Build an Excavator from Scratch

[pufferfish]

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/gallery/bagger/img_5838.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/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/gallery/bagger/img_6147.jpg

shaped
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6151.jpg

drilled and provided with bushings and axles
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/18784fe6-a579-4652-a6d0-175243be0f24.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/gallery/bagger/img_6160.jpg

[pufferfish]

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/gallery/bagger/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/gallery/bagger/img_6258.jpg

in the box laying the crawler plates too.

drive train is ready for testing

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6334.jpg

first little testrun on the terrace

https://blog.rb-fotos.de/wp-content/uploads/2022/01/testrun.m4v


The connector between undercarriage and body is done.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6366.jpg

That is the actual standing of this project.

More to come....

....if anyone is interested

[Tgrzes]

I can’t even think as fast as you fabricate/Machine stuff…lol.

[bigpipespete]

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.

[frizzen]

Wow, that's looking like its going to be great!

[pufferfish]

Last post with pre-fabricated things.


i first attempt for crawler-plates. they need some improvements

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6310.jpg

the large bolt for the rotary union

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6361.jpg

fits perfect
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6364.jpg

but with a bit weight n the upper base plate, the bolt tilted

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6389.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6390.jpg

so i've made today a counterpart to avoid this.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6425.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6426.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6427.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6428.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6437.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6439.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6391.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6440.jpg


Thats it. From now on my posts in this thread coming not so fast anymore :D

[pufferfish]

Finetuning of the crawler plates. 1,5mm between work and crash
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6460.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6461.jpg

70 times
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6462.jpg

no more collisions
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6468.jpg


last pic: first attempt of the teeth.
Not scale, i know. But they will make grip, I hope

[pufferfish]

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/gallery/bagger/img_6472.jpg

Now I'm waiting for the next attack for the second track :D

[pufferfish]

The undercarriage gets his stabilizations.
Looks a bit rough, but later invisible.
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_6474.jpg

After this succesful test, the hull work started
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6477.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6478.jpg

[bigpipespete]

Its looking really good so far.

[pufferfish]

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/gallery/bagger/img_6479.jpg

raised thickness to hold the threads for the nipples
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6485.jpg

the ring welded on one sheet and cutting the excesses
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6486.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6487.jpg

testing with water and fixing some micro holes
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6489.jpg

ready for tetris :)
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6492.jpg

[pufferfish]

Hi,
positioning was easy. I wish, I have so much space in every model :D

https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_6514.jpg

ready
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6518.jpg

valves and tank are mounted too
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6519.jpg

[bigpipespete]

Very nice , sorry if i missed it but what is the scale of this excavator ?

[pufferfish]

Very nice , sorry if i missed it but what is the scale of this excavator ?

sorry, it's 1/10.

because i've no idea from excavators so far, i've roughly copied the sizes from the liebherr r966

[pufferfish]

This will be my last post here. too much work for just a few clicks and almost no replys.

Enjoy your hobbies.


Bye

[Soul2012]

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.
:(

[frizzen]

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

[Tgrzes]

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.

[Jared]

I hope you'll change your mind! I've enjoyed watching the progress and your methods which are different from most on here.

[bigpipespete]

Thats a shame and i hope also you will change your mind and continue to post progress.

[pufferfish]

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/gallery/bagger/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/gallery/bagger/img_6575_0.jpg

[kerst]

Thank you, I have been reading your posts with much interest!

Kerst

[Jared]

I'm glad you changed your mind!

[pufferfish]

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/gallery/bagger/img_6664-2.jpg

an intermediate stand together with a bit of cardbord aided design
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6678.jpg

the monobloc body is ready and bending the hydraulic pipes begins
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_6804.jpg

30 kg ballast lead arrived
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_6902.jpg

[pufferfish]

stick, bucket and bucket mechanic
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_6903.jpg

the very noisy pump gets a leadfilled cover.
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/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/gallery/bagger/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/gallery/bagger/img_7012.jpg


today , a big milestone has reached. the drivetrain is done and a first driving lesson occurs.

[jerry56]

WOW that thing is huge !!!! it will be a monster... nice to see it progressing...

[pufferfish]

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/gallery/bagger/img_7099.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7100.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7102.jpg

[Jared]

Very nice pipe work. What is your method for bending without kinking them?

[frizzen]

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.

[skeeter]

AWESOME project!
This thing should be a beast of a machine once completed!

[pufferfish]

Very nice pipe work. What is your method for bending without kinking them?
Thank you. I've choosen the easy way. 6x1mm stainless pipes are not easy to bend but with the right tools it's possible and up from 15mm radius without any kink. I'm using a "RIDGID 600 series lever bender" for 16mm radius.
with the enclosed examples you are quickly enabled to make reproducable multi-angle bendings.

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. It was called "s.o.f.t. superfast offroad fire truck" and should be a quick response bush fire truck.

"ejector seat" :D:D

AWESOME project!
This thing should be a beast of a machine once completed!
indeed.
----------

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/gallery/bagger/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/gallery/bagger/img_7128.jpg

On the outside are three grooves for o-ring sealings.
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7127.jpg

Threads will be sealed with loctite 542.

[pufferfish]

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/gallery/bagger/img_7133.jpg

The thread was filled with loctite

https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/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/gallery/bagger/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/uploads/2022/04/first-moves-stick-1.m4v
(moving from the nineth second on)

[trucker n]

man very nice and smooth

[skeeter]

Great job with them cylinders!

[pufferfish]

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/gallery/bagger/img_7160.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_7159.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7158.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7161.jpg

[pufferfish]

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/gallery/bagger/img_7173.jpg

max Height over ground approx. 130 cm
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7175.jpg

max Depth ca. 100 cm
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7177.jpg

Next big steps are learning to operate it and building the hull and the cabin and 347586 other little things.

[Lil Giants]

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

[pufferfish]

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/uploads/2022/04/firstbuddeling.m4v

some issues found but nothing worse (i hope :D )

Have a nice easter weekend

[Lil Giants]

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.

[pufferfish]

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/gallery/bagger/img_7214.jpg

This thing pulled through a heat shrink tube.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7207.jpg

After shrinking the wires get more stiffer and bends reproducable nice way

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7217.png

[pufferfish]

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/gallery/bagger/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/gallery/bagger/img_7219.jpg

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

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

the punch guide
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/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/gallery/bagger/img_7224.jpg

[jerry56]

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

[Zabco]

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

[frizzen]

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

[pufferfish]

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

[pufferfish]

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/gallery/bagger/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/gallery/bagger/img_7282.jpg

After deburring and polishing the sprocket a first test

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

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

And the side view before

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

and after the improvement

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

[pufferfish]

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

the first inner rear cover too
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_7332-2.jpg

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

[pufferfish]

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

.3 mm stainless steel.

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

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

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

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

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

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

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

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

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

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

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

[pufferfish]

the stick need some reinforcements.

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

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

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

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

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

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

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

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

[frizzen]

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

[pufferfish]

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/gallery/bagger/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/gallery/bagger/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/gallery/bagger/img_7398.jpg

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

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

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

[pufferfish]

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/gallery/bagger/img_7419.jpg

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

[ddmckee54]

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

[pufferfish]

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
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.

[Blender]

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.

[pufferfish]

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/gallery/bagger/img_7422.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/img_7424.jpg

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

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

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

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

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

more to come....

[pufferfish]

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

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

fits well


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

[pufferfish]

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/gallery/bagger/img_7445.jpg

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

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

After this a first setup of the mechanism happens

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

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

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

[pufferfish]

Last part of the rotary drive.

clamp screws with stainless bolts to avoid damaged threads
https://blog.rb-fotos.de/wp-content/gallery/bagger/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/gallery/bagger/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/gallery/bagger/img_7458.jpg

[pufferfish]

The work on the cabin begins.

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

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

together with a 90

[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
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7487.jpg

and a parallel guide for the press break
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7475.jpg

i'm able to made reproducable cuts
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7482.jpg

and after bending
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7484.jpg

more cuts
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7486.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7487.jpg

i'm able to make exact angles with 7mm length
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7489.jpg

after solving a puzzle the frame of the cabin is done

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7495.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7494.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7493.jpg

[pufferfish]

some impression from the cabin
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7510.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7511.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7512.jpg

The stick are display holders
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7513.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7515.jpg

[pufferfish]

cabins upper guard

3mm stainless rods
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7516.jpg

welding setup
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7517.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7518.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7519.jpg


operators joystick.

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

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7524.jpg

looks similar enough as little details on the chair.
https://blog.rb-fotos.de/wp-content/gallery/bagger/04e41b41-c2ec-434a-9082-777a12449ef2.jpg

[ddmckee54]

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

[pufferfish]

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.
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7548.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7549.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7551.jpg

The complete ensemble is dismountable in seconds to reach on the ballast sections.
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7552.jpg

The cabin is done :bounce:

[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 :D

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.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7579.jpg

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 :)

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7580.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7581.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7582.jpg

[pufferfish]

The superstructure and the undercarriage are now connected.

The electro block has moved from vertical
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7584.jpg

to horizontal
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7586.jpg

to get room for ballast, if i need some
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7585.jpg

[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.:o

[pufferfish]

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

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7608.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7607.jpg

[frizzen]

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

[pufferfish]

Using two old smd led stripes
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7626.jpg

to make the working lights (just mocked up. some shaping still needed)
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7629.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7628.jpg

works
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7627.jpg

[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

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7651.jpg

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.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7661.jpg

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)
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7675.jpg

Also the space in Front of the excavator is bright.
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7677.jpg

[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.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7698.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7699.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7700.jpg

I think, the operator needs some handrails
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7703.jpg

[Tgrzes]

I think it

[pufferfish]

Todays work was a repair of the stick cylinder. Before the final assembling i've made the mistake to pull the rod complete to the end. During normal operations this never will happen due to the geometry of the stick.

At the end of the cylinder the piston collides with the oil input flange
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7708.jpg

thereby the piston seals get damaged

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7711.jpg

To open the cylinder i have to loosen the head. Sealed with loctite 542 thread sealant it just needed some hot air

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7710.jpg

After replacing the piston o-rings and refilling the oil then thread sealant is applied
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7712.jpg

Now I have to wait 24 Hours before the glue is cured.

[pufferfish]

24 hours later: The repair was successful.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7717.jpg
The stick holds his position.

After this I've made a last stress test.

Mounting all the 20kg ballast as counterweight
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7720.jpg

And a little mandrel press was the lifting object
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7718.jpg

her weight
https://blog.rb-fotos.de/wp-content/gallery/bagger/heavylift2.jpg

and finally the test. lift and hold. passed.
https://blog.rb-fotos.de/wp-content/gallery/bagger/heavylift1.jpg

I'm very satisfied with this result. After a holiday the final work on the hull begins...

[pufferfish]

Detailwork.

A rough sawed
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7752.jpg

and fine filed patch for the cutout of the ladder lever
https://blog.rb-fotos.de/wp-content/gallery/bagger/0203d94c-5427-448f-bef7-d9950314e8c3.jpg

A door handle
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7751.jpg

and handrails complete the second of four parts of the hull.
https://blog.rb-fotos.de/wp-content/gallery/bagger/16ca794a-dbdc-42f4-bd05-78d78fb5cb9a.jpg

[pufferfish]

Hi. Nothing new due to a vacation, but today i have a first training session for my eye hand coordination.

Works a bit better but still much to learn

A short clip

https://vimeo.com/727432466

[pufferfish]

At least, the Beast is done :D

The official pictures of my first scratch build of an excavator in 1/10 scale.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7986_0.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7982_0.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7983_0.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_7984_0.jpg


Thanks for watching

[Blender]

Looks great.

Will it be painted in a specific brand's colors or left in bare metal?

[frizzen]

Great job, that's an amazing machine!!!

[pufferfish]

Hi there,
during some test digs i've noticed that the beast have an issue when the body stands not exactly horizontally. due to gravity and the small rotary drive motor/gearbox the loaded arm turns every time toward the lower end. just active steering against is avoid uncontrolled movement of the arm. thereby it was difficult to dig and put the load into the dumper.

Somebody told me, that cascaded planetary gears are tends to self-locking. I buy some of them and a couple of tests later i decided to change the rotary drive.

old motor vs new motor
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9153.jpg

after some adjustments of the sledge it fits well.
the gear ratio is 130:1

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9180.jpg

mounted in his small place

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9182.jpg

and then the first test. i'm happy when i've realized that it works pretty well :D

it runs smooth and hold the arm with load even if the body is tilted
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9186.jpg

additionally i've changed the esc to a hobbywing 1080 with active hillbreak for the last bit of holding power.

[jerry56]

I never thought about that ... but yeah I can see where you would need either a planetary gear or a worm gear to hold the boom in place once you stop swing...
I used a 90 degree worm drive motor in mine so I never had the problem...

[pufferfish]

Thanks. This is my first excavator and i don‘t have any experiences or knowledge of these monsters before the build. Thereby i‘ve underestimate massively the working forces.

Learning by doing :)

[frizzen]

That's really cool!
I didn't know that stacking planitary gears like that could give a locking geartrain.

[kerst]

Impressive!

Kerst

[pufferfish]

thank you guys.

The next step was the improvement of the hydraulic cylinders. The old version works well, but is a little bit leaky.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9283.jpg

I've used O-Rings as seals and simple Stainless Rods. The upgrade is replacing the o- through x/quad-rings and using hard chrome plated rods.
It was not easy to find them in only 10mm diameter. But here they are
https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9257.jpg


First item was the bucket cylinder.

A challenge for me was the new material C45/1.0503/AISI 1045 but it was easier than expected, including turning a m10 thread (a tap wrench doesn't work proper)

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9261.jpg


Additionally I've made better fitting pistons

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9263.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9265.jpg

To change the cylinder head from o ring to x ring grooves i need a 3mm wide internal grooving tool.
I've grind a rough thing from a blank

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9272.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9273.jpg

close but works

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9274.jpg

Aaaand after a 20 min testdig with really heavy clayey ground (directly from the excavators trailer to avoid too much dirt in the shop)

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9281.jpg


the cylinderhead is still sealed :bounce:

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9284.jpg

Next step: upgrade the other cylinders.

[egronvold]

Always a great feeling when the hours in the shop finally pays off :)

[pufferfish]

Indeed :)

After upgrading all other Cylinders i've discovered the new opportunity to move more than one Cylinder at a time :D

https://player.vimeo.com/video/779644929

Upgrading is done. Next step will be a quick change system.

[pufferfish]

Actual work: A little Rock Ripper and a first Setup of the Quick changers locking mechanism.

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9314.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9315.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9316.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9317.jpg

https://blog.rb-fotos.de/wp-content/gallery/bagger/img_9318.jpg

[pufferfish]

After 16 month of work on this Project, it finally comes to an end :D

The ripper is ripping, the changer changes and all other things are now oil-proofed and working.

A last clip from this little Monster while ripping and digging compacted embankment in my garden.

https://vimeo.com/787182149



Thanks for watching.

[Krewmember]

Awesome build, and to your own design as well that makes it even better!
It looks like it has good digging power.


-Shawn-