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  #21  
Old 02-07-2022, 02:59 AM
pufferfish pufferfish is offline
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Default Re: Build an Excavator from Scratch

Hi,

you've convinced me
I wonder, why this forum isn't using such simple quick-response buttons as a "like". Its quickly made for you without spamming the thread and a response for the thread opener. thereby the opener hasn't the feeling to write soliloquies.

A little sideeffect for me of writing in an english speaking forum is to improve my written english with non-trade-affected terminologies. I'm programmer by trade and the vocabulary of ibm books is restricted

So I'll try to write more about my thougths why I do something so or not.

----------
Let's go back to the barrel tank. Looks good but it has some imperfections. I've forgotten a oil level indicator and a ventilation.
I can add them outside, but a second point is more important. A kind master of hydraulics told me, that with my "big" pump
and the small usual hoses I'll ran into problems with cavitation (pitting in the pump).
The pump offers a g1/8 thread instead the usual m5 threads.

to compare the hose sizes (top down):

normal pressure hose id 2,5mm od 4mm
normal pressureless hose id 4mm od 6 mm
the new pressureless hose id 8mm od 10mm

this reduces enormous the flow speed and avoid cavitation.



Unfortunately, the hole for a g1/8 thread is bigger than the doublings in the tank.

So i've decided to build another tank with all the needed holes and threads.
This time a cubic form to get a feeling wich form is easier for me to build.
I've not noticed significant differences, thus it will be simple a question of style in the future.

The result. oil proofed and mounted. Ready to use.

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  #22  
Old 02-07-2022, 06:14 AM
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Default Re: Build an Excavator from Scratch

Thank you, I have been reading your posts with much interest!

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  #23  
Old 03-24-2022, 11:37 PM
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Default Re: Build an Excavator from Scratch

I'm glad you changed your mind!
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  #24  
Old 03-30-2022, 03:26 PM
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Default Re: Build an Excavator from Scratch

Hi,

I haven't been lazy whilst the long break here.
A short summary jump to the actual standing:

the work on the monobloc has begun


an intermediate stand together with a bit of cardbord aided design


the monobloc body is ready and bending the hydraulic pipes begins


pipebending is done and the first cylinders of the second genereration are done.
some issues on the first generations forced my to do so.


30 kg ballast lead arrived


a new dimension of metal handling for me: 1,5mm stainless sheets. very stable and very hard for me and my little tools. but at least the first simple bucket is done
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  #25  
Old 03-30-2022, 03:56 PM
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Default Re: Build an Excavator from Scratch

stick, bucket and bucket mechanic


the very noisy pump gets a leadfilled cover.


an overview of the deck with all the hydraulics and electronics. this is the almost final view. only minor changes will happen


and then? then there was a very shocking moment. with a thoughtless movement of the superstructure i've pushed a former build from its rest.
result: a 100% total loss.


the base , a traxxas trx6, ist still useful, maybe a following project.

parallel to all these steps i've made some trials and errors to get a reproducible method to build a proper hull.
a first success was my first pretty 3d corner




today , a big milestone has reached. the drivetrain is done and a first driving lesson occurs.
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  #26  
Old 03-30-2022, 04:06 PM
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Default Re: Build an Excavator from Scratch

WOW that thing is huge !!!! it will be a monster... nice to see it progressing...
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  #27  
Old 03-31-2022, 12:44 PM
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At the beginning of my research for an excavator i've found a flyer from liebherr. There was the model 966 noticed as a perfect fit for 30 tons dumpers. My dumper is a 30 tons one. Thereby the 966 became my model for principal sizes.
Later I was surprised too that you need a monstrous excavator to load a small dumper

------
Todays work were the operators gangways.





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  #28  
Old 04-01-2022, 11:34 PM
Jared Jared is offline
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Default Re: Build an Excavator from Scratch

Very nice pipe work. What is your method for bending without kinking them?
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  #29  
Old 04-02-2022, 01:25 AM
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Default Re: Build an Excavator from Scratch

Looks like a lot of progress! Shaping up into a very impressive machine

Was the totaled truck something like an Airport Fire engine, or a Trial Truck? Atleast the ejector seat worked.
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  #30  
Old 04-08-2022, 12:38 AM
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Default Re: Build an Excavator from Scratch

AWESOME project!
This thing should be a beast of a machine once completed!
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  #31  
Old 04-09-2022, 02:44 PM
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Default Re: Build an Excavator from Scratch

Quote:
Originally Posted by Jared View Post
Very nice pipe work. What is your method for bending without kinking them?
Thank you. I've choosen the easy way. 6x1mm stainless pipes are not easy to bend but with the right tools it's possible and up from 15mm radius without any kink. I'm using a "RIDGID 600 series lever bender" for 16mm radius.
with the enclosed examples you are quickly enabled to make reproducable multi-angle bendings.

Quote:
Originally Posted by frizzen View Post
Looks like a lot of progress! Shaping up into a very impressive machine

Was the totaled truck something like an Airport Fire engine, or a Trial Truck? Atleast the ejector seat worked.
It was called "s.o.f.t. superfast offroad fire truck" and should be a quick response bush fire truck.

"ejector seat"

Quote:
Originally Posted by skeeter View Post
AWESOME project!
This thing should be a beast of a machine once completed!
indeed.
----------

After a short vacation I've save up enough point on my patience account to begin with the last two hydraulic cylinders. Patience is needed because me and turning internal threads are not friends.
fortunately, this time it works at the first attempt and some other parts are build too.
Pistons and guide rings from brass, rod and cylinder from stainless and the cylinderhead is from aluminium. (nothing to weld on the head and very easy to turn)


The head is the most complicated part. Internal thread and a recess for the guide ring on the inner side. thereby the guide ring is oil lubricated.



On the outside are three grooves for o-ring sealings.


Threads will be sealed with loctite 542.
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Last edited by pufferfish; 04-09-2022 at 02:46 PM.
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  #32  
Old 04-10-2022, 01:54 PM
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Default Re: Build an Excavator from Scratch

Todays work: The completion of the stick cylinder.

After applying the orings i've prefilled the cylinder with oil



The thread was filled with loctite



after 4 hours the glue isn't 100% but for a first little test tight enough
but before, i've made a hose-guard from 5x0,3 stainless for the hose to the front



the last cylinder for the bucket is prefilled too and can't wait to mount him





The cylinder and stick in action you can see in this little clip (self hosted)

https://blog.rb-fotos.de/wp-content/...es-stick-1.m4v
(moving from the nineth second on)
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  #33  
Old 04-10-2022, 02:41 PM
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Default Re: Build an Excavator from Scratch

man very nice and smooth
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  #34  
Old 04-10-2022, 11:03 PM
skeeter skeeter is offline
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Default Re: Build an Excavator from Scratch

Great job with them cylinders!
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  #35  
Old 04-12-2022, 03:02 PM
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Default Re: Build an Excavator from Scratch

thank you guys.

the temporarely used threaded rods will be switched into much more stylish bolts with circlips.






And the driver makes a visit. A good thing to see the dimensions of this rig.





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  #36  
Old 04-13-2022, 01:33 PM
pufferfish pufferfish is offline
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Default Re: Build an Excavator from Scratch

After six months of almost daily work at this project, all mechanical todos are done

Parking position


max Height over ground approx. 130 cm


max Depth ca. 100 cm


Next big steps are learning to operate it and building the hull and the cabin and 347586 other little things.
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  #37  
Old 04-14-2022, 08:17 AM
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Default Re: Build an Excavator from Scratch

Great work on the project to date Ralf, well done

What is the ground level reach?

Learning to operate it, I would suggest getting a big bag of rice or pellet dog food & a couple of cardboard boxes, transfer from one box to the other & back again inside the comfort of your house daily.
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  #38  
Old 04-14-2022, 10:13 AM
pufferfish pufferfish is offline
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Default Re: Build an Excavator from Scratch

Thank you. Thats a good Idea, but too late.

The first loading of my Dumper happens in my garden .

https://blog.rb-fotos.de/wp-content/...tbuddeling.m4v

some issues found but nothing worse (i hope )

Have a nice easter weekend
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  #39  
Old 04-16-2022, 09:10 PM
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Default Re: Build an Excavator from Scratch

Watching your dig video, perhaps if you lowered your EPAs of swing & valves then your movements wouldn't be so quick & twitchy. Takes more radio stick throw to make something happen making far less sensitive.

Also, with your hyd motor running continually at a very low speed, as low as possible so the motor doesn't chatter trying to run & using valve mix to speed up movement helps to smooth out movement too. And it helps keep your pump motor esc from over heating too from additional stall current start ups.
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  #40  
Old 04-17-2022, 01:25 PM
pufferfish pufferfish is offline
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Default Re: Build an Excavator from Scratch

Thanks for the advices, Joe. I appreciate them and will give them a try at the next dig.

But due to a complete disassembling of the excavator this will take some time.

Disassembling for fixing issues , improvement and so on.

Til waiting for easter brunch with the family I've made the cables for the working lights on the monobloc.
Simple wires are bending in very unpredictable ways.
To tame them I've used a simple but effective method.

Whilst the hole procedure take care that the wires laying flat side by side.

Two single wires are bound with a very thin stainless wire


This thing pulled through a heat shrink tube.



After shrinking the wires get more stiffer and bends reproducable nice way

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