Atempting some Zub-Woofers?

[Jerry]

I thought I'd try my hand at the famos Zub-Woofer pipe blades.

My problem was trying to cut a straigt line down the lingth of the pipe.

So I built a box of scrap wood that fits tighly around the pipe. Then I deturmind the center of the box and cut the box and the pipe together.

Heres the box and the 6" pipe befor the pipe went into the box.

Next the pipe is in the box.

Now the box is marked for cutting although I used the saws fence to set center.

Here I clamped the pipe to the box so it could not move and scew my straight line.

This shows how the saw blade will line up and miss the clamps.

After the cut I secured the cut opening with a scrap of plywood.

Here are the 4 slices of pipe after the ruff cut.

After the ruff cut I trued the blades to each other by 1 more  pass on the table saw using the fence guid.

Here I'm seting the root to tip tapper angle.

Here is a smaller version I did last week. I did this one free hand. I want this next group to come out more even and matched.

I hope to build the triangle wooden hub this comming week? The root angle looks real good and the tip is allmost flat. Good cup and twist on the blade.  I'm shooting for 48"s tip to tip.

                      JK TAS Jerry

[Countryboy]

Hi Jerry,

  It's looking good so far.

I took a piece of large packing paper and drew the outline of the blade on the paper.  I cut out the paper blade with scissors, and then used that as a pattern template when I made my blades.  By using the same pattern template for every blade, it helped to insure all the blades were consistent with each other.

[hiker]

   

    nice work jerry..

    are those going on your new alt?..kinda courious to see the diffrent power outputs

    on the two stators.[stock - vs - jerryrigged]

[coldspot]

Jerry-

looks more like "jerry's blades" than zub-woofers.

lol

zw's  are just a single piece and work ok to a point.

Your very good with the band saw by the way.

Have you tried anything else on your hub?

Whats the shaft hole size on it?

[wooferhound]

Well

Those are just PVC Blades

ZubWoofers are a single piece design

[kenputer]

Hi Jerry,

  I have made a few of those blades and find that a piece of angle iron layed on the pipe will help get you straight lines and also use the saw blade turned around and spinning backwards as a better way to cut pvc.

For a stronger blade I wrapped the pipe with mylar and few layers of fiberglass cloth and resin around a length of pipe let it set up and the cut my blades out and with a little sanding on the edges they came out good and strong not much flex in them.

Ken

[Slingshot]

That's an interesting idea, turning the blade backwards.  What tooth blade is it, or does this matter?

[tecker]

A good way to get a straight line on round stock is with steel angle or channel that's good sized .

[pepa]

hi ken, please use blades without carbide tips for this application as the carbide teeth tips have a habbit of coming off when worked backward and it takes major surgury to remove them from different parts of the body. i've been there, pepa

[Jerry]

Thanks Country Boy.

That sounds like a good plan.

                          JK TAS Jerry

[Jerry]

Hi coldspot.

Never had a band saw wish I did. I cut this on a table saw. I'll be using a wood hub on this one.

I'm not sure what the root angle will be? My 1/4" steel hub I use on the "Jerry Blades" is 23 degrees at the root.

Here is a picture of a simular blade I made 3 years ago. I've been flying this on an Ametek since then. works real well.

                     JK TAS Jerry

[Jerry]

Hi Hiker.

Yes. I'll be making a compairison with 3 diferant type of 4FT blades on the same alt.

This will requier my same quiky wind tunnel I used last time.

                           JK TAS Jerry

[Jerry]

I used carbid tip blade in the normal cutting direction. This pipe matireal is 5/16" thick and cut real smooth without chipping.

                              JK TAS Jerry

[Norm]

   Well I just used a chalk line to mark the

straight cuts and used a hand saw then a paper

template for the curved tips and a sabersaw...

a utility knife to scrape and round the edges..

amazing how smooth you can get the edges this

way....

      ( :>) Norm

[kenputer]

I just use a rough cut blade,learned the trick from vinyl siding installer.

[coldspot]

OOP's,

Was remembering when I made some, used a band saw.

Wish it had a nice fence type set-up like table saws can have.

Anyway, what about the shaft hole size in your hub??

[cyplesma]

I use the angle iron for the straight cuts, I use a sewing measuring tape to put some dots on the pipe where I want angles to start and stop and then drawing a line using the sewing measuring tape as a guide.

maybe want I call a sewing measuring tape is also called a taylor's measuring tape. I bought my wife a couple of them a few years back, and I'm just borrowing one.

Some tools you can never do with just one.

[Jerry]

Hi coldspot.

At this point i can make any shaft hole size. Lattley I've been useing 3/4" shaft size.

                      JK TAS Jerry

[Jerry]

I think this might be diferant pipe then whats normaly used.

The brand is PWPipe it 6" and it says on the pipe IPS Sch. 40 Series COEX-CELLULAR CORE PVC-DWV PIPE. I'm not shouting this is capitolized on the pipe.

Its thick 5/16" and seams very strong. The foam center does look diferant the skin layers.

                     JK TAS Jerry

[nothing to lose]

Your blades look amazingly the same as what I been making and selling on Ebay.

 20" blades in a 3 blade set.  I geuss last of November was last I made any, been busy with other stuff and holidays, but getting back into them soon.

Your pictures are much better than mine, but that last picture of yours in the first post almost looks like one of mine laying there.