Build an Excavator from Scratch

[frizzen]

Nice machining! That slew motor clamp with dovetailed adjustment is really slick!

I'm not sure if adjusting your feed speeds for the material might help with edges on breakout, or if i'm just used to seeing parts after a deburr tool has done a little chamfer.

The micro bench sander could be its own write up over in the Tools section.

[pufferfish]

thanks frizzen.

my last post looks a bit breaked. I'm sure i've wrote it much longer.
Anyway. edit: I've found that the degree character has broken the post. so i'll ignore it from now on

together with a 90 degree guide for the lever sheare


and a parallel guide for the press break


i'm able to made reproducable cuts


and after bending


more cuts




i'm able to make exact angles with 7mm length


after solving a puzzle the frame of the cabin is done

[pufferfish]

some impression from the cabin






The stick are display holders

[pufferfish]

cabins upper guard

3mm stainless rods


welding setup







operators joystick.

freehand cutted from some stock aluminium using a ball vise and a foredom hanging motor.



looks similar enough as little details on the chair.

[ddmckee54]

I think you've already told us, but what do you use for a welder?

[pufferfish]

Originally Posted by ddmckee54

I think you've already told us, but what do you use for a welder?

Its called lampert m280. Pulsed tig. Very expensive but extremly useful foe this kind of hobby.

[Zabco]

Very nice craftsmanship. Really like your 'whittled out' control handle.

[pufferfish]

thank you, zabco.

----
The cabin gets a bit more interieur and a fire extinguisher.
All windows are in and the cabin is installed on the under construction.






The complete ensemble is dismountable in seconds to reach on the ballast sections.


The cabin is done

[Tgrzes]

I really am amazed at how quickly you complete all this fabrication! Very nice!

[pufferfish]

Thank you.

Fast? This build is running since eight Months. But the end is nigh

The Cabin is done and the work on the Hull has started.
Unfortunately I'm not able to "metal shaping" with a shrinker/stretcher/english wheel in a proper way. So I've decided to make the back not really round but in five parts.



After two hull panels (the back and the small part behing the cabin) I've mocked up all the parts to check the proportions.
I like it so far

[pufferfish]

The superstructure and the undercarriage are now connected.

The electro block has moved from vertical


to horizontal


to get room for ballast, if i need some

[ddmckee54]

Pufferfish:

I've been watching a youtube channel called Fitzee's Fabrications. He does bodywork including fabricating some very complex replacement panels using simple hand tools, including some tools that he has built himself. Check out his videos if you haven't already seen them. While his go to welder is a 120V MIG, and your go to welder is NOT - they might still give you some ideas. 40+ years ago I was trained as an autobody repairman, and Fitzee is an education in how much you can do with simple tools.

Don

[pufferfish]

Hi Don,
thank you. I'll will give him a look.
Machining is easy for me. Make an approach, measure, finishing, ready.
Metal shaping is a thing for wich I need more "feeling" for sculpting than I have.

[pufferfish]

The first side of the Hull is done. All brushed stainless steel.
No color is planned.

[frizzen]

Awesome workmanship!
Love all the detailing going on with the cab. Each update is pretty epic

[pufferfish]

Using two old smd led stripes


to make the working lights (just mocked up. some shaping still needed)




works

[pufferfish]

Most of the time my mantra is "keep it as simple as possible" also for my strategy in making things. The earlier shown second version of the rotary drive was build in three parts some of them from brass because it's easier to handle on the mill.
The drive works well under lab conditions but not if some cross forces comes up. If I increase the clamping to handle the forces this happens



Major problem was the lack of a baseplate.
To build the complete lower part from a massive block would be too expensive.
Thereby I've decided to build it from stainless parts and weld them together.



Works now perfect with all forces up to a stalled motor.

[pufferfish]

Working lights done
overall 18 smd leds.

The illumination of the working area fits good. (completely dark room)


Also the space in Front of the excavator is bright.

[egronvold]

Very nice build. Impressive skills!

[pufferfish]

Thank you.

I'm a fan of functional gimmicks. So i've spend the last two days in the shop to make a remote controlled ladder for the operator.







I think, the operator needs some handrails