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Thread: R.a.g.e

  1. #1
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    71
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    5,942

    Default R.a.g.e

    I get some interesting jobs.
    My boss at River City Trailers, along with his father, a few years back, built a press to do the floors on the sheep ramps, out of 200mm channel. Instead of drilling the holes for the pins for the Hydraulic Ram, they oxy cut them. On the clevis yokes, the gap is 30mm and he used 25mm flat bar for the supports, consequently a 5mm gap between them, causing the 1" pins to constantly shear/bend or both. To remove the bottom pin, I had to cut between the clevis yoke and the flat bar with a Milwaukee Hackzall, as it was that bent, it wouldn't come out.
    Over the Christmas break, I decided to fix the problem, as it always failed when we were under pressure to get the floor panels out, approximately 125 of them at a time, these are a 2400 mm X 900mm X 1.2mm panel, that has a top hat shape pressed into them, resulting in the sheets finishing up at about 1800mm long.
    Mind you NOTHING is/was bolted, everything being welded, hence the R.A.G.E. title, Rough As Guts Engineering. I've been on this project for about 5 days, dismantling and repairing as I go, the top support was welded in, couldn't get a grinder in to slice the welds, so I had to drill a 5mm location hole to estimate where the plate started. Then work out how far out I was, and cut with the angle grinder, through 2 layers of channel to separate the support block on one side, then measure to the other side and slice through the other 2 sections. To ensure that it went back in the same spot, I drilled and tapped for 2X8 mm bolts, before the final partings of the top hanger and frame. These were eventually drilled and tapped at 12mm.

    Where it came from.jpg

    Here you can see the bolt holes and the cuts to free the top hanger.
    I took out what I could of the remaining weldment, with a cutting disc and cleaned up a bit with the flap disc, still to clean up the rest with a die grinder as I can't get anything else in there. I'll be putting in a brass bar there to fill the slots with weld, to minimise the clean up.

    Top hanger.jpg
    The top hanger after being bushed. Forgot the before shots.
    The bushes started off as 50mm round bar, cut to 35mm long and then drilled with a MAG drill to 1" ID, then turned down to 41mm OD, and faced off a 29mm long.
    I was going to fit spherical bearings in there, but as it's only working in a vertical motion I decided against it, as they were only 20mm wide, I'd have to make special bushes to take up the extra spaces each side.
    Had to purchase a 41mm cutter for the MAG drill to bore the flat bars.

    Top Tool.jpg

    The top part of the press tooling after the bush was welded in.

    Top.jpg

    A view of the general area of the main workings. You can imagine the limited room to work in.
    The top will eventually have a piece of 20mm or 25mm X 50mm flat bar on edge for extra support as it still bends there.
    More to follow tomorrow, I HOPE.
    Kryn
    To grow old is mandatory, growing up is optional.

  2. #2
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    71
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    5,942

    Default Update

    I did manage to finish the press off yesterday, but because of the outage, couldn't do the update.
    Manage to find some brass flat bar to put under the slots, to allow welding them up, a couple of pieces of scrap with a 12.5 mm hole was used to clamp them in place.
    That was the last piece of major welding to be done, so it was then onto assembly.
    Welds and holding bolts.jpg

    After a minor clean up of the bushes, amazing how a small piece of weld spatter will stop a pin going through, everything fell together easily.
    Once I can get power into the shed, so I've been promised for the last 8 months, I plan on working on the top die again, as it allows the pressing to have a curve in the finished sheet, as can be seen in the photo.
    Floor Sample .jpg

    Still need to work out guarding for this, the problem is that the guard has to be lifted up to allow for the next placement for pressing. I also welded a double hose clamp here to keep the hoses out of the way.
    Assembled Press.jpg

    Top pin, once the other end was out, this came out with the aid of a hammer and punch. This had sheared off in the machine.
    Remains of Top Pin.jpg

    Bottom pin, it wouldn't come out on it's own, I wonder why???
    Bottom Pin.jpg

    I plan on machining the bottom 2 surfaces, square to the vertical main beam and then machine the side ends about 30mm in, so that proper lubricated guides and gibs can be installed.
    Gibs.jpg

    Thanks for looking,
    Kryn
    To grow old is mandatory, growing up is optional.

  3. #3
    Join Date
    Oct 2019
    Location
    Adelaide, SA
    Posts
    1,198

    Default

    One question: How do you find the energy to do so much?

    That is a serious question. 🥹

  4. #4
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    71
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    Default

    Hi Kafie, interesting question, you tell me and we'll both know.
    It was a job that needed doing and I did it on my own over several days, that's the way I am, I suppose.
    I'm also doing a brake job on the forklift, replacing both slave cylinders, 1 started and the other totally US, as well as the seals and gaskets there.
    Still have the Bandsaw to tidy up, and modify, but as the blokes will be back to work on Monday, I'll leave that till the next Long Weekend.
    When it's cutting at 45 degrees, a lot of the coolant spills off the machine, my plan is to extend the tray out to catch the coolant, also the vertical cutting needs adjusting, so that'll be seen to at the same time.
    I don't usually tell a lot of people the type of work I do here, but thought that project might be of interest.
    Kryn
    To grow old is mandatory, growing up is optional.

  5. #5
    Join Date
    Oct 2019
    Location
    Adelaide, SA
    Posts
    1,198

    Default

    Always great to have a list of projects in the pipeline for the quiet days.

    Busy is good.

  6. #6
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    71
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    Default

    What's a quiet day????? I've nearly always got 5 or 6 projects on the go at any one time, trailers to repair, modify, build a special for my Club, plus the general stuff that comes in.
    Kryn
    To grow old is mandatory, growing up is optional.

  7. #7
    Join Date
    Dec 2013
    Age
    56
    Posts
    1,416

    Default

    Quote Originally Posted by kafie1980 View Post
    One question: How do you find the energy to do so much?

    That is a serious question. 🥹
    Funnily enough, Bollie, on here, asks me the exact same question as I share what I'm doing with him, I don't stop doing or thinking of projects and work arounds, workholding, etc, daily.

    Same as Kryn is doing great work as I know him personally and is as dedicated.
    It's in the blood.

    Sent from my SM-A235F using Tapatalk
    Using Tapatalk

  8. #8
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    71
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    Default

    If anyone wanted to make a press like this, let me know and I'll get the ram details, as I think it would make a great Brake Press project, that should handle up to 2mm X 900mm, with a bit more REFINEMENTS.
    Kryn
    To grow old is mandatory, growing up is optional.

  9. #9
    Join Date
    Sep 2021
    Location
    Western Sydney
    Posts
    262

    Default

    Quote Originally Posted by KBs PensNmore View Post
    If anyone wanted to make a press like this, let me know and I'll get the ram details, as I think it would make a great Brake Press project, that should handle up to 2mm X 900mm, with a bit more REFINEMENTS.
    Kryn
    Nice work ! Is that press used for making mudguards and blinker brackets for the trailers ect ?

  10. #10
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    71
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    Default

    Hi IT, it's just for the pressing of the floors, similar to the picture of the https://metalworkforums.com/attachme...1&d=1704509214
    We have a Chinese POS 135 tonne, 3 metre long brake press for doing small stuff like mudguards, tail light brackets etc. Lately we've been getting them laser cut and they press them up as well.
    Thanks
    Kryn
    To grow old is mandatory, growing up is optional.

  11. #11
    Join Date
    Mar 2011
    Location
    Southern Flinders Ranges
    Posts
    1,536

    Default

    Yeah, those pins were properly munted.

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