1/10 Mining Dump Truck

[pufferfish]

Hi,

at first some few Words about what and why.

I've build a Russian Mining Dump Truck called Belaz 7540.
It is the smallest Model with 30 tons payload. In 1/10 that is 20KG weight and 30 kg payload.

btw: wich measurement is usual in this forum, metric or imperial?

Anyway.

Why? Simple. I was tired of my small skills in handling plastics. So i've tried to handle metal. After many errors my skills has risen and little by little i've bought a lathe and a mill for widen my possibilities.

So I've learned machining. And I've don't learned something called metal shaping. i.e. with a english wheel.

By that, I have to look for simple shaped, edgy Bodies.

And here it is

https://blog.rb-fotos.de/wp-content/gallery/belaz/e1b-foto_belaz_7540.jpg

Looks simple but it will be complicated in details.

Key features: Hydraulic Steering, Rear Drive, two telescopic lift cylinders.

Latest Tool in my Shop is a Lampert M280 micro tig welder.


And now the build starts.

Fortunately i've found a very good parts catalogue with many sketches. Without any sizes but from the tire-size upwards i've take all needed sizes to start.

Material will be stainless sheet metal .3 und .5 mm thick.


First greater parts are the Backplate and the frame.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4034.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4052.jpg
The frame are just four sheets without any additional internal structures.

[pufferfish]

My simple "rules" for a all parts of a build

a) try to make on my own. if it is scale: wonderful. If not: so what. :rolleyes:
b) if a) is negative or I'm too lazy for it: buy it.

------
So i've tried to made my own shock absorbers with internal springs.
The result made from aluminium. With a minimum lubrication they works as I want up to 20 kg payload. Above this they are compressed, but that will be rare moments in the life of the dumper.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4105.jpg

on their places

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4092.jpg

[frizzen]

That's a neat looking truck.

Nice metalwork on the frame. Which welding method are you using?
Those massive shocks look really amazing.

A large portion of us use Imperial measurements, some Metric, some include both to be inclusive. Use what you're comfortable with

20kg payload dump truck is going to be a very impressive

[pufferfish]

Which welding method are you using?

It's a pulsed tig.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4031.jpg
Originated at jewellers and dental technicians.

-----------
During a former Project i've built a hydraulic cylinder. The car isn't run anymore so i've used the cylinders body again. A hydraulic steering needs piston rods in both directions.

I convert it from
https://blog.rb-fotos.de/wp-content/gallery/belaz/h06059.jpg

to
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4067.jpg

For scale it is way to big, but i need the diameter to get enough pressure for steering.

Parallel the work on the trough begins

the rough form is easy
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4169.jpg

but the typical beads are an enormous bulk of work

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4182.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4183.jpg

an intermediate result
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4201.jpg


-----
50 kg / 110 lbs total weight? A usual 540 motor will be a bit overwhelmed.
From a kind hobby colleague I've get two big 24v motors with very tough planetary gearboxes.
side by side with a usual 540 with planetary gearbox

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4282.jpg

[Jared]

That's some nice looking work! Looking forward to watching your build progress.

[Lil Giants]

That's a great start to what I'm sure will be a rewarding project Ralf :cool:

[Hemi1966]

Nice work Ralf:)

How do you like that Lampert M280?
I have the older version M200 and I love it.

[Blender]

What's the learning curve like on the pulse TIGs? Seams "easier" than tradition TIG welding, but looks can be deceiving when watching experts.

[pufferfish]

Nice work Ralf:)

How do you like that Lampert M280?
I have the older version M200 and I love it.

I love it too. It's so simple to make a connection without screws, bolt or something.

@blender: i don't have any other experiences with welding. for me the simpliest material to handle is 1.4301 stainless. and welding with additional wires are still not my thing :o

thereby my models are mainly from stainless :rolleyes:

[pufferfish]

rear axle. the middle piece from stainless for the flanges for links and suspension.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4324.jpg

50 kg total weight was too much for a usual 1/10 drivetrain
but the fat wheels with their 60mm diameter enabled me to built a motor-in-axle drive

the half axles are from aluminium 50 mm od.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4292.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4297.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4298.jpg

to compare with a usual old scx10/1 axle.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4308.jpg

the middle part. flanges from 4mm stainless
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4619.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4618.jpg

[pufferfish]

The build started in juni '21.
End August '21 i've reached a first milestone.

the trough and his bead are provisional welded
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4615.jpg

the rear axle gets her links
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4676.jpg

so the axle is mounted on the frame and a first loading test starts

pre weighed 10 kg stones
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4697.jpg

nothing cracked . the shock absorbers moves just a few mm.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4698.jpg

20 kg stones
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4699.jpg

nothing cracked . the shock absorbers moves just a few more mm.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4700.jpg

30 kg stones. maximum payload is reached
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4701.jpg

nothing cracked . the shock absorbers down.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4702.jpg

some manual flexing works well too.

Now I've knew, that all the main components will work on full payload.

At this point i'm very pleased with the build so far.

[Zabco]

Very interesting build, will be quite fun to watch your progress. Sounds like you got into this hobby for the same reason I did, learn new methods and techniques. Keep up the great work and post often.

[pufferfish]

Sounds like you got into this hobby for the same reason I did, learn new methods and techniques.
Indeed , thats my intension.

--------
After this Milestone, I've got the motivation back to weld all the beads on the trough (endless small sparks in .8 second rythm) and improve the strength of the frame.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4710.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4711.jpg

Frame and struts are real scale. Always fascinating what a few pieces of sheet metal doing with the stability.

Meanwhile the tires arrived.
Bespoked fabricated. Full, hard Rubber.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4772.jpg

The enormous wheigth...
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4771.jpg
.... result in exact 8 kg for the completed rear axle.

I think it looks quiet nice
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4778.jpg

rims made
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4806.jpg

and a little stack of wheel caps too
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4834.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4840.jpg

As a little intermezzo the non-functional fuel-tank was done
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4866.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4872.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4885.jpg

[Tgrzes]

Very nice fabrication! That is one solid looking truck!

[pufferfish]

Thank you.

Making the front axle was much more complicated as the rear axle.
Due to the great weight i need a real brake. the esc hillbreak wasn't enough to hold the little monster. The motors in the rear axle prohibit any break in them.
Ergo the front axles must have breaks. The original has drum brakes. Consequently I plan my first drum brake in my life. That was a real exciting phase of the build.

The axles body is from stainless 30mmx3 to hold the steering cylinder, three links and the panhard. The space looks wide but, as usual, at least I've to fight for every mm.
The c hubs are made from aluminium.
All sizes and shapes, except the hydraulic cylinder, are scale.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4905.jpg

the c-hubs gets 3° tilt to prevent understeering
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4921.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4922.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4931.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4933.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4938.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4940.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4941.jpg

Flanges are from 4mm stainless....
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4992.jpg

....or some more mm :D
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4998.jpg

Links done
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5026.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5027.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5028.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5029.jpg

overview and end of the simple part of the axle

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5030.jpg

[bigpipespete]

Nice work , you should be proud of yourself.

[pufferfish]

Nice work , you should be proud of yourself.

Thanks. I am :D

-------------
The complicated parts of the front axles needed intensely research and planning time. Enough time for painting. Not my favourite task. But sometimes it has to be
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5172.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5173.jpg
Bored from painting, i've made the baseplate for the Front
(1mm stainless)

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5182.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5207.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5208.jpg


Planning has closed and the work begins.

Milling the Joints from stainless

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5145.jpg

After some tests about steering radius etc i've to shorten the steering cylinder. So i've take the opportunitiy and build it a bit more scale. later you will see nothing from it, but i know, it's almost scale.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5185.jpg

changed cylinder needs a changed flange. from

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5192.jpg

to

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5191.jpg

at least mounted and covered from a heavy duty skid plate
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5193.jpg

[Rvjimd]

I always enjoy seeing machine work photos, especially like seeing the work holding solutions. Jim

[pufferfish]

Drum Brakes.

some stainless sheet , 3mm thick, aluminium for the drums and some 6x1 stainless pipes

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5250.jpg

the square sheets are turning into round and welded together with the pipes

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5278.jpg

welded onto the joints
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5286.jpg

first tests. all things going well.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5288.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5289.jpg

i need stops on the axles to prevent the drum from contact with the baseplate

a lack of suitable stainless washers forces me to made my own
small pieces of a 1mm sheet
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5292.jpg

turned together to the od
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5293.jpg

et voila
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5294.jpg

welded on position
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5296.jpg

in the their front , the drums has holes to hold two bearing and a spacer.
in the back the big hole for the brake pad holders
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5279.jpg

put on the axle, the drum fits well and has no contact. the double bearings are strong enough to avoid tilting.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5297.jpg


A good start into this chapter.

[pufferfish]

Drum bakes: Brake pad holders.

aluminium round
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5504.jpg

simple method to hold the round parallel to the middle
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5505.jpg

sawed and milled
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5526.jpg

brass bolts

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5525.jpg
fitted with springs
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5527.jpg


set up

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5530.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5532.jpg

a little problem are the brake pads themself. after a lot of research i've found the tip that gasket paper (abil eg) was a pretty simple material

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5534.jpg

and really: it works perfect.

mocked up
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5559.jpg

next and last part: bowden cable and the mechanics to activate the breaks.

[bigpipespete]

Simply, wow !

[cooker2003]

Real drum brakes even! Impressive!

[pufferfish]

Thanks.

I need two different actuators for my breaks, like the big ones I need a driving and a parking brake.

But i won't two bowden cables. Therefor i've made a central platfrom between the frame. Later truly invisible.

A simple sledge to hold a constant direction. left to the actuators . right to the drums.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5718.jpg

the testing arrangement was simple and ugly.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5719.jpg
that must be prettier.

to get a weldeable bowden tube in my tiny sizes was impossible. so I've bought

a really small tube stainless
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5742.jpg

[pufferfish]

....
bending such a small tube :confused:
An inlay from 1mm brass rod was the solution
Bending worked wonderful smooth
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5728.jpg
but i need not a ring but four 90° parts.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5735.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5737.jpg

inner deburring with a small ball end mill
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5740.jpg
and welding on the screw wich hold the axle onto the c-hub
to avoid length-changing while steering.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5744.jpg

On the other side, a servo and a small n20 gear motor has taken their place.
together with two end switches for the motor, they are the rest of the mechanics.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5752.jpg

A short clip of their work, you can see here (https://blog.rb-fotos.de/wp-content/uploads/2022/01/drumbreaks.m4v)

[Originalrob]

Wow what a great scratch build !

Keep up the good work !

[Hemi1966]

Looks like you got a Optimum milling machine, is that BF20 ?
Did you cut all the sheet metal parts yourself ?

And also, great work :)

[pufferfish]

thanks again.
Looks like you got a Optimum milling machine, is that BF20 ?
Did you cut all the sheet metal parts yourself ?


yes. its a bf20l.
and yes. i buy simple sheets and cut them self. my tools are a simple lever shear, flex bandsaw, some bender and a old bosch belt sander.

I'm a programmer by trade, so i could use a cad and buy laser cutted metal, but i won't work with computers after the whole day on it.

------------------
Last complicated parts are the telescopic lift cylinders.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_4052.jpg
They are located in the big slots inside the frame.
Big? When you plan and estimate the sizes of the cylinder, the slots gets smaller and smaller :eek:

Seldom I've planned so long for a single part. Maximum and Minimum Angles, posibilities in machining, needed pressure to lift, sizes of the cylinder, rods and pistons and so. So much interdependent variables. :eek: I think, the fifth or sixth plan was the base for the first try.
I'll show you the second and last attempt :cool:

[Hemi1966]

thanks again.


yes. its a bf20l.
and yes. i buy simple sheets and cut them self. my tools are a simple lever shear, flex bandsaw, some bender and a old bosch belt sander.

I'm a programmer by trade, so i could use a cad and buy laser cutted metal, but i won't work with computers after the whole day on it.



I thought the parts ware laser cut:)
I also have a BF20L that I converted to cnc , and I love it.

[pufferfish]

Well, after planning, the doing was a simple turning job

the guard rings are very small.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5607.jpg

seals are simple o-rings
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5624.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5626.jpg

big thread on the lid
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5637.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5639.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5638.jpg

Fits perfect
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5648.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5649.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5650.jpg

To lock the trough in open state for working on the hydraulics are at the big ones simple Us wich will hook on the back plate.

So do i
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5679.jpg

Works
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5683.jpg

Here you can see the last part of the cylinder with the flange. both from stainless to be able to weld. All other parts are from aluminium.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5916.jpg

the original have a maximum tilt angle of 53°.

almost :D
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5680.jpg


later, after some test and measuring, i'm able to raise the size of the guard-rings. that brings a lot more stability.

[pufferfish]

Last post so far :bounce:

The exciting parts are done. Followed by things i have to do.

Hydraulic arrangement
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5381.jpg

Many stainless sheets .3mm or .5 mm are cut, bend and welded to build the front.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5769.jpg

The bonnet is parted.
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5771.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5790.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5785.jpg


on the back the massive airfilters
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5806-2.jpg

tank
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5812.jpg

battery tray
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5814.jpg

after all the yellow some belaz blue

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5884.jpg

and, tradional for me, the last thing: The cabin

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5915.jpg





Et voila. Almost completed:bounce:

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_5918.jpg


Actually the one and only clip with my Belaz 7540 Mining Dumper working.

(Don't mind the unscale Loader :D )

Here it is (https://blog.rb-fotos.de/wp-content/uploads/2022/01/dumping1.m4v)

Now it's waiting for Spring to make a better clip and get some interieur into to the cabin.



Thanks for your Interest.

Maybe you'll watching my thread to build a more scale Loader :D

[bigpipespete]

Yours looks better than the real thing. Fantastic build.

[Tgrzes]

Nicely done! I always enjoy the imagination and skill involved with scratch builds.

[frizzen]

Beautiful machining work on everything!

Even the latches for engine cowls are amazing

[pufferfish]

Hi,

A usual method to move an excavator is to use a dumper and transport

[pufferfish]

Hi there,

some months later......
(during them i've built a 1/10 stainless steel land rover forward control)
....... the dumper needs an improvement of his drive train.
fully loaded it was a bit weak.
After a detail research i've found some issues. The rims are able to get contact with the axle and the motors don't get enough power to work properly.

First attempt to seperate rims and axles are a gliding tape glued onto the axles. Unfortunately works is not good.

Second attempt are these brass rings with the function of very small bearings.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_9068.jpg

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_9069.jpg

After a couple of new escs i've found the working solution with seperate hobbywing 1080 for each motor.

Now the dumper can work in soft and hilly terrain too.

https://blog.rb-fotos.de/wp-content/gallery/belaz/img_9072.jpg

traces in the sand (including a footstep in size 16)
https://blog.rb-fotos.de/wp-content/gallery/belaz/img_9076.jpg

[frizzen]

That came out really awesome!

Your mining truck is a beast

[Krewmember]

Impressive work, I really like the working drum brakes.


-Shawn-