I´d have the original within reach. Still I´m lucky, cause the BAUMA fair is within 1 hour driving distance.


Thank you, Ed.

Stefan

Re: Volvo G990 Grader
 

Impressive video and photos of the work you do, Stefan. I think Your work is inspriring for most of us. Looking forward to coming updates!
Dan

Re: Volvo G990 Grader
 

Terrific project. Great photos.

Re: Volvo G990 Grader
 

Wow Stevan,

This is a FANTASTIC build thread and words can't discribe how great the level of skill needed to complete this task well done keep up the great work

:jaw::jaw:

Re: Volvo G990 Grader
 

Thanks for the recent comments. Now, to the bevelled ends the recessed portions were separately attached.

https://drive.google.com/uc?id=0B_yT...VNkc00wemREZ2M

https://drive.google.com/uc?id=0B_yT...ndsRThKeWZPS2c

Simple jig :D to align the lose parts.
https://drive.google.com/uc?id=0B_yT...TU3Y2QySWVodWs

Some tig spots.
https://drive.google.com/uc?id=0B_yT...zNGNzhqbzhVUm8

https://drive.google.com/uc?id=0B_yT...WZPaUExVDZIdDQ

Before and after hard soldering.
https://drive.google.com/uc?id=0B_yT...lp3T2E3Z2JRWGc

Stefan