Re: Great Dane excavating co.
 

http://i1357.photobucket.com/albums/...ps1dcrl8ct.jpg

This is the cylinder I had made for the dump project, just to show size,

http://i1357.photobucket.com/albums/...psejsuedn9.jpg

One of the 4200 cylinder side by side. Same .75 od with same .315 rod. (Standardmetric ruler :)). 4200 has id of .635, that equates to more hydraulic pressure but I think 80 pounds will be plenty with the .5 id of the brass rod I have. I purchase the rod already. I tried to drill/lathe out but it's me or my machine, I can't get precise results on the longer cylinders.

Re: Great Dane excavating co.
 

Sweet! I think the air line that I use is rated for 300psi and the burst strength is 1200psi. I run around 435psi in my excavator and have never had a hose blow.

Re: Great Dane excavating co.
 

Very nice Coop, I think you made the right decision. These excavators , in my opinion, are kinda nice the way they come stock, but the scale of the cab is really off. Really think you are doing it the right way and I need to remember this thread when I go about my transformation on my 4200 some day.

Oh, I like that you are making it a Cat, Joe Idea is good for the 345 series.

David

Re: Great Dane excavating co.
 

Ok it's done 345 it will be :). Or close to resembling one , logo and number :).

http://i1357.photobucket.com/albums/...psyizxy9ka.jpg

Last night I got most of the wiring done. I put bullet connectors on most everything. I hope to make enough room that I can have those two 3s batteries in there, more weight at back and 10amps to play for a while. I wish I could find a controller like saber tooth for brushless motors. I could then mod the radio with an xbox joystick for track drives.

Re: Great Dane excavating co.
 

Had some time before it got dark to formally test the dumptruck.

http://youtu.be/ZVABVUYxeqQ

And did a little off roading, it had rained early in morning so dirt was wet but not muddy. The camera doesn't really show but it was a pretty decent incline for her to walk up. And then just had to use the front bumper for a plow in the piles:)

http://youtu.be/rDs9KJvIA7s

Re: Great Dane excavating co.
 

Love the dump truck Coop. looks like a great job site workhorse for all seasons.:D

I also wondered what Cat model to repaint my 4200. Based on undercarriage width of 10" that does suit a 345. Adding to the upper structure will definitely add to the 345 look.

For me, I'm going with a 330B. I've worked on so many of them years ago, only seems appropriate I have one at home to work on again. :D :lol:

Re: Great Dane excavating co.
 

And just an idea of undercarriage speed. I have it set to 45% and brakes too.
http://youtu.be/fq0uvQuRmuc

Re: Great Dane excavating co.
 

Thanks Mario, I never get to run the big stuff, usually mini exes and skidsteer. I think if I can get the cab scaled down and a bigger exhaust cover that will help the scale look. Like I said before if I mess it all up the logos and numbers will be good enough for scale :). Lol!! I would love to put better hydraulic pump and valves in but cost is making me think. Oh maybe Santa can read this :lol:

Re: Great Dane excavating co.
 

The undercarriage would be a great deal of work to reproduced in steel, but seeings how you're re-doing the house anyway, why not do it all from scratch with plate steel to get your weight up? No point going big power on hydraulics if it aint gonna stay planted.

You could mill down each center grouser bar of each pad a few mm so it grabs the ground better too.

Re: Great Dane excavating co.
 

I'll look I to that joe, more weight would be good. And if it's possible to mill the middle groused out and keep tracks together I may do that. There should be more spacing between shoes also. Wouldn't bind as much. I just don't want to have to remove and install all those roll pins :(.

Between shoveling and plowing I got a good window seat today:)
http://i1357.photobucket.com/albums/...pslwrvhqyx.jpg

Re: Great Dane excavating co.
 

Between sporadic work calls and thanksgiving I got some more done, I'll just post the pics. Hope you guys like pics, I always like to see what others do :)
http://i1357.photobucket.com/albums/...psdl8aprsj.jpg
http://i1357.photobucket.com/albums/...psj0gvofwe.jpg
http://i1357.photobucket.com/albums/...psnuuo012c.jpg
http://i1357.photobucket.com/albums/...psw5t4i46g.jpg
http://i1357.photobucket.com/albums/...psauls805p.jpg

Re: Great Dane excavating co.
 

http://i1357.photobucket.com/albums/...psahtwezpk.jpg
http://i1357.photobucket.com/albums/...psuodducky.jpg

Made this up so I could get precise 180 degree cuts, I had this collets and never use them, use r8 now. And don't want to switch to ER collets.

http://i1357.photobucket.com/albums/...ps9mhqv03i.jpg
http://i1357.photobucket.com/albums/...pswdnlnk2n.jpg


Soldered ends on temporarily to mill ends
http://i1357.photobucket.com/albums/...psli14fwfx.jpg
http://i1357.photobucket.com/albums/...psruoqeua4.jpg
http://i1357.photobucket.com/albums/...psemrsds0f.jpg

Reusing the ball ends, saves a lot of work turning those little ends!!
http://i1357.photobucket.com/albums/...psmmoqwohq.jpg

http://i1357.photobucket.com/albums/...psu2jj4pp8.jpg
http://i1357.photobucket.com/albums/...pslzk8fitj.jpg

Now on to the hard lines and trashing a lot of wrong bends!!! (Hopefully not but pretty sure:(). Some thing I've learned along way, I'm using stainless (forget the number ) but got the easy machinable stuff and wow it's like easy to cut!! Got new industrial (not hobby grade ) taps and cutting oil. It really makes a difference on this stainless. I always cringed when I had to work with stainless, work hardening and just tuff on my tooling. Now that I got correct stuff and tightened up the lathe it really isn't as difficult to work as I had experienced before. Yup I'm capable of learning!!! Lol!!! Now I have to drill and tap a bunch of 2-56 holes for the cylinder hardware. I use to use rotary table but for anyone fairly new to machining purchase a dro unit!! I don't know how I could do without!! Oh and took the time to get precise numbers on loading the seals and clearances on cylinder/rod. Have been exact down to .0005+\- on seals and .001+\- on length of cylinder/rods/pistons. So hopefully some long life before any leaks and not too much resistance on hydraulics.

Re: Great Dane excavating co.
 

I didn't forget, something like this stuff? It gives me some more ideas of making printed parts :bounce:

http://i1357.photobucket.com/albums/...pswcpvl8d5.jpg

Thanks Neil!

Re: Great Dane excavating co.
 

Many great pics of the process RW, thanx for taking the time to post them. :cool:

Re: Great Dane excavating co.
 

Yah, that stuff!
Cheers!

Re: Great Dane excavating co.
 

No problem, hope some might give some insight into the processes. And for those that are machinists, if you see something wrong or easier please tell :)

Well spent the better part of my toy time making parts to make tools to make parts:(.
First I had to make a cutter for 5/16 tubing die
http://i1357.photobucket.com/albums/...psydn9stmv.jpg

Then had to turn out a couple 5/16 dies, 3/4", 1" and a 1/2". And this is what I came up with to get those impossible tight bends in tubing (and making them look good).
http://i1357.photobucket.com/albums/...ps5ufkbtqc.jpg

That's the 3/4" bend. I don't know if I'll need a tighter bend.

Re: Great Dane excavating co.
 

Did you use heat to bend it or just bend it?

Re: Great Dane excavating co.
 

I did take the hand torch to it before bending. And let it cool then a bit of oil on the roller and bent to shape. The brass will re temper over time, not by a quench. Now if I can make some measure marks and degree lines I'll be in great shape!!

Re: Great Dane excavating co.
 

http://i1357.photobucket.com/albums/...ps3vqkdida.jpg
http://i1357.photobucket.com/albums/...psrnwiuv9x.jpg

Made some boom support for the stick like the cats have, drilled-bolted together to keep symmetry.

http://i1357.photobucket.com/albums/...ps8ikmz6vs.jpg
And that Crome ball in the vise is from my wedding, the name cards were in the slit for on the tables. They are hard steel and have a flat bottom. Perfect for irregular shapes in the vise :)

http://i1357.photobucket.com/albums/...psssjtnlfu.jpg
http://i1357.photobucket.com/albums/...psmveb7ufd.jpg
http://i1357.photobucket.com/albums/...psuijx25ud.jpg

I wanted to take apart the boom and stick but the hardware is seized. Heated and pounded but a few will not move, stripped the heads so it's being worked on as one piece.

Re: Great Dane excavating co.
 

http://i1357.photobucket.com/albums/...ps2ct5nwcn.jpg
Replacing all the pivot parts and installing bushings and stainless shafts. Also trying to reinforce the arm but keeping it simple.

http://i1357.photobucket.com/albums/...psnyqbaxvj.jpg
http://i1357.photobucket.com/albums/...psnu2azy8n.jpg

Once everything is together and ready for paint most of the hardware is going to be filled over and sanded smooth. I figure I can't take it apart and if I had a tig it would have been welded anyway.
http://i1357.photobucket.com/albums/...pst1roqckj.jpg
http://i1357.photobucket.com/albums/...psztofixnx.jpg
http://i1357.photobucket.com/albums/...pswvhggvgw.jpg

Re: Great Dane excavating co.
 

Nice machining, those cylinders look great!
Your right about the DRO, I wouldn't be without mine on the mill, I've fitted one to the lathe too.

Re: Great Dane excavating co.
 

Thanks Stuart, I would like to say I got them down but still finding ways to make um better.

This is my heat shield to prevent caps from coming loose. Probably didn't need it as a lot of room between heating area and caps but I would be cussing for a while if not. :).
http://i1357.photobucket.com/albums/...psa94wzmem.jpg

And after some clean up the joint is barely visible. Even though it's getting yellow or black paint I was happy with it.
http://i1357.photobucket.com/albums/...pstufzt3qr.jpg
http://i1357.photobucket.com/albums/...ps73f14zvr.jpg


My honing and polishing station
http://i1357.photobucket.com/albums/...psrv8xgqns.jpg
http://i1357.photobucket.com/albums/...psfrodniq9.jpg
http://i1357.photobucket.com/albums/...psns7wdnli.jpg

Using stainless for the shafts, it actually looks more polished than pics show.

Re: Great Dane excavating co.
 

Man that looks purdy! Have you tried using drill rod for the shafts?

Re: Great Dane excavating co.
 

Nice work!
Did you solder them together or did you braze them?

Kerst

Re: Great Dane excavating co.
 

Silver solder on those parts and then just reg solder (lower melting temp) on the tubes and hardware. I think next cylinders I make I will braze those and solder the smaller stuff.

Re: Great Dane excavating co.
 

Never thought of drill rod. I know the tolerances are a lot more exact than the stainless I use but for these I think it's fine. And that tool steel might be more of a pita for me to work :). Although I need to get some to make shafts for prop balancers. (Center ground on ends but I will get a chance to machine that stuff).

Re: Great Dane excavating co.
 

All my hydraulic cylinder's shafts are made with drill rod. For tool steel it actually machines very well. It even threads really nice. That's not to say that there is anything wrong with what you are doing at all. Just another option.... I have found out that it does weird things after you have welded it though. It seems that it becomes very brittle after turning red:eek:.

Re: Great Dane excavating co.
 

Which grade are you using RCP? Could be overheating? Or the part is possibly cooling too quickly? I ran into that during my welding class at school (in the dead of winter) would weld a part and put it on my hand carry toolbox to cool in a different room, come back and there's some flaw... took me a minute to realize it was my routine not my welding causing the problem.

Other than that, Cooper very impressive work! Keep it up :D

Re: Great Dane excavating co.
 

Well if it machines not too bad then I will use that for next project. I did look into McMaster and the different tool steels, easy to machine.

Like I said before I can't take the boom apart cuz of seized screws (without a lot more work). I was using the 6mm shaft for centering the part on the table. That way I could make sure both top n bottom were lined up.
http://i1357.photobucket.com/albums/...psky8qck3w.jpg

And bushings, bushings, bushings. Also used them for a bit of spacer.
http://i1357.photobucket.com/albums/...psmxsafqk6.jpg
http://i1357.photobucket.com/albums/...pstkqxkfzd.jpg
http://i1357.photobucket.com/albums/...psxpujgiv6.jpg

And made this up, some added support for end of stick where bucket connects. I do want to add weight to the machine but not to the arm, rather like joes idea of plate steel on frame. Somehow I'll bulk her up :).
http://i1357.photobucket.com/albums/...psud5k3bzz.jpg

Re: Great Dane excavating co.
 

The drill rod could be in it's tempered form ( not heat treated ) .

Re: Great Dane excavating co.
 

I'm not sure what grade the drill rod I have been using is. The local metal supplier only has one kind so I just get what they have(blue paint on one end). I know that I overheated the piece I was referring to. I welded a very small piece to a big piece and then tapped it with a hammer to straighten it. It broke right off but not at the weld. Anyway, I went back to using mild steel for those parts because it's much cheaper and I save the drill rod for the important parts!lol

Sorry for taking your thread off topic RW. You're doing a great job on the excavator rebuild. By the time you are done it will be a whole new machine!

Re: Great Dane excavating co.
 

Never off topic at this company:). I have realized lately that using the right tool and materials make a difference. I got spring steel before unheat-treated and it was like butter. Then torched it to harden and it got its properties back. Just have to have the knowledge, I may be slow,,,,, but can still learn :). Lol. Yes the 4200 transformation into a 345d cat is getting extensive. I'm not sure how the details will end up but the structure and functionality are what I'm aiming for. I'm not going to mess with the swing gear assembly, just get right mesh and everything tightened up. Although,, I may look into a more robust gear head???? And possibly a touch faster swing.

Re: Great Dane excavating co.
 

So I should be done bushwacking!! I tried to keep bushings sticking out a touch. All have been undersized boared and pressed in. Then .001 oversized reamed for shafts to operate smooth from the start.
http://i1357.photobucket.com/albums/...psjcozvpuc.jpg
http://i1357.photobucket.com/albums/...pseiup28gk.jpg

Now to start on hard lines or new bucket. Any areas you guys think need some tlc?

Re: Great Dane excavating co.
 

And again had to make parts to make parts :).
http://i1357.photobucket.com/albums/...pshhdayoib.jpg
http://i1357.photobucket.com/albums/...psvbjyc8ky.jpg

Re: Great Dane excavating co.
 

Don't you mean "buckets"?

Re: Great Dane excavating co.
 

Humm,, lol,, I'm thinking of that, don't know how much work it will be making one. I'm not a fan of the thin metal work :). But once one is made, well might be two, then a claw, then a sifter and ,,,,,, oh where does it end? I have to find that thread someone had with an electronic quick connect. I do want to somehow put a dremell blade on the end and use it as a makeshift harvester for a lot of saplings growing under the deck. :)

Re: Great Dane excavating co.
 

http://i1357.photobucket.com/albums/...psxrm4ay2v.jpg

Just dropped this off at home, another project that will never be completely finished :). A conveyor and/or screening plant

Re: Great Dane excavating co.
 

Oh this is just great! Another hoarder like me! Misery loves company!:D There's a special place in heaven for our wives....:rolleyes:

Re: Great Dane excavating co.
 

Ha!! Lol!!! About peed pants!! Ya know, I've been into a lot of different stuff, ski racing, motorcycles, boats, rc stuff,, and pretty sure I've finally found my home that I've been unwittingly searching for!!! I've always love this stuff but never had the been or ability to get into it. I work for myself, small family business and my dad has a barn and several outbuildings. It's pretty safe to say if there is room there is something to put in it. Fittings, wood, metal, broken stuff, it all gets carefully thrown into some pile :). I'm pretty sure I could tell anyone where anything is and what shape it's in. It's a very well kept property from the road but inside the barn (non working farm) it's my ,and your paradise !!! And reason I say this is home is I've noticed that just about all of ya can see the potential in something like an old microwave turn table mechanism. :lol:

Yea, I told the wife when she happen to stop by when I was unloading the latest treasure that my mom had this old treadmill that she wanted me to take a look at, as it didn't work. Kinda funny as she immediately replied " why, that junk doesn't work and she already has one,,,,,,oh ,,, no,,, wait a minuet, did she ask you to fix it or toss it??" Then the fun deceitful creativity took over, hope she doesn't talk to her about me "fixing" the old treadmill!!! It will be in pieces and neatly stowed waiting to become another backyard landscape feature that will only improve property value:).

Re: Great Dane excavating co.
 

Haha! The one I have came from my wife's parents. It still worked but they didn't use it anymore as they have taken up running and swimming. I found out that it was going to the scrap yard so I told them I needed it! My wife and mother in-law gave me a weird look(the same look your wife gave you) as my father in-law and I quickly proceeded to go down stairs and prepare it for "transport". It is stowed in a canvas car shelter just waiting for the day that I decide I need a conveyor that's 6' long.lol I prefer to call myself a "re-purposer"(not a real word) rather than a hoarder. There isn't much that I don't see potential in.... It's how I was raised so I guess that explains why my shop is cluttered with "stuff" from one end to the other:cool:.