Project Porn

[fabricator]

Who said anything about using it for anything but just monitoring what's going on in the Hammosphere, it wouldn't even have a mic or key.

[Frank S]

Who said anything about using it for anything but just monitoring what's going on in the Hammosphere, it wouldn't even have a mic or key.

Yea well it never hurts to know whats going on, that way when the balloon goes up and turns into a mushroom cloud you can be forewarned and know if its time to dig up your ammunition

[halfcrazy]

Who said anything about using it for anything but just monitoring what's going on in the Hammosphere, it wouldn't even have a mic or key.

Yea well it never hurts to know whats going on, that way when the balloon goes up and turns into a mushroom cloud you can be forewarned and know if its time to dig up your ammunition

+1

[fabricator]

Exactly.

[Mary B]

Just get a ham license, it is easy  I got mine when I was 14 and that was a looong time ago.

[fabricator]

I looked into it a loooong time ago and you had to learn Morse code and be able to do so many words a minute, I didn't like that idea, do they still do that?

[halfcrazy]

Code has been dropped as part of licensing

[fabricator]

Cool, maybe I'll look into it.

[dloefffler]

When the bolt flange and the top were welded to the cylinder, were they clamped to a steel bench to prevent wraping?

It is beautiful, but keeping the distortion down is an art you have masterd well, no so my efforts.

Dennis

[fabricator]

No, first the cylinde (wrapper) ends are clamped to a flat surface and tacked then the wrapper is tacked to the front cap, then the bolt flange is tacked on and bolted to the back cap.
After that, all the welds are made, this is using a tig welder with filler rod, this is much better for precise heat control, also, you weld three inches in a spot then move to another spot and weld three inches until everything is welded.
With everything tacked together then bolted together and precise heat control it's almost impossible to warp a weldment like this.

[dloefffler]

Thanks for the reply on weldments, your generosity in sharing is appreciated.

When the bearing is hardened, is it heated  in a furnace? You responded to a second post regarding variable pitch with a 30cm ring. That is a somewhat large furnace.

Dennis

[fabricator]

No, my part was only 8" dia, I heated it on propane heater.

[dloefffler]

Thanks, very clever.

Dennis

[tecker]

 I think you got a fine build but that spring is a ware point that's going to bleed rust down on the rotor as well as the pivots . Some kind of boot on the tail shaft it's right over the rotor also .

[fabricator]

It's a galvanized spring and I'm totally unconcerned by it as Chris Olson has several similar machines flying and has had none of the problems you predict.

[tecker]

 Zinc I think you'll be able to see the rust form and the spring will  probably brake before the rust migrates to the mags . Good luck

[fabricator]

I don't need luck I got talent.

[tecker]

I agree

[midwoud1]

Hi fab.

High piece of craft.
Nice machining and welding .
I missed Fieldlines 2 weeks ,was in Eastern Europe without PC.
Good to see you carry out your own ideas .

 Rgds.  - Frans -

[fabricator]

Hi fab.

High piece of craft.
Nice machining and welding .
I missed Fieldlines 2 weeks ,was in Eastern Europe without PC.
Good to see you carry out your own ideas .

 Rgds.  - Frans -

Not as high tec as yours but it'll probably work.

[dloefffler]

FAb,

Again, the guy with a thousand questions. What size is your shop if I may ask? I have a 24'x40 foot pole shed that I am thinking of converting to a machine shop. It has a gravel floor, 14' ceilings, so I could put in an insulated slab, build an insulated shell and avoid some of the costs and associated RE taxes with a new building.

I have the usual stuff, Bridgeport, drillpress, lathe, die tables for work/welding tables.

I notice you have an overhead lift. It is supported by steel I-beams.

Sorry to give so little and ask so much.

Again, thanks for all your helpful comments and photos.

Dennis

[kitestrings]

Fab,

Great looking project. I'd hoped to get back here sooner, but really nice build. Hope it performs as well.

I like the idea of using the solid spacers instead of the more typical threaded rod. Do you have a shroud of sorts to cover the terminations?  What's it weigh?

Thanks for sharing.  Very impressive

~kitestrings

[fabricator]

FAb,

Again, the guy with a thousand questions. What size is your shop if I may ask? I have a 24'x40 foot pole shed that I am thinking of converting to a machine shop. It has a gravel floor, 14' ceilings, so I could put in an insulated slab, build an insulated shell and avoid some of the costs and associated RE taxes with a new building.

I have the usual stuff, Bridgeport, drillpress, lathe, die tables for work/welding tables.

I notice you have an overhead lift. It is supported by steel I-beams.

Sorry to give so little and ask so much.


Again, thanks for all your helpful comments and photos.

Dennis

My shop is exactly 24 x 40, the track for the hoist is an I beam that has 3/8" bolts going through the ceiling into every truss the entire length of the shop, the trusses are on 24" centers.
The hoist has a 90 degree long radius turn that goes out into the 48 x 64 pole barn then there is another 90 that goes out to an over head door in the pole barn.

[fabricator]

Fab,

Great looking project. I'd hoped to get back here sooner, but really nice build. Hope it performs as well.

I like the idea of using the solid spacers instead of the more typical threaded rod. Do you have a shroud of sorts to cover the terminations?  What's it weigh?

Thanks for sharing.  Very impressive

~kitestrings

Yep, the terminations will all be covered, it weighs 195 lbs without the blades or hub.

[dloefffler]

Again, from the question king.

Your pictures show holes drilled in the rotor. Did you dynamically balance the assembly?

Very cleve design as others have noted.


Thanks,


Dennis L.

[fabricator]

Yep, you balance each part individually otherwise you could get what's called coupling affect which will make you pull your hair out.

[AERCO]

Very professional design. Can you give me the specifications of the alternator? It looks like a much larger rotor/stator than the standard OtherPower design. I am very interested in larger designs. I have a 1.4 and dual 2.8 design I build routinely. Larger diameters significantly increase the linear velocity and low RPM response. Do you have any test data on the APMA?

AERCO

[fabricator]

It's actually about the same as most otherpower alternators, the rotors are only 11" dia.

[kitestrings]

Fab,

How did you balance the magnet rotors?  ~ks

[midwoud1]

On a wheel balance-machine at the local garage.
The holes in the rotordiscs are often the same as a car hub.
Used the weights that stick on aluminum rims.
- Frans -

[fabricator]

I used two bearings on a shaft and just let the heavy side go down, I kept drilling holes until there was no heavy side, I'd give it a spin and it'll keep stopping at random spots.

[kitestrings]

Fab, Frans,

Thanks for the reponses.  It is good timing for us as we're just completing the magnet rotors on ours.  I was leaning toward using a (dynamic) tire balancer if possible.  Is it better to balance each magnet rotor plate individually or as a pair in their final resting place?

Again terrific work on this one Fab.   I look forward to seeing the completed turbine.  ~ks

[fabricator]

They MUST be balanced individually.