Machinists Gazette

PROJECTS => Documenting Projects in pictures, or a dedicated thread of your project. => Topic started by: savarin on July 22, 2018, 10:09:48 PM

Title: Giant binocular
Post by: savarin on July 22, 2018, 10:09:48 PM
I cant re do this project at present as I had a catastrophic computer melt down a fortnight ago. 2 different techies have failed to re build it so far. Thankfully I have all the data and pics but no system to use.
The bino project has also suffered a major set back as I'm not as clever as I thought I was. (par for the course) :'(
The clever captured thumb screws and alignment pins held everything together very firmly but were extremely difficult to release for break down so I am cutting them off and revisiting how I accomplish  this part.
There were also a couple of miss alignment problems in more than one axis between the two tubes so a bit of wiggle room is being introduced to sort this out.
Hopefully some pictorial updates will follow once I get a computer back on line.
Title: Re: Giant binocular
Post by: grumpygator on July 22, 2018, 10:18:28 PM
I have faith that you will work it out.
Post when you can.
**G**
Title: Re: Giant binocular
Post by: Terrywerm on July 22, 2018, 11:14:36 PM
Sorry to hear that you are having trouble, but we know that you will soon be back on top of things as usual.
Title: Re: Giant binocular
Post by: Carpenter84 on July 23, 2018, 12:25:01 AM
Oh man. One thing after the other can be really discouraging, a huge downer. Man, do I know how that feels.
I hope you can get things sorted out and back on track.
Title: Re: Giant binocular
Post by: savarin on August 13, 2018, 09:06:20 AM
At long last I have the computer re built and all software installed and running smooth.
So, back to work.The first job was cutting out all the brackets that held the taper pins and thumb screws.Then I turned up 12 small rods with an m3 hole in them so it will be easier to drill out full size once welded in (new fix 1), drilled the square tubes to take them, welded them in and ground them flush.Then re-drilled and tapped M5. (new fix 2)
At the moment I'm using screws but these will be knurled knobs later.I decided to weld these in and tap all the way through so I can use a long thread on the knobs so there is less chance in losing them at night.The 3mmx25mm flange is held on with 2 screws and I will be using a rubber section covering it so it wont mar the paint when thats eventually done. (new fix 3)
I am amazed at how tight and rigid this holds the two sections together but even better is that loosening the knobs allows the flange to fall away allowing easy separation .Each pair of tubes will use three of the flanges, set on every other side.

Title: Re: Giant binocular
Post by: chips and more on August 13, 2018, 09:21:29 AM
Good for you!!! Canít pat you on the back, my arms ainít loooooong enouph. Youíve got me on the edge of my seat waiting for those ET pics. Thanks for sharingÖDave
Title: Re: Giant binocular
Post by: savarin on August 14, 2018, 05:36:23 AM
For those who never saw the original posts I thought I would add a reminder.This is what I wanted(http://i64.tinypic.com/2wly97n.jpg)
and this is as far as I had got before the problem (I've just fixed) raised its ugly head.
(http://i66.tinypic.com/2prtbuh.jpg)
Title: Re: Giant binocular
Post by: 34_40 on August 14, 2018, 05:56:21 AM
I've been following along - even "across the street", and am inspired by your vision! Pun intended!  ;)
Title: Re: Giant binocular
Post by: chips and more on August 14, 2018, 01:53:57 PM
That is soooooo cool!
Title: Re: Giant binocular
Post by: Uncle Buck on August 14, 2018, 04:17:32 PM
Ginormous binoculars! COOL!
Title: Re: Giant binocular
Post by: Bill Gruby on August 16, 2018, 08:47:53 AM
 Buck, be careful, he is collecting IP addresses to spy on people around the globe.  ROTFLMAO

 "Billy G"
Title: Re: Giant binocular
Post by: savarin on August 16, 2018, 08:14:49 PM
Not a chance Bill, you must have me confused with a paranoid tosser ;D
Title: Re: Giant binocular
Post by: Bill Gruby on August 17, 2018, 07:06:54 AM
 8) 8) 8) 8) 8) 8) 8) 8) ROTFLMAO

 The one and only "Billy G"
Title: Re: Giant binocular
Post by: Terrywerm on August 17, 2018, 08:58:24 AM
Not to sidetrack this thread, but a neat little aside:

My granddaughter is interested in astronomy, and I purchased a used telescope at a yard sale this past spring. Not knowing anything about telescopes at the time, I did not perform proper due diligence and ended up purchasing a reflector telescope with no mirror.  :(     Luckily, I only paid $40 for it but that's another story. I contacted Savarin at the time and we discussed a few things and I started learning more about scopes and astronomy in general.

So, for her birthday, my son purchased a brand new One Sky 130 telescope through the Astonomers without Borders program. We've done a few things with it, but lately the skies here in the central US have been terrible due to the smoke in the air from the western wild fires.

Anyway, the whole point of my post is that I have been amazed at what we can see with her small 5" scope. I cannot imagine what you will be able to see with your giant binocular! Anyway, I am still following along, even more interested now than before.
Title: Re: Giant binocular
Post by: savarin on August 17, 2018, 08:40:54 PM
Thats really good to hear Terry, Try and find a local astronomy club close by and visit.If they are anything like all the ones I know they do presentations and maybe hold training sessions for kids. We do, its very satisfying listening to the ohhs and ahhhs as they find saturn or jupiter etc for the first time.Just as a matter of interest lay back in a deck chair with a pair of 10x50's binoculars (when there are no clouds) and cruise the bright patches of sky, so much more pops out. Check the moon with them from when its just a sliver up to 3/4s full.It gets too bright after that and you will be amazed at all the extra detail that becomes visible. (no, cant see any footprints though)
Title: Re: Giant binocular
Post by: Terrywerm on August 18, 2018, 12:24:28 AM
Well I guess your telescope just isn't good enough then. ;D


All kidding aside, we did find a local club and they have some events coming up this fall that we plan to check out.


We found out about the moon being too bright when it is close to full. We did manage to get a peek at Saturn but it was pretty fuzzy. Looking forward to doing and seeing more once the smoke clears and we get rid of the hazy skies of summer.
Title: Re: Giant binocular
Post by: savarin on September 03, 2018, 07:34:56 AM
4 down, 8 to go.The new thumb screws to hold the sections together.
(http://i67.tinypic.com/2ldfuc3.jpg)
19mm stainless rod, turned down to 11.5mm, then turned down to 5 mm

(http://i65.tinypic.com/acza15.jpg)
threaded M5
(http://i67.tinypic.com/34sf2wk.jpg)
knurled with the camjack knurler

(http://i68.tinypic.com/j6jr52.jpg)
the amount of pressure required to knurl this stainless was huge.

(http://i63.tinypic.com/20u795g.jpg)
parted off, nice long swarf curls
(http://i66.tinypic.com/314y16e.jpg)
a bit of embelishment just because.
(http://i65.tinypic.com/2mo6xvt.jpg)



Title: Re: Giant binocular
Post by: 4GSR on September 03, 2018, 08:47:26 AM
Looking good!
Title: Re: Giant binocular
Post by: Uncle Buck on September 10, 2018, 08:45:54 AM
Good to see you using a scissor type knurling tool. Job well done!
Title: Re: Giant binocular
Post by: savarin on October 10, 2018, 08:38:48 AM
The new fixings work great.
I was going to add some pics but that useless piece of crap from vomitsoft win 10 suddenly has decided it wont recognise my phone so I cant edit and load them.
All those unhelpful hints on line are crap and useless as well.
Do you get the feeling I'm well pissed off?
The more we advance and supposedly get better the worse off we become.

Title: Re: Giant binocular
Post by: chips and more on October 10, 2018, 09:02:23 AM
I hear you loud and clear! Todayís programmers forgot about the word/phrase user-friendly when they make an OS, apps and all for the general public. They also donít care if it works or not.
Title: Re: Giant binocular
Post by: Carpenter84 on October 10, 2018, 10:29:37 AM
Charles, try using Tapatalk on your phone and upload photos. It auto-resizes them for you.
Title: Re: Giant binocular
Post by: savarin on October 10, 2018, 09:17:04 PM
I owe vomit soft an a apology this time around as it wasnt their fault for once.
I went through 5 usb plugs till I found one that worked.
Hmm, why so suddenly.
Heres the clips
(http://i64.tinypic.com/15eelco.jpg)
Now they are clipped together another problem has reared its ugly head, welding distortion.
The two side plates that the pivot will be bolted to do not sit parallel when bolted up, on one side the truss is slightly warped.
To solve this I made four exact sized spacers from some thick walled aluminium tube and bolted them together.
This has worked to get the side plates spot on parallel and square.
Now I will bolt the two trusses together using shims to take up the slack and keep them parallel.
Here they are just sitting at the top of where they must go.
(http://i66.tinypic.com/303bb52.jpg)
Now I either have to re-make the bottom and back plates or re-drill the fixing holes to get some wriggle room so they fit.
we will see.
Those four spacers will be replaced with the pivot unit but I cant bolt on that yet as I dont know where the balance point will end up.


 
Title: Re: Giant binocular
Post by: savarin on October 15, 2018, 08:11:44 PM
I meant to add in there that when turning the spacer tubes they got pretty hot from the friction of the steady and expanded.
I had to wait for each one of them to cool to ambient to get the real measurement and then finish off their length.
They came out to within 2 thou of each other. I felt that was close enough.

Title: Re: Giant binocular
Post by: grumpygator on October 15, 2018, 09:23:38 PM
Damn it C , don't tell them all the secrets They are liable to get big heads.
  So if I got this right , With the tilt of the earths orbit and you being in the Southern Hemisphere we see different star groups.You see some that we don't. Same Sky with different points of view
 So here is the question who was it that put both north and south together to make sense of it all?
 Ball is in your court 
  **G**.
 
Title: Re: Giant binocular
Post by: savarin on October 18, 2018, 07:33:13 AM
After sorting out the central plates and re-aligning the tubes I had to make a new bottom plate.
I first cut the half circle section out where the main support will fit with a jig saw which was not very accurate but I stayed inside the line.
Then milled it to size with a  4mm end mill in the drill press. (yeah yeah I know you shouldnt but it worked).
(http://i68.tinypic.com/2aep66h.jpg)

Then I smoothed the milled cut with a flap sander, it doesnt actually touch the table it just looks like it does.
(http://i65.tinypic.com/20zqy50.jpg)
Once this was in place I could bolt the whole assembly back up and find the balance point.
(http://i66.tinypic.com/2ry2at4.jpg)
To get a more accurate idea of where it should balance I added the mirrors and more metal to take the place of the mirror cells and a package of the four secondary and tertiary mirrors and a couple of eyepieces at the top end.
(http://i67.tinypic.com/2vifkp1.jpg)

It balanced 1/8 of an inch below where I thought it would have when I first planned it out. I felt good at that point.
But, we always have to have one of those, that 1/8 of an inch placed the central hole in the pivot just off the diagonal brace so I had to cut a small section out.
Bah humbug. Actually because there is a plate bolted all around that section I dont think it needs the diagonal at all so I will cut it completely out once I tear it all down again.Now to the difficult part. 
I'm not sure what you mean here Terry.  Dont know why I typed Terry here seeing as it was "G" who asked the question. I'm getting old, you all look the same.
Yes we see parts of the sky you cannot 
But I had never thought of this question before - 
who was it that put both north and south together to make sense of it all?
I think it could have been this gentleman. https://www.davidrumsey.com/blog/2012/8/21/mapping-the-heavens-in-1693 (https://www.davidrumsey.com/blog/2012/8/21/mapping-the-heavens-in-1693)
Even if he wasnt the first his was still an awesome piece of work.
Title: Re: Giant binocular
Post by: chips and more on October 18, 2018, 08:54:02 AM
You mean you used the 4mm end mill and drill press kinda like a pin router? And free handed it? Thatís amazing, never would have thought of that. Four flute end mill?
Title: Re: Giant binocular
Post by: 4GSR on October 18, 2018, 09:42:57 AM
Just imagin, If NASA had built this same binocular, the cost plus over runs, would have been north of two billion dollars and six years behind schedule!

That is one fine job your doing there with limited resources to build with.  ;)

Thanks for sharing savarin.
Title: Re: Giant binocular
Post by: savarin on October 18, 2018, 08:31:03 PM
You mean you used the 4mm end mill and drill press kinda like a pin router? And free handed it? Thatís amazing, never would have thought of that. Four flute end mill?
I need to get some multi flute cutters just for this as I do it more times than than I can count. I had the drill running at its fastest speed.
Sometime I use the woodworking router blades on the table but that was set up with the saw blade where I cut the panel to size and I was too lazy to change everything.
It must be heaven to have each item of equipment set up to enable you to go from machine to machine as you need it.

Just imagin, If NASA had built this same binocular, the cost plus over runs, would have been north of two billion dollars and six years behind schedule!
Only 6 years? I first started this in 2011 but did stop for a couple of years. Theres probably still a couple of years to go as the mirrors wont be a quick job.
Thanks for the kind words.
Title: Re: Giant binocular
Post by: savarin on October 19, 2018, 04:07:01 AM
Simple job today, fitted the pivot in place.
(http://i63.tinypic.com/2zrq55f.jpg)
Theres lots of empty holes as with all the assembling and disassembling going on it got a tad annoying to do everyone.
Title: Re: Giant binocular
Post by: chips and more on October 19, 2018, 08:50:07 AM
You are doing one hella of a project! Did you cast those aluminum end pieces? How is getting material and other supplies in the down under part of the world? Hope your dream comes to life soon!...Dave
Title: Re: Giant binocular
Post by: savarin on October 19, 2018, 11:35:53 AM
Thanks. The bosses are from a chunk of 100mm dia real aluminium not the gummy stuff I cast.

Most raw materials are available but sometimes a tad expensive, good job theres the internet.
Title: Re: Giant binocular
Post by: savarin on October 21, 2018, 06:50:09 AM
 This is roughly what I will be doing for the pivot bearings.
I'm considering casting those wooden blocks in brass and squaring them up on the lathe, boring then for the shaft splitting them so they can be finger tightened and hinged for easy assemblyand bolting them from underneath that blue cap (I'm changing this from a cast ally part to a steel fabrication) I first thought of casting them in aluminium but decided brass would be better with no galling.
Can anyone think of a reason not to use brass or if something better could be used.
(http://i63.tinypic.com/a3l84z.jpg)

I have decided to make the internal unit that holds the bearings for the azimuth system from some steel plate and short lengths like the bottom unit of the pier.
This meant I had to weld both sides of some 150mm wide plate so I could turn a 154mm dia circle.
(http://i65.tinypic.com/ets9rm.jpg)
I hacked the corners off with the trusty old angle grinder and turned it using a braised carbide tool that I ground to a sharp edge and left a small flange that will sit on top of the tube.
(http://i67.tinypic.com/24n4kcy.jpg)
Then I flipped it around to bore a recess to hold a 90mm dia taper roller bearing.
Not finished yet but it was tea time.
(http://i67.tinypic.com/5cgmep.jpg)


Title: Re: Giant binocular
Post by: chips and more on October 21, 2018, 07:08:24 AM
How heavy is your GB getting to be? Brass blocks sounds like a lot of weight unless you hollow cast them? Some plastics are hella strong, like Delrin, but your wallet will take a big hit for blocks that big! You could cast the blocks in aluminum and make Delrin bushings to fitÖmaybe? Or some other kind of bushing material that is gall resistant and slick for a nice bearing surface.
Title: Re: Giant binocular
Post by: savarin on October 21, 2018, 07:30:34 PM
Yep, its getting heavy. Its a strange dichotomy, weight means more stability, a breeze wont move it but more weight means more inertia when slewing.For comfort it will need two people to move and assemble it, I can just do it my self but its a struggle.I guess the next one will be the ultra light.
Title: Re: Giant binocular
Post by: 4GSR on October 21, 2018, 07:42:26 PM
Need a Warner & Swasey dividing engine to go with your telescope?

Woah, wait a minute. That stuff is history now days, it all done digitally.  What kind of precision movement instruments do they use now days?

Ken
Title: Re: Giant binocular
Post by: savarin on October 22, 2018, 03:36:25 AM
one of these?
I had to look it up ::)
Title: Re: Giant binocular
Post by: savarin on October 23, 2018, 08:01:15 AM
finished the first plate for the azimuth bearing.
(http://i67.tinypic.com/sxceg5.jpg)
this sits into the main pier tube
(http://i64.tinypic.com/axb0y1.jpg)
and the 90mm taper roller bearing sits into the recess.
(http://i65.tinypic.com/5xkfuv.jpg)
Normally I would use a thick enough plate so the bearing can sit in it deeper but I didnt have any other material.
So a major question - as there is no real pressure on these bearings and zero speed do you think the small recess is sufficient to hold them?
They cant move sideways and will be set with locktight
The plate than holds the altitude bearings will sit on this.
Title: Re: Giant binocular
Post by: chips and more on October 23, 2018, 08:24:55 AM

Not sure about using Loctite? Maybe not enough lip for the Loctite to work? But if you hold the bearing into place mechanically, that should do it. Looookin gooood.
Title: Re: Giant binocular
Post by: f350ca on October 23, 2018, 08:29:30 AM
The small recess should locate it fine. Could you make a cap that goes over the bearing with the top at shaft size to keep the bearing covered, then bolt the cap to the plate.

Greg
Title: Re: Giant binocular
Post by: savarin on November 01, 2018, 10:17:37 PM
Finished the bearing assembly and it slides into the tube easy but firm.
I will drill and tap some fixing holes once the tube is cut down to size.
I parted off 4 lengths of 16mm stainless, so easy now I have the solid plinth. (thanks Bill)
Now I have an excuse to use my latest acquisition, a crotch centre.
Mounted in the crotch centre, drilled, tapped 8 x 1 mm, counter bored 2mm for the bearing clamps (when I get them cast)I started threading the 8mm rods that will screw into these but had something happen I've not heard of before.
The die broke in half and all the cutting teeth on one set snapped off as well.
It happened when I backed off the die and it seemed to jam, wouldnt go forwards or reverse, this was by hand no power.I assume it was hardened but not tempered, bugger. (no pics as I threw it across the shop in disgust)

Title: Re: Giant binocular
Post by: savarin on January 27, 2019, 02:53:07 AM
The bino build came to a halt whilst I cleaned and tidied up the workshop, something that was long overdue.
In the course of tidying up I found my mirror tester covered in rat crap so took a short break to re furbish it even though I am no where near requiring it for testing as I havnt started grinding the mirrors yet but I just couldnt leave it in that appalling state.
The micrometers had to be stripped and cleaned so I painted the base and added better slide supports and a fourth adjustable foot so it would sit in a stable position no matter what the surface.

RT1
 
The long white rectangle is a glass microscope slide for the next stage to slide upon.
 
RT2

This is the second stage for the "X" direction and sits on the base like so. 2 "V" blocks slide on the stainless rail with the adjusting screw just to the left of the micrometer slides in the glass slide. Those little knurled thumb screws are the ones that filled my thumb with invisible splinters of stainless steel.
 
RT3
 
The "Y" and "Z" are a single unit on the third stage
 
RT4
 
and sits on the second stage.
 
RT5
 
Both the second and third stage have lead blocks bolted to them as vibration dampers.
The sliding head is held with 2 nylon screws for friction and are locked when everything is in alignment.
 
RT6
 
The wheel contains 6 diodes, red, green, blue, white, yellow and orange. No real reason as most testing will be done in green but I wanted to see if there was any difference in the readings with different colours,
The diodes are are switched on when they are directly below the peep hole.
 
RT7
 
The rheostat controls the brightness of the diode.
I still have to attach the magnet that holds the screens or razor blade in place over the diodes as the rat crap ruined them.
Now I need some dry days to do a bit of casting and continue with the real job.
Title: Re: Giant binocular
Post by: 4GSR on January 27, 2019, 08:22:07 AM
If the USA govenment had built this, it would cost us taxpayers over a million dollars to build!

Great job Savarin!
Title: Re: Giant binocular
Post by: Carpenter84 on January 27, 2019, 08:54:18 AM
What's this crotch center? Bit more detail?
And, the cross members you welded in, are they stainless or mild? How are you welding?

Thanks Charles, really nice work.
Title: Re: Giant binocular
Post by: savarin on January 27, 2019, 09:21:09 AM
All welding on the bino is mild steel either rod or mig with some tig depending on what gas I had.
The crotch centre is a M2 taper to sit in the tail stock with a "V" block attached and a clamping bar with different sized mandrels for drilling dead on the centre of a round bar.
https://www.amazon.com/Lathe-Tailstock-Adaptor-Drilling-Engineering-Machinist/dp/B075XGYDNL
 (https://www.amazon.com/Lathe-Tailstock-Adaptor-Drilling-Engineering-Machinist/dp/B075XGYDNLMine) Mine was cheaper than that and came from ebay via china but I cant find the advert now.
Title: Re: Giant binocular
Post by: 4GSR on January 27, 2019, 09:48:07 AM
Here's a link for us in North America.

https://www.amazon.com/Lathe-Tailstock-V-Adaptor-Drilling-Engineer-Machinist/dp/B072JXZHVD/ref=sr_1_3?ie=UTF8&qid=1548603953&sr=8-3&keywords=Lathe-Tailstock-Adaptor-Drilling-Engineering-Machinist

Charles, Just trying to help out here.

Ken

Oops!  Just notice the link I posted above is for one with a No. 1 MT.

Here's a link for one with a No.2 MT shank.

https://www.amazon.com/Lathe-Tailstock-Adaptor-Drilling-Engineering-Machinist/dp/B07JRB12C5/ref=sr_1_1?ie=UTF8&qid=1548603953&sr=8-1&keywords=Lathe-Tailstock-Adaptor-Drilling-Engineering-Machinist

Ken
Title: Re: Giant binocular
Post by: Carpenter84 on January 27, 2019, 10:35:21 AM
Got it! Very nice.
Title: Re: Giant binocular
Post by: Terrywerm on January 27, 2019, 11:00:53 PM
Nice work Charles! I'll be looking forward to seeing more.
Title: Re: Giant binocular
Post by: Bill Gruby on January 28, 2019, 06:42:41 AM
 So is he. LOL

  "Billy G"
Title: Re: Giant binocular
Post by: savarin on February 25, 2019, 08:33:29 PM
For want of a shoe. OR, How I passed the last three weeks of wet.

Needed 4 chunks of aluminium for the altitude bearings for the bino.
Guess I had better cast some.
Hmm, floods and rain so better not.

so I knocked these out for the secondary mirror adjusters.
(secondary adjusters 1.jpg)
Just have to silver solder the brass nut to the brass plate, its a larger version of what I made for the tertiary holders.
BUT, my gas torch wouldnt quite get hot enough for a good joint so cant finish them off, Gaaaa.
Need a bit of brass for the remaining adjustment screws, none here, I know, cast some, oh, I cant its still raining, bugger, getting totally fed up with it so a change of tack was called for.

I had a go at turning a crankshaft, I dont have a use for it (yet) it was just for kicks to see if I could.
Got this far
(c shaft 1.jpg)
then Whoops! crashed the tool onto the chuck and snapped the belt and the parting tool. They are now on order so what can I do now?
As its still bloody raining I still cant cast anything but I suddenly had a light bulb moment, maybe I can machine down these horrible failed castings for two of the bearing blocks.
(ally halves.jpg)
I started facing off the bottom of the bowel as the other side allowed (sort of) clamping.
 The centre is only just there to help prevent it from moving towards the tailstock.   
(start block.jpg)
Then I thought why not cut the ends off with the table saw
(second block.jpg)
Now I can use the rear face of the jaws or chuck to get parallel faces then square up for the other two sides then the ends.
Many many hours later and half a ton of swarf
(swarf.jpg)
these materialised.
(finished block.jpg) 
The arrowed corner will be rounded eventually which will remove that unsightly bit then I may powder coat or polish depending upon how I feel.

From what I thought was a totally buggered up melt came the best cast aluminium I have ever poured, not an inclusion to be found. Just goes to show.
 Oh for a mill or shaper, perchance to dream.

Mind you the lathe certainly got a real flogging getting these down to size.

Ahh, the rain has stopped, the water damage has been repaired and the land is drying out.
Ta Da, casting time.
Out with the muller and prep the sand.
Not a chance, the motor has failed.
(muller.jpg)

I have a 1/4 horse I can "borrow" from the mulcher so I've cut the old brackets out ready to re build.
A major problem is the motor is rated at 2850 rpm. Thats a lot of speed dropping to get down to 30 rpm.
I can make some new pulleys and whack a jack shaft in, hang on, I need the muller for the sand so I can cast the pulleys.
Guess I had better spring for a new slower motor, found a 1/3 hp 900rpm for $140AU all up so I think thats the way to go.
They say in never rains but it pours, weve certainly had that in spades of late.
Now how do I get this purchase pass the financial controller???

Title: Re: Giant binocular
Post by: Terrywerm on February 25, 2019, 10:18:11 PM
When life hands you lemons, you make lemonade!!
Title: Re: Giant binocular
Post by: chips and more on February 26, 2019, 08:47:51 AM
He can make lead into gold!
Title: Re: Giant binocular
Post by: 34_40 on February 26, 2019, 07:33:27 PM
I love you're "get it done" attitude. Always forward progress.

An inspiration to be sure.
Title: Re: Giant binocular
Post by: savarin on March 17, 2019, 10:14:47 AM
The weather dried out enough to start casting again but with no muller I couldnt use green sand so elected to try some welded moulds.
 Heres the melt with the new moulds for the bearing caps heating up on top. (altitude bearing 1a)

No pics of the pour as I didnt have any more hands available.
 They turned out very well EXCEPT----- I followed the interwebs of miss information and degassed with washing soda. Bad move, the worst case of porosity I've had. I now have more info regarding the causes so we will see what the next pours do. Check out the sprue and gate design as well. Very informative.

https://www.youtube.com/watch?v=SfTIv0hLSBs (https://www.youtube.com/watch?v=SfTIv0hLSBs)

I obtained some acetal for the altitude bearings.(altitude bearing 1)
I left it long enough to keep sufficient in the chuck to work it.
 First bored to size then turned to O/D and length (altitude bearing 2)

Then flipped it to thin down the flange that was left.
 Next I bolted the bearing blocks together and fixed them to the face plate for boring.
 I clamped them together with a 3mm length of ally between them so the finished hole would leave a 3mm gap between the halves. (altitude bearing 3)

The black marks are high accuracy depth gauge lines.(altitude bearing 4)
 
Once bored they were mounted in the vertical slide for the remaining machining.
 Here I'm using a 6 mm end/slot milling bit for the release slots. (altitude bearing 5)
and then all the corners were rounded over with a carbide rounding bit.(altitude bearing 6)

this is how they will sit on the top plate.
(altitude bearing 7)
Title: Re: Giant binocular
Post by: savarin on March 17, 2019, 10:19:18 AM
Some thoughts-----
Do I slit the acetal so they will clamp tighter for friction? A quick test showed not for light loads but maybe for the total unit.
If more pressure is required I may have to make larger knobs for better grip.
The purpose of the slots in the bearing blocks is to allow easy fitting without having to totally unscrew and possibly loose parts in the dark. Or so I hope.

Title: Re: Giant binocular
Post by: chips and more on March 17, 2019, 03:29:12 PM
Like always, you are amazing with what you make and what you have to make it with!
Title: Re: Giant binocular
Post by: savarin on March 17, 2019, 09:32:59 PM
Thanks Chips thats very kind of you.
Title: Re: Giant binocular
Post by: savarin on March 28, 2019, 09:46:49 PM
Slitting the acetal had a better result in that it removed all play in the bearings.
Now to make the disk brake rotors for the altitude mechanism.
I have some 2mm stainless of unknown composition and the largest rotor I can make is 235mm dia.
The largest bicycle disk rotor I can buy (buy? Thats heart attack material right there) is 203mm dia
I'm hoping the leverage at that size will allow an adjustable smooth friction resistance with an extra twist to the control to lock in place.
The difficult part is its too large a dia to fit on my lathe so I will have to go the old route before I owned a lathe, ie. the drill press.
First I used a hole saw to remove the centre then the angle grinder to remove as much of the waste as possible.
I made a mandrel from a cast billet I had to hold the disk.
Then mounted onto the drill press I got it pretty round with the flap disk then and used a hss tool bit clamped to the wooden block knudged with gentle taps of a  hammer as a feed mechanism to get it fully round.
Slow but it worked.
The top disk is a standard bicycle disk, the card is the largest dia disk I could purchase and the bottom disk is the new stainless one.
Now I have to cut it in half and pray it doesnt distort.
The matched left and right hand calipers should arrive on monday so I dont want to make the brackets for them till they arrive.
Title: Re: Giant binocular
Post by: Terrywerm on March 29, 2019, 08:58:13 PM
Nice work, Charles.  Looking forward to more as you continue with this project!
Title: Re: Giant binocular
Post by: savarin on April 07, 2019, 08:26:05 PM
The disk cut in half with no distortion so that was good.
 So the next job was a very simple one, make a clevis assembly to actuate the caliper brake.
 What a palaver such a simple job turned out to be.
It took 5 attempts to fabricate this simple device.
The first one was a piece of 16mm stainless turned down to 6mm and threaded with the clevis milled out at the large end.
This jammed up somewhere through the motion no matter what I tried.
Various ideas around this theme also failed until I got to the version shown.
The threaded shaft is silver soldered to the small barrel that fits between the brass section so it has some play but cannot turn round.
I made a dolly of the correct size to fold the brass around.
The bracket the thumb screw tightens up against actually sits flat once its tightened to the start of the friction.The steel bracket the two calipers sit on will be bolted to the top plate.
 As a guide when assembling the bottom half of the bino I think I will chamfer a lead in on the front part of the brake pads so the disks easily slip into place.
Now the calipers are in place I can now cut the excess from the bottom of the disks.
Title: Re: Giant binocular
Post by: savarin on April 18, 2019, 06:24:41 AM
I had to resort to a hand powered lathe for this part.
 The brass footed brakes rubbing on what I thought was a smooth surface gave a lie to that thought.
 There were slight high spots above all the welded spacers so the movement was more a stick and go stick and go.
 A pipe centre in the chuck and a standard live centre in the tailstock held it in the lathe.
Obviously the chuck wouldnt power the assembly so I had to spin it by hand pulling it towards me sharply.
 The weight of the unit acted like a flywheel so I could take a very fine cut in tiny short amounts until I had a smooth path for the brake shoes to rub against.
This was a long process due to the tiny amount I could remove per spin but it was worth it as now the brakes rub smoothly with no stops and starts.

Title: Re: Giant binocular
Post by: Carpenter84 on April 18, 2019, 06:48:00 AM
Looking good, Charles.
Just A thought on the hand power, you could have spot welded a piece of small bar stock to one side of that assembly passing through the spider plate in order to turn under power, lightly anyways. Then just remove the weld once complete.
Title: Re: Giant binocular
Post by: savarin on April 18, 2019, 10:13:00 AM
I could have shawn but once I spun it by hand it just seemed natural to keep doing it that way. 
And I didnt feel like making a bolt and arm to reach from the faceplate cos I'm a lazy bastard at times ;D :o
Title: Re: Giant binocular
Post by: chips and more on April 18, 2019, 11:00:38 AM
You dropped my jaw again!
Title: Re: Giant binocular
Post by: grumpygator on April 18, 2019, 05:41:46 PM
As always C,
 You never fail to come up with a simple soultion to a problem.
 You out think it and adapt and overcome.
 My hat is off to you.
 You have taught me to look at other simpler ways to solve any problem.
  Thank You, Brother.
**G**
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Title: Re: Giant binocular
Post by: savarin on April 18, 2019, 08:13:58 PM
Thanks G, much appreciated
Title: Re: Giant binocular
Post by: savarin on April 24, 2019, 09:53:51 PM
Not much done of late.
Drilled and tapped all the holes to hold the alt/az bearing assembly to the pier.
Then bolted it all together to see how it looked.
The disk brake idea is awesome, so smooth with steady friction up to total lock.
Its not balanced yet as there are no mirrors or mirror cell in place yet but there appears to be no no slop or backlash in the altitude bearing.
Bloody ell, its a big scope. I will need 3 steps to get high enough to view the zenith.

Title: Re: Giant binocular
Post by: Carpenter84 on April 24, 2019, 10:19:41 PM
Well, I'll say this. I've not understood half the things you've talked about... zenith?? Thaaaat..... sounds made up.
But the bino sure does look bad ass as hell!
Title: Re: Giant binocular
Post by: savarin on April 27, 2019, 09:18:31 PM
Had a mate up from Ipswitch for a week so in between beer, soju and food I only got this done
A tommy bar for the azimuth brake.
Title: Re: Giant binocular
Post by: chips and more on April 28, 2019, 06:57:01 AM
You go ahead and live it up! You deserve it! Nice little touch with the end caps!
Title: Re: Giant binocular
Post by: savarin on June 16, 2019, 07:02:49 AM
Started sand blasting today, not an auspicious start, the see through shroud worked fine keeping the area clean but not much sand came out the gun and the compressor needed to re start every 10 seconds. Not so good.
(sb1 shroud)
I decided to remove the jet but it was deep inside the gun and the only tube spanner I had (shops closed) was too small.
 I heated it up to glowing red and hammered it onto the jet to conform. It worked and the jet came out easily.
(sb2 jet removal)
Once out I soldered the end up and re drilled it to 1.5mm (my smallest drill)
(sb3 jet)
My reasoning was a smaller hole should give more speed to the air stream and allow longer blasting time.
(sb4 jet back in)
Which it did, from 10 to 35 seconds but still not a lot of sand coming out.
 So I made a new nozzle with a longer taper inside and a smaller hole.
(sb5 nozzle)
everything back together on the backpack that holds the sand.
(sb6 gun)
It works way better than before, steady stream of fast sand and it removes rust and paint.
 BUT, 30 seconds at a time only, I need a better stronger compressor.
 No idea where thats going to come from.
Title: Re: Giant binocular
Post by: chips and more on June 17, 2019, 03:37:15 PM
Maybe not a stronger compressor. Maybe just put two, three or whatever compressors working together. Sometimes just adding a cheap contactors 3CFM compressor works ???
Title: Re: Giant binocular
Post by: grumpygator on June 17, 2019, 04:49:29 PM
C,
 Just scrounge up a bigger storage tank.
 My big compressor head on an 80-gallon tank wore out so I grabbed my small 3-gallon unit and let it feed the bigger tank. Sure it takes some time to fill the tank at first but after that, I can run my high usage air tools for 4 or 5 minutes at a time.
 I have never had much luck running multiple compressors to run a tool. It seems like they would fight with each other.
     **G**
Title: Re: Giant binocular
Post by: 4GSR on June 17, 2019, 08:50:41 PM
I heard in the news this morning that Ne Zealand had a bad earth quake yesterday. I hope he's alright.
Title: Re: Giant binocular
Post by: chips and more on June 17, 2019, 09:34:00 PM
C,
 Just scrounge up a bigger storage tank.
 My big compressor head on an 80-gallon tank wore out so I grabbed my small 3-gallon unit and let it feed the bigger tank. Sure it takes some time to fill the tank at first but after that, I can run my high usage air tools for 4 or 5 minutes at a time.
 I have never had much luck running multiple compressors to run a tool. It seems like they would fight with each other.
     **G**

I have three hooked up together. I have adjusted each pressure switch to turn on at its own unique pressure zone and not all at the same time. For just shop air (90% of the time) I use a cheap compressor. Donít care if I wear it out. But darn, its been going strong for soooo long I canít remember when I got it LOL. Shop air tools, then the second one kicks in. When I glass bead the third one kicks in. When all three are running I have plenty of air to feed a 3/32Ē orifice @90psiÖDave
Title: Re: Giant binocular
Post by: Terrywerm on June 17, 2019, 09:58:05 PM
Used to work in a plant that had a bank of four 40HP rotary screw compressors all feeding the same header. All were set at successively higher cut-in pressures, each one separated from the next by 5 PSI increments. The pressures were changed every Monday to put a different compressor into the lead position, first lag, second lag, and third lag. This kept the operating hours roughly equal on all four compressors. The plant would run at full capacity on three of them, always leaving the fourth available to come online if one of the others failed. This also permitted one unit to be down for repairs or normal maintenance without affecting the operation of the plant in a negative way.
Title: Re: Giant binocular
Post by: Carpenter84 on June 17, 2019, 10:10:56 PM
Thatís a lot of air...
we ran 60hp with a 120gal tank with a 400 gal receiver tank. Everything we did was pneumatic operated.
Title: Re: Giant binocular
Post by: Terrywerm on June 17, 2019, 10:34:38 PM
Yes it is! Six bottle filling/capping/weighing/labeling lines, with automatic case packers at the end of each line. Palletizing was done manually but the pallet sat on a pneumatic lift that kept the top layer level at optimum height for that job. Two automated high speed shrink wrapping machines were kept busy by the six bottling lines. All of the valve controls in the mixing/blending area were pneumatic also. The worst was one machine on the high speed line which was a pneumatic cap sorter. It was so noisy we had to install a series of noise cancelling curtains around it.
Title: Re: Giant binocular
Post by: Carpenter84 on June 17, 2019, 10:44:17 PM
Very similar to what I did in my last factory. Made composite cans. Peanut cans, coffee cans. Spiral winders, flangers, cappers, palletizer, labeling machines (Paco), wrappers, can turners (air jets). Similar, but usually only one or two lines running at a time.
Title: Re: Giant binocular
Post by: savarin on June 18, 2019, 09:07:26 AM
well thats it, nothing for it but to go larger and higher pressure.
My little pony of a compressor is not rated higher than 80psi.
Now how on earth do I get this one past the financial controller especially after nearly cutting her toe off.
Snowballs chance in hell anyone?????
Title: Re: Giant binocular
Post by: savarin on June 18, 2019, 09:11:03 AM
I heard in the news this morning that Ne Zealand had a bad earth quake yesterday. I hope he's alright.
No worries Ken, thats only 2080 miles from me  :-\ but thanks for the thought.
Title: Re: Giant binocular
Post by: 4GSR on June 18, 2019, 10:10:29 AM
I heard in the news this morning that Ne Zealand had a bad earth quake yesterday. I hope he's alright.
No worries Ken, thats only 2080 miles from me  :-\ but thanks for the thought.

Glad all's okay.  From here, 2080 miles could be down the street to me here.  Coming from all the way over there. ;)
Ken
Title: Re: Giant binocular
Post by: chips and more on June 18, 2019, 11:28:08 AM
Thatís a lot of air...
we ran 60hp with a 120gal tank with a 400 gal receiver tank. Everything we did was pneumatic operated.
Everything was pneumatic, wow. I would be going nuts if the plant had any air leaks. Air leaks = $$$ out the window. You canít electrocute yourself with air. But you sure can start an air leak easy enough and not give it any thought. I hate air leaks. 
Title: Re: Giant binocular
Post by: Carpenter84 on June 18, 2019, 01:01:07 PM
Lol. Air leaks...
About a month after the millwrights installed the new compressor setup, the whole plant did an air leak fix. Well, all the maintenance staff and operators - the people who actually knew the production lines (I was an operator).

The management was trying to make improvements to save on overhead. Yeah, air is free... Compressing it is anything but.
That air would hiss away for about 35 minutes till dry... Catch that? 520 gallons of air would leak out to the point you couldn't hear it anymore over the usual background hum of a plant closed up for the night, in 35 minutes.... Air leaks? Haha.

Over the course of a week (slow time of year), the labourers cleaned things that hadnt been cleaned in years, and the operators and maintanence removed probably 500 feet of redundant air line/pipe, removed dozens and dozens of redundant ball valves (for permanent caps), and replaced probably a hundred air nozzles, air jets, air blades, solenoids, dumps, cylinders, etc. At what I'm sure was an incredible cost to the company.
But, the result was, the oil temp in the screw compressor was way lower, it engaged a fraction as often (I could always hear when it engaged, it would make a *thoomp* noise), and there was still 100 pounds of air in the tanks when you started up the next morning.

Management was happy... Maintanence was happy to be doing less maintenance... The maintanence was always happy to maintain less. Lol. Grumpy old men... and I was happy because the new compressor setup was quieter and cooler. They also vented the compressor rad outside instead of up into the air. My line was closest to the compressor. Summer was brutal. Easily 110į where I stood. You just stand, and sweat. I used to bring two changes of underwear, and change at lunch cause sweating that much creates skin problems.....
 
Title: Re: Giant binocular
Post by: Terrywerm on June 19, 2019, 07:59:15 AM
We purchased an ultrasonic leak detector and regularly performed an audit of the entire system and addressed any leaks that were found. The leak detector was expensive, but it made the process easy and fast. Saved the company thousands.

As for heat, it was ducted outside during the summer and exhausted inside the building during the heating season.
Title: Re: Giant binocular
Post by: savarin on June 27, 2019, 05:30:39 AM
I raised the the cutoff on the compressor to 120psi.
Still not working that well.
The hose from the sand container was sealed in place but I heaved and heaved until I got it out.
AH HA! theres the problem, when they drilled the hole for the hose they left the plastic swarf inside and that got sucked and jammed into the end of the hose preventing the suction of sand.
The design of the carrier is such that the end is impossible to see or feel.
A quick test and I am now officially a happy little vegemite (obscure aussie reference)
It works fine, just need to link another to get a larger reservoir.
Title: Re: Giant binocular
Post by: Jake Parker on June 27, 2019, 02:07:55 PM
I'm glad to hear it sucks again. ::)
Title: Re: Giant binocular
Post by: savarin on July 12, 2019, 09:45:34 AM
Good and bad today.First the good.I added a mates 4hp compressor along with a manifold to link mine and I can now say the blaster works, it stung like hell when it hit my fingers.I actually blasted two of the feet (the bino feet, not mine) clean in 10 minutes.
Now I need to make a better container as the sand sucks and seems to form a cavity before it collapses again and more sand comes through.Maybe hire a lad to shake the canister to keep the sand flowing.Now the bad.My 3 in one welder karked it just as I was welding up the last drill press table clamp.The machine starts but as soon as I try to strike an arc it goes dead.The lights are on but theres no one home.Turn it all off and wait for 5 mins and it will start again but dont do anything and it cuts out again after 2 mins of running but not welding.Not being an electronics guru I have no idea how to repair it. I think the cost of getting a shop to look at it will out weigh the price of a new one.It has earned its keep as it only cost $340 a few years ago and the projects I used it for would have cost thousands to get done at a shop.A word to the wise, dont even consider buying one of these cheapo welders as they are a pain to keep running.I have an old transformer type mig that was a goodie so I will replace the liner and get that running again.Fingers crossed, I hope to be powder coating very very soon.
Title: Re: Giant binocular
Post by: Carpenter84 on July 12, 2019, 09:59:49 AM
The inverter machines seem to have all kinds of neat bells and whistles, but I feel like unless you spend big bucks on an HTP or something, you're gonna regret it. my monstrous transformer Airco dip/stick weighs 250lbs but it'll weld anything for any duration of time. It would be nice to have high frequency start Tig, and the ability to weld aluminum, but I've gotten fairly good at scratch start and haven't had a need to weld aluminIUM so badly that ive went out and bought an inverter machine...
Title: Re: Giant binocular
Post by: f350ca on July 12, 2019, 01:28:21 PM
The home made blast cabinet I built did the same thing savarin. Bought a small used commercial one a while back. I has a u shaped tube that drops down into the sand, with a maybe 1/8th hole drilled in the top of the bent section to let the sand in. The gun sucks on one end of the tube, the other is open allowing a lot of air through but picks up the sand on the way. Works great.

Greg