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Building an Excavator from Scratch
Hi,
actually my Mining Dumper is completed for 98 percent and just waiting for spring to get some small details out of my resin printer. But playing only with a dumper is quickly boring. So I need a suitable loading vehicle. After some research I decide to build a tracked excavator. From scratch of course. I don't have any experiences with excavators so the complete project will be a great challenge. First, i would like to say that it will be a fantasy rig, no original, no liebherr, no cat. Just a little big monster with tracks and a bucket on the other end. My goals are learning much about excavators and get a feeling for this, for me, new genre. ----------- All starts with the tracks. Researches show me, that real scale tracks are very expensive. Too expensive for a project whose ending is doubtful. So I've ordered a standard industrial chain with brackets to hold the crawler plates https://blog.rb-fotos.de/wp-content/...r/img_5838.jpg https://blog.rb-fotos.de/wp-content/...r/img_5839.jpg The form isn't flat like the real chains so i've to use a simple trick to prevent the running wheels from hopping. I orderded simple small chain wheels and cut the half of the teeth. https://blog.rb-fotos.de/wp-content/...r/img_6117.jpg So it will be a smooth rolling with the ability to hop over a little stone. The holders of the tracks and their wheels follows 10 blocks of aluminium https://blog.rb-fotos.de/wp-content/...r/img_6147.jpg shaped https://blog.rb-fotos.de/wp-content/...r/img_6151.jpg drilled and provided with bushings and axles https://blog.rb-fotos.de/wp-content/...r/img_6154.jpg mounted on a stainless sheet. (The complete holder will get a optical more suitable hull later.) https://blog.rb-fotos.de/wp-content/...5243be0f24.jpg shortly before christmas i've made a little cardboard model to get a feeling for sizes. the table has 120cm length https://blog.rb-fotos.de/wp-content/...r/img_6160.jpg |
Re: Build an Excavator from Scratch
While waiting for material i've made the hydraulic cylinders
the cylinder are made from seamless, high precision stainless tubes https://blog.rb-fotos.de/wp-content/...r/img_6144.jpg almost ready. just the ports are missing. i don't know the exact positions so far. https://blog.rb-fotos.de/wp-content/...r/img_6258.jpg in the box laying the crawler plates too. drive train is ready for testing https://blog.rb-fotos.de/wp-content/...r/img_6334.jpg first little testrun on the terrace https://blog.rb-fotos.de/wp-content/...01/testrun.m4v The connector between undercarriage and body is done. https://blog.rb-fotos.de/wp-content/...r/img_6366.jpg That is the actual standing of this project. More to come.... ....if anyone is interested |
Re: Build an Excavator from Scratch
I can’t even think as fast as you fabricate/Machine stuff…lol.
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Re: Build an Excavator from Scratch
Must be nice to be able to make machines that are yours instead of paying thousands to someone else to make it. I admire you guys.
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Re: Build an Excavator from Scratch
Wow, that's looking like its going to be great!
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Re: Build an Excavator from Scratch
Finetuning of the crawler plates. 1,5mm between work and crash
https://blog.rb-fotos.de/wp-content/...r/img_6460.jpg https://blog.rb-fotos.de/wp-content/...r/img_6461.jpg 70 times https://blog.rb-fotos.de/wp-content/...r/img_6462.jpg no more collisions https://blog.rb-fotos.de/wp-content/...r/img_6468.jpg last pic: first attempt of the teeth. Not scale, i know. But they will make grip, I hope |
Re: Build an Excavator from Scratch
Today, in an attack of work mania, I've made 140 threads and mounted the crawler plates for th first track.
https://blog.rb-fotos.de/wp-content/...r/img_6472.jpg Now I'm waiting for the next attack for the second track :D |
Re: Build an Excavator from Scratch
The undercarriage gets his stabilizations.
Looks a bit rough, but later invisible. https://blog.rb-fotos.de/wp-content/...r/img_6475.jpg Stable enough, I think (The carriage isn't so small, my feet have size 16 1/2:rolleyes:) https://blog.rb-fotos.de/wp-content/...r/img_6474.jpg After this succesful test, the hull work started https://blog.rb-fotos.de/wp-content/...r/img_6477.jpg https://blog.rb-fotos.de/wp-content/...r/img_6478.jpg |
Re: Build an Excavator from Scratch
Its looking really good so far.
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Re: Build an Excavator from Scratch
Thank you.
For better planning the positions and pipe layout upwards, I need all components for a manual tetris. electronics, pump, valves etc. are already on board. just the oil tank is missing. 500ml volume is needed. Welding is expensive in labor. So i've calculate the seams length of a quader and a cylinder. The cylinder wins with 30cm lead. And here is the building of the oil-tank https://blog.rb-fotos.de/wp-content/...r/img_6479.jpg raised thickness to hold the threads for the nipples https://blog.rb-fotos.de/wp-content/...r/img_6485.jpg the ring welded on one sheet and cutting the excesses https://blog.rb-fotos.de/wp-content/...r/img_6486.jpg https://blog.rb-fotos.de/wp-content/...r/img_6487.jpg testing with water and fixing some micro holes https://blog.rb-fotos.de/wp-content/...r/img_6489.jpg ready for tetris :) https://blog.rb-fotos.de/wp-content/...r/img_6492.jpg |
Re: Build an Excavator from Scratch
Hi,
positioning was easy. I wish, I have so much space in every model :D https://blog.rb-fotos.de/wp-content/...r/img_6498.jpg the sandwich construction of the baseplate prevents a simple fasteting from below. Thereby i've made a socket. https://blog.rb-fotos.de/wp-content/...r/img_6514.jpg ready https://blog.rb-fotos.de/wp-content/...r/img_6518.jpg valves and tank are mounted too https://blog.rb-fotos.de/wp-content/...r/img_6519.jpg |
Re: Build an Excavator from Scratch
Very nice , sorry if i missed it but what is the scale of this excavator ?
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Re: Build an Excavator from Scratch
Quote:
because i've no idea from excavators so far, i've roughly copied the sizes from the liebherr r966 |
Re: Build an Excavator from Scratch
This will be my last post here. too much work for just a few clicks and almost no replys.
Enjoy your hobbies. Bye |
Re: Build an Excavator from Scratch
I am really sorry to hear this.
It would figure I get in here a day to late. I am really enjoying following this build even if it was all here in 1 day. I can only hope we can get you to change your mind about this because I feel I am learning a lot just by following along. I hope to see this completed and in action one day. Best of luck to you, Brian M. :( |
Re: Build an Excavator from Scratch
I'm sorry you feel that way, and that feeling is a large part of why so many forums and message boards become ghost towns.
Your solutions and build techniques are really impressive. I've been watching in awe without having much that would add to the conversation since i don't know much about the machining syde of things. I didn't want to clutter up your builds with too much of the same sounding praise and admiration |
Re: Build an Excavator from Scratch
Same here. I enjoy looking at all the builds and have learned a lot so far, but I often find it hard to comment if I don’t fully understand all the trucking/construction terminology and can’t contribute solutions. Would love to see the end result of this build.
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Re: Build an Excavator from Scratch
I hope you'll change your mind! I've enjoyed watching the progress and your methods which are different from most on here.
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Re: Build an Excavator from Scratch
Thats a shame and i hope also you will change your mind and continue to post progress.
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Re: Build an Excavator from Scratch
Hi,
you've convinced me :D I wonder, why this forum isn't using such simple quick-response buttons as a "like". Its quickly made for you without spamming the thread and a response for the thread opener. thereby the opener hasn't the feeling to write soliloquies. A little sideeffect for me of writing in an english speaking forum is to improve my written english with non-trade-affected terminologies. I'm programmer by trade and the vocabulary of ibm books is restricted :D So I'll try to write more about my thougths why I do something so or not. ---------- Let's go back to the barrel tank. Looks good but it has some imperfections. I've forgotten a oil level indicator and a ventilation. I can add them outside, but a second point is more important. A kind master of hydraulics told me, that with my "big" pump and the small usual hoses I'll ran into problems with cavitation (pitting in the pump). The pump offers a g1/8 thread instead the usual m5 threads. to compare the hose sizes (top down): normal pressure hose id 2,5mm od 4mm normal pressureless hose id 4mm od 6 mm the new pressureless hose id 8mm od 10mm this reduces enormous the flow speed and avoid cavitation. https://blog.rb-fotos.de/wp-content/...r/img_6536.jpg Unfortunately, the hole for a g1/8 thread is bigger than the doublings in the tank. So i've decided to build another tank with all the needed holes and threads. This time a cubic form to get a feeling wich form is easier for me to build. I've not noticed significant differences, thus it will be simple a question of style in the future. The result. oil proofed and mounted. Ready to use. https://blog.rb-fotos.de/wp-content/...img_6575_0.jpg |
Re: Build an Excavator from Scratch
Thank you, I have been reading your posts with much interest!
Kerst |
Re: Build an Excavator from Scratch
I'm glad you changed your mind!
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Re: Build an Excavator from Scratch
Hi,
I haven't been lazy whilst the long break here. A short summary jump to the actual standing: the work on the monobloc has begun https://blog.rb-fotos.de/wp-content/...img_6664-2.jpg an intermediate stand together with a bit of cardbord aided design https://blog.rb-fotos.de/wp-content/...r/img_6678.jpg the monobloc body is ready and bending the hydraulic pipes begins https://blog.rb-fotos.de/wp-content/...r/img_6711.jpg pipebending is done and the first cylinders of the second genereration are done. some issues on the first generations forced my to do so. https://blog.rb-fotos.de/wp-content/...r/img_6804.jpg 30 kg ballast lead arrived https://blog.rb-fotos.de/wp-content/...r/img_6771.jpg a new dimension of metal handling for me: 1,5mm stainless sheets. very stable and very hard for me and my little tools. but at least the first simple bucket is done https://blog.rb-fotos.de/wp-content/...r/img_6902.jpg |
Re: Build an Excavator from Scratch
stick, bucket and bucket mechanic
https://blog.rb-fotos.de/wp-content/...r/img_6903.jpg the very noisy pump gets a leadfilled cover. https://blog.rb-fotos.de/wp-content/...r/img_6966.jpg an overview of the deck with all the hydraulics and electronics. this is the almost final view. only minor changes will happen https://blog.rb-fotos.de/wp-content/...r/img_6967.jpg and then? then there was a very shocking moment. with a thoughtless movement of the superstructure i've pushed a former build from its rest. :jaw: result: a 100% total loss. :mad: https://blog.rb-fotos.de/wp-content/...r/img_6987.jpg the base , a traxxas trx6, ist still useful, maybe a following project. parallel to all these steps i've made some trials and errors to get a reproducible method to build a proper hull. a first success was my first pretty 3d corner https://blog.rb-fotos.de/wp-content/...r/img_7012.jpg today , a big milestone has reached. the drivetrain is done and a first driving lesson occurs. |
Re: Build an Excavator from Scratch
WOW that thing is huge !!!! it will be a monster... nice to see it progressing...
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Re: Build an Excavator from Scratch
At the beginning of my research for an excavator i've found a flyer from liebherr. There was the model 966 noticed as a perfect fit for 30 tons dumpers. My dumper is a 30 tons one. Thereby the 966 became my model for principal sizes.
Later I was surprised too that you need a monstrous excavator to load a small dumper :D ------ Todays work were the operators gangways. https://blog.rb-fotos.de/wp-content/...r/img_7099.jpg https://blog.rb-fotos.de/wp-content/...r/img_7100.jpg https://blog.rb-fotos.de/wp-content/...r/img_7102.jpg |
Re: Build an Excavator from Scratch
Very nice pipe work. What is your method for bending without kinking them?
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Re: Build an Excavator from Scratch
Looks like a lot of progress! Shaping up into a very impressive machine
Was the totaled truck something like an Airport Fire engine, or a Trial Truck? Atleast the ejector seat worked. |
Re: Build an Excavator from Scratch
AWESOME project!
This thing should be a beast of a machine once completed! |
Re: Build an Excavator from Scratch
Quote:
with the enclosed examples you are quickly enabled to make reproducable multi-angle bendings. Quote:
"ejector seat" :D:D Quote:
---------- After a short vacation I've save up enough point on my patience account to begin with the last two hydraulic cylinders. Patience is needed because me and turning internal threads are not friends. fortunately, this time it works at the first attempt and some other parts are build too. Pistons and guide rings from brass, rod and cylinder from stainless and the cylinderhead is from aluminium. (nothing to weld on the head and very easy to turn) https://blog.rb-fotos.de/wp-content/...r/img_7129.jpg The head is the most complicated part. Internal thread and a recess for the guide ring on the inner side. thereby the guide ring is oil lubricated. https://blog.rb-fotos.de/wp-content/...r/img_7128.jpg On the outside are three grooves for o-ring sealings. https://blog.rb-fotos.de/wp-content/...r/img_7127.jpg Threads will be sealed with loctite 542. |
Re: Build an Excavator from Scratch
Todays work: The completion of the stick cylinder.
After applying the orings i've prefilled the cylinder with oil https://blog.rb-fotos.de/wp-content/...r/img_7133.jpg The thread was filled with loctite https://blog.rb-fotos.de/wp-content/...r/img_7134.jpg after 4 hours the glue isn't 100% but for a first little test tight enough but before, i've made a hose-guard from 5x0,3 stainless for the hose to the front https://blog.rb-fotos.de/wp-content/...r/img_7137.jpg the last cylinder for the bucket is prefilled too and can't wait to mount him https://blog.rb-fotos.de/wp-content/...r/img_7138.jpg The cylinder and stick in action you can see in this little clip (self hosted) https://blog.rb-fotos.de/wp-content/...es-stick-1.m4v (moving from the nineth second on) |
Re: Build an Excavator from Scratch
man very nice and smooth
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Re: Build an Excavator from Scratch
Great job with them cylinders!
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Re: Build an Excavator from Scratch
thank you guys.
the temporarely used threaded rods will be switched into much more stylish bolts with circlips. https://blog.rb-fotos.de/wp-content/...r/img_7160.jpg https://blog.rb-fotos.de/wp-content/...r/img_7162.jpg And the driver makes a visit. A good thing to see the dimensions of this rig. https://blog.rb-fotos.de/wp-content/...r/img_7159.jpg https://blog.rb-fotos.de/wp-content/...r/img_7158.jpg https://blog.rb-fotos.de/wp-content/...r/img_7161.jpg |
Re: Build an Excavator from Scratch
After six months of almost daily work at this project, all mechanical todos are done :bounce:
Parking position https://blog.rb-fotos.de/wp-content/...r/img_7173.jpg max Height over ground approx. 130 cm https://blog.rb-fotos.de/wp-content/...r/img_7175.jpg max Depth ca. 100 cm https://blog.rb-fotos.de/wp-content/...r/img_7177.jpg Next big steps are learning to operate it and building the hull and the cabin and 347586 other little things. |
Re: Build an Excavator from Scratch
Great work on the project to date Ralf, well done :cool:
What is the ground level reach? Learning to operate it, I would suggest getting a big bag of rice or pellet dog food & a couple of cardboard boxes, transfer from one box to the other & back again inside the comfort of your house daily. :D |
Re: Build an Excavator from Scratch
Thank you. Thats a good Idea, but too late.
The first loading of my Dumper happens in my garden . https://blog.rb-fotos.de/wp-content/...tbuddeling.m4v some issues found but nothing worse (i hope :D ) Have a nice easter weekend |
Re: Build an Excavator from Scratch
Watching your dig video, perhaps if you lowered your EPAs of swing & valves then your movements wouldn't be so quick & twitchy. Takes more radio stick throw to make something happen making far less sensitive.
Also, with your hyd motor running continually at a very low speed, as low as possible so the motor doesn't chatter trying to run & using valve mix to speed up movement helps to smooth out movement too. And it helps keep your pump motor esc from over heating too from additional stall current start ups. |
Re: Build an Excavator from Scratch
Thanks for the advices, Joe. I appreciate them and will give them a try at the next dig.
But due to a complete disassembling of the excavator this will take some time. Disassembling for fixing issues , improvement and so on. Til waiting for easter brunch with the family I've made the cables for the working lights on the monobloc. Simple wires are bending in very unpredictable ways. To tame them I've used a simple but effective method. Whilst the hole procedure take care that the wires laying flat side by side. Two single wires are bound with a very thin stainless wire https://blog.rb-fotos.de/wp-content/...r/img_7214.jpg This thing pulled through a heat shrink tube. https://blog.rb-fotos.de/wp-content/...r/img_7207.jpg After shrinking the wires get more stiffer and bends reproducable nice way https://blog.rb-fotos.de/wp-content/...r/img_7217.png |
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