Re: Build an Excavator from Scratch
 

Several times before, in some other projects, I've wished to be able to build my own little louvers.
A previous attempt to make a punch and die works but has imperfections to build a even row of identical louvers.

Today i've started another attempt.
the groove for the die was made with a radius mill and cut off one side.
A sharp cutting edge was added.

https://blog.rb-fotos.de/wp-content/...r/img_7218.jpg

The die mounted on a piece of wood together with a stop and a ratched grip

https://blog.rb-fotos.de/wp-content/...r/img_7219.jpg

with a quadrant milling cutter i've made the punch.

https://blog.rb-fotos.de/wp-content/...r/img_7220.jpg

the punch guide
https://blog.rb-fotos.de/wp-content/...r/img_7221.jpg

all together clamped an read for the next louver

you can use a hammer or a press.

https://blog.rb-fotos.de/wp-content/...r/img_7223.jpg

the result. I'm happy with it and look forward to make some of them for the hull of the excavator.

https://blog.rb-fotos.de/wp-content/...r/img_7224.jpg

Re: Build an Excavator from Scratch
 

WOW that took a lot of work but excellent results...

Re: Build an Excavator from Scratch
 

Very nice piece of work there. May just have to copy that. Thanks for sharing.

Re: Build an Excavator from Scratch
 

That louver punch is wild, they look great!
How do you register alignment between the base and punch holder?

Re: Build an Excavator from Scratch
 

I've faced both parts sides together on the mill. Thereby they are absolutely even and a optical alignment was exact enough.

Re: Build an Excavator from Scratch
 

A medium issue I've found was the unwanted contact between the superstructure and the undercarriage regardless all the ball-bearings.
https://blog.rb-fotos.de/wp-content/...r/img_7276.jpg

So i've added another dedicated flat bearing from igus. called "iglidur"
A .5mm thick plastic, easily cutable with a sciccor.
Glued direct onto the stainless steel with a combination of loctite 770 and 401.

https://blog.rb-fotos.de/wp-content/...r/img_7282.jpg

After deburring and polishing the sprocket a first test

https://blog.rb-fotos.de/wp-content/...r/img_7277.jpg

Then the optical improvement of the undercarriage begins

The front inner View is now this

https://blog.rb-fotos.de/wp-content/...r/img_7266.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7267.jpg

And the side view before

https://blog.rb-fotos.de/wp-content/...r/img_7302.jpg

and after the improvement

https://blog.rb-fotos.de/wp-content/...r/img_7301.jpg

Re: Build an Excavator from Scratch
 

Second side panel is done.
https://blog.rb-fotos.de/wp-content/...r/img_7309.jpg

the first inner rear cover too
https://blog.rb-fotos.de/wp-content/...r/img_7310.jpg

a bit bored by all the cutting and bending I need a bit alternation. so i've milled the teeth for the bucket.

https://blog.rb-fotos.de/wp-content/...img_7332-2.jpg

https://blog.rb-fotos.de/wp-content/...img_7333-2.jpg

Re: Build an Excavator from Scratch
 

Making the working lights. Modern squared style. 15x15x8mm.
each includes 8 smd leds.

.3 mm stainless steel.

https://blog.rb-fotos.de/wp-content/...r/img_7337.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7338.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7339.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7341.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7342.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7343.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7344.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7345.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7351.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7352.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7349.jpg

Re: Build an Excavator from Scratch
 

the stick need some reinforcements.

copying the shapes
https://blog.rb-fotos.de/wp-content/...r/img_7380.jpg

apply to 1mm stainless
https://blog.rb-fotos.de/wp-content/...r/img_7381.jpg

saw
https://blog.rb-fotos.de/wp-content/...r/img_7382.jpg

sawed
https://blog.rb-fotos.de/wp-content/...r/img_7383.jpg

after welding these points
https://blog.rb-fotos.de/wp-content/...r/img_7385.jpg

turned into this
https://blog.rb-fotos.de/wp-content/...r/img_7386.jpg

with this little tool
https://blog.rb-fotos.de/wp-content/...r/img_7384.jpg

stick is finally finished and ready to use
https://blog.rb-fotos.de/wp-content/...r/img_7387.jpg

Re: Build an Excavator from Scratch
 

These parts are looking great, and it looks like you'll have a bulletproof model when its done.

Re: Build an Excavator from Scratch
 

bulletroof? i hope so :)

-----

the bucket links are done in a really quick and dirty way. they work but are very wobbly and a good portion of the hydraulic power goes not in the correct direction.

https://blog.rb-fotos.de/wp-content/...r/img_7393.jpg

for a proper working they need more guidance.
Therefor i've turned some brass washers 10x15x1mm

https://blog.rb-fotos.de/wp-content/...r/img_7397.jpg

and fitting bolts and screws . ( sorry no pic)

every joint is now backlash free and covered with brass bearings.

https://blog.rb-fotos.de/wp-content/...r/img_7398.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7400.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7401.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7402.jpg

Re: Build an Excavator from Scratch
 

finishing the parts was much more work than expected.
improvements, making more finger friendly, welding all the lines complete and not just some points.
and at least put a brushed surface on it.

https://blog.rb-fotos.de/wp-content/...r/img_7419.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7420.jpg

Re: Build an Excavator from Scratch
 

I was going to ask how you were cutting your parts, then I saw your saw. You've got some fairly tight curves that you appear to be cutting. What are you using for a blade on that saw?

Don

Re: Build an Excavator from Scratch
 

Hi Don,

the saw is a Proxxon MBS 240/E and the blade a proxxon 28 172 for stainless steel.

The shown curves are the limit for this blade. Narrower curves are possible only with little steps side by side.

Re: Build an Excavator from Scratch
 

This is looking great. The beauty panels pulled it all together so well. The metalwork shows your high standards.

The hard pipes on the boom are a great detail.

Re: Build an Excavator from Scratch
 

thank you.

Next thing to improve is the motor mount of the rotary drive.

first attempt. principally working but too weak for the complete weight of the upper construct.
https://blog.rb-fotos.de/wp-content/...r/img_7422.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7423.jpg

The motor is strong enough, so i need just a better adjustment technic and a more stable mount.

First part is the combined clamping and movement thing

a plan
https://blog.rb-fotos.de/wp-content/...r/img_7424.jpg

and the real thing
https://blog.rb-fotos.de/wp-content/...r/img_7426.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7427.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7428.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7429.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7425.jpg

more to come....

Re: Build an Excavator from Scratch
 

the wedge bar is done. cutted from a stainless steel bar.

https://blog.rb-fotos.de/wp-content/...r/img_7442.jpg

fits well


https://blog.rb-fotos.de/wp-content/...r/img_7441.jpg

Re: Build an Excavator from Scratch
 

Still working on the rotary drive.
Today the outer clamps and their flanges to the platform were built.

Befroe that, the old flanges have to remove from the platform. i've used the little 35 mm cuttings discs from proxxon.

https://blog.rb-fotos.de/wp-content/...r/img_7445.jpg

The outer clamps get some recesses for the weldable flanges with m4 threads.

https://blog.rb-fotos.de/wp-content/...r/img_7446.jpg

After this a first setup of the mechanism happens

https://blog.rb-fotos.de/wp-content/...r/img_7447.jpg

https://blog.rb-fotos.de/wp-content/...r/img_7448.jpg

works fine but needs some more details before completed....

Re: Build an Excavator from Scratch
 

Last part of the rotary drive.

clamp screws with stainless bolts to avoid damaged threads
https://blog.rb-fotos.de/wp-content/...r/img_7456.jpg

adjustment with a simple block on the maximum position and an offset of 1/10 mm with a feeler gauge
https://blog.rb-fotos.de/wp-content/...r/img_7461.jpg

clamps very well, no more wobble even if i simulate lateral forces like when the bucket is digging
https://blog.rb-fotos.de/wp-content/...r/img_7458.jpg

Re: Build an Excavator from Scratch
 

The work on the cabin begins.

Some angle-guides...
https://blog.rb-fotos.de/wp-content/...r/img_7472.jpg

for this little micro belt sander,...
https://blog.rb-fotos.de/wp-content/...r/img_7473.jpg

together with a 90