Demag TC 500 truck crane in scale 1/24

[kerst]

Demag TC 500 truck crane in scale 1/24

Now that the LTM1800 is more or less finished it is time for a new project. I have been thinking about which crane to built for quite a while and I actually started with some parts a few months ago. Before deciding to actually build this crane. It is a German built Demag crane on a Faun carrier and was produced in the late 70’s. There are still some around, one at Inland Crane hire in in Idaho.
On this page you can see the TC500 ready for action: http://www.heavyequipmentforums.com/showthread.php?14902-Bridge-replacment
Van Seumeren also had a few: https://www.flickr.com/photos/73498813@N02/6641955839/

The Demag TC500 is the successor of the TC400 and is basically the same crane, just a few reinforcements and more counterweight and is rated at 125 metric tons capacity.
Here two pictures, one from the back of a leaflet and the other taken by myself. I will build the version with the very low-line carrier cab.
https://farm8.staticflickr.com/7020/6556974279_783b6096c0_b.jpg
https://farm9.staticflickr.com/8281/7833557070_6d11fc6700_b.jpg

Here are two pictures of the rims:
https://farm8.staticflickr.com/7430/11612749836_4933d8a7ca_b.jpg
https://farm6.staticflickr.com/5488/11962861234_dbfc70e3a7_b.jpg
The tires come again from the All American Toy Company.

At the moment I am working on the drive axles, which is a challenge, because space is very limited. I decided to completely build the axles myself. Pictures will follow.


Kerst

[TRUCKMAKER]

Got the popcorn going! Another cool crane build :bounce::bounce::cool::cool:

[dabears]

What tires are those?

[kerst]

What tires are those?
They are from here:
http://www.allamericantoyco.com/kwkit.html
Scroll down the page, it is part # 34
They are very nice tires for this purpose.

Kerst

[kerst]

At the moment I am working on the drive axles, which is a challenge, because space is very limited. I decided to completely build the axles myself.
Here are some pictures:
https://farm6.staticflickr.com/5572/14388520629_bbb67fcde7_b.jpg
https://farm6.staticflickr.com/5529/14387085489_c3985d18af_b.jpg


Kerst

[doodlebug]

Wow:D double reduction, just like what Mack Truck's build's! I like them:jaw:
Cheer's, Neil.

[kerst]

I am steadily working on the rear axles of the Faun carrier. When I last posted I had everything figured out, so now it is a matter of realizing it all and it is coming together nicely. I am pretty happy with the result. The axles are functional and hardly to scale, but they won’t be visible at all once they are in place. I put all the parts together in a mock-up to see how it will look.
https://farm4.staticflickr.com/3917/14635745274_ba83209009_b.jpg
https://farm4.staticflickr.com/3894/14635744044_a47637b510_b.jpg
https://farm3.staticflickr.com/2917/14451236680_d208ba48cd_b.jpg

Kerst

[TRUCKMAKER]

Those are looking strong, I think they'll pretty much move anything!:jaw::jaw:

[kerst]

Those are looking strong, I think they'll pretty much move anything!:jaw::jaw:

Thank you.
These axles need to be strong. The real ones are rated (static) at around 90,000 lbs each.

kerst

[Jared]

Wow, that's a very nice bit of brass fabrication there. Mine work has solder slopped everywhere. Looking forward to seeing more!

[kerst]

I made the drive shaft between the two axles. This was tricky, because they are very close together.
https://farm6.staticflickr.com/5577/14600548399_0e2483b88f_b.jpg (https://flic.kr/p/ofcCn6)Axles FAUN (https://flic.kr/p/ofcCn6) by kerstdejong (https://www.flickr.com/people//), on Flickr

Kerst

[kerst]

The summer has been busy with all kind of activities, including making a Board room table to fit 22 people for our new office.
But I picked up again in the Fall and got a good start. I finished the tandem axles, started on the frame and just now started making the wheels for the other three axles.

Tandem axles:
https://farm6.staticflickr.com/5616/15618495709_06920b521a_b.jpg
https://farm6.staticflickr.com/5603/15619467610_2f03cd1556_b.jpg

Frame:
https://farm8.staticflickr.com/7546/15805892912_79925e19c1_b.jpg

Soldering the parts together for the front wheels:
https://farm9.staticflickr.com/8600/15804311865_e99bbbfa1d_b.jpg
Front wheels in the making:
https://farm8.staticflickr.com/7548/15619460130_e87f437f3d_b.jpg

Kerst

[kerst]

I made some progress with the wheels. The tandem axles are done and I have been working on the other wheels. These are the three axles with single tires and one of the three axles is driven. For these I used brass, because it is so easy to solder and machine. I will focus on the driven axle next. It is very similar to the rear axles.
The picture shows all the front wheel parts in various stages of assembly. The bearings are 14 x 8 x 4. I got a whole lot of them for very little money:
https://farm9.staticflickr.com/8668/15916712245_695d328f58_b.jpg

The tandem axles with walking beam suspension:
https://farm9.staticflickr.com/8663/15729419180_15774f5106_b.jpg

Here is the frame, made of AL:
https://farm8.staticflickr.com/7546/15805892912_79925e19c1_b.jpg

Kerst

[modelman]

Very nice work on the wheels. Good attention to details!

[kerst]

I made some progress with the Faun carrier. The suspension of the two front axles was quite a challenge, mainly due to little room. The first axle is a driven one and the second non-driven. I also had to keep as much room as possible for the motor, which will be mounted above the front axles.
https://farm8.staticflickr.com/7463/16160199110_39be02b906_b.jpg
https://farm9.staticflickr.com/8623/16347548595_28f59c929e_b.jpg
https://farm8.staticflickr.com/7517/16161670997_093fdf4523_b.jpg
https://farm9.staticflickr.com/8598/15727606383_e73db66c18_b.jpg

Kerst

[aussietruckerguy]

Looking great

[Southgate]

Hey, Kerst, I just caught up with this one. Again, another knock-out! I love the herkiness of your builds, and that everything is metal. Super work on those hubs and wheels, they look great. And another great crane in 1/24 scale, to boot! I'll be following.

[kerst]

I made some nice progress, although things are not as finished as they seem. Today I made good progress on the third axle. I still have to finish the suspension and the steering.
https://farm9.staticflickr.com/8669/16418692950_732c482bc7_b.jpg

kerst

[bigford]

thats looking great!! have you ever thought about doing
a crane in 1/14 or 16 scale?

[kerst]

thats looking great!! have you ever thought about doing
a crane in 1/14 or 16 scale?

I find those scales too big. It would open up a lot of new possibilities, but I like 1/24. It is easy to handle and fits my spaces. And when fully rigged it will still be over 10' high.

Thanks,

Kerst

[tc1cat]

Excellent machining on the wheels and frame work. Question for you- how are you fastening the wheel centers to the rims on the front 3 axles? Are the center bolts and nuts gripping on the rim?

[kerst]

Excellent machining on the wheels and frame work. Question for you- how are you fastening the wheel centers to the rims on the front 3 axles? Are the center bolts and nuts gripping on the rim?

That is right, it works like the real thing.

Kerst

[kerst]

The beginnings of the cab are here:
https://farm6.staticflickr.com/5331/17353886993_4c235a6211_b.jpg
I also started on the outrigger boxes. They are pretty straightforward. I decided on Steel and I brazed them together. Now they are definitely strong enough. The second picture shows some parts added using solder. They need to be cleaned up a bit and they are ready. Next are the outrigger beams.
https://farm1.staticflickr.com/542/19942146106_97a432c010_b.jpg
https://farm1.staticflickr.com/375/19780328318_46f1d63e2c_b.jpg

Kerst

[kerst]

Faun carrier

The outrigger boxes are ready and bolted to the carrier. Next will be the outrigger beams. I am also thinking how to build the gearbox and transfer case and which motor to use. There is not a lot of space, so they need to be designed carefully.

https://farm1.staticflickr.com/562/19927589238_d3f8010499_b.jpg

https://farm1.staticflickr.com/461/19926406088_d1c42d6105_b.jpg


Note: The third axle is missing.

Kerst

[bigford]

if this is anything like you had at cabinfever it will be amazing

[kerst]

Transfer box

In the last couple of weeks I have been experimenting with a planetary reduction, which I got from a small geared motor. A lot of trial and error! The outside diameter is 22 mm and all the gears are steel.
The trick was to incorporate it in the transfer box. I tried a lot of different setups, but I think I found a setup that works. The transfer box will have two speeds (direct and very low) and front wheel drive can be engaged or disengaged. The real one has an inter-axle diff, between the rear axles and the front axle, but I couldn’t find the right planetaries to accomplish that. It would need a 1:2 ratio.
It turned out nice and compact. But it hasn’t been tested yet.
https://farm6.staticflickr.com/5669/20850882381_5f37927e55_b.jpg

Kerst

[9W Monighan]

Love to see gearing!!

[Pricer]

Kerst,

Very nice build. I hope to learn more about building small controllable transmission like this. Have you done any experimentation with electromagnetic clutches or other types of clutch set ups in any of your work? I have been thinking about how a clutch could be used to precisely control a hoist.

[kerst]

Kerst,

Very nice build. I hope to learn more about building small controllable transmission like this. Have you done any experimentation with electromagnetic clutches or other types of clutch set ups in any of your work? I have been thinking about how a clutch could be used to precisely control a hoist.

Thank you!
I haven't worked with any type of remote controlled clutches yet. I have thought about it, including using pneumatics or servos.
This gearbox will have a simple lever.

Kerst

[kerst]

During the past couple of weeks I worked on the universal joints. I always make them myself, mainly because they need to be very specific in size, but also because good quality universal joints are very expensive. The final assembly of the joints is always tricky, because I solder the pins (1/16" diameter) in from the center and the solder easily flows in the wrong spaces. It needs to be heated just enough for the solder to flow, but not too long. I had a cup of water handy to cool it down quick once I thought it was done.

In the pictures the motor is directly connected to the transfer box, but I might add a 2-speed gearbox. I want to first try out the speeds and see if this is the right motor, etc.

https://farm6.staticflickr.com/5711/20674803363_2d4acb6e87_b.jpg
https://farm1.staticflickr.com/755/20673201324_31f05558f1_b.jpg

Kerst

[kerst]

The transfer box is finished:
https://farm6.staticflickr.com/5730/21427529512_491dc74a08_b.jpg
https://farm1.staticflickr.com/593/21250650968_bef639e545_b.jpg
https://farm6.staticflickr.com/5761/20815772004_cb047e6b9e_b.jpg

Kerst

[modelman]

Nice work in a tight space. Very nice build you have started.

[Jared]

That looks like it should handle a pretty good load. Those U-joints are beautiful! Did you use ball bearings or bushings?

[sparkycuda]

I've really enjoyed following this build and am very interested in your u-joint fabrication. Would you post a bit more detail on how you make them?

Thanks!

Ken

[Trucker_Jo]

Very impressive home made parts! Nice job.:cool:

[speedy8305]

Mr. Kerst Sir you are are very impressive cant wait to see the final build and here I thought the last crane you built was amazing this will be a masterpiece

[kerst]

I did some work on the cab. I added the doors with homemade hinges. They still look clunky, but this was the best I could do.
https://c2.staticflickr.com/6/5757/22288865739_7bfb5b40b9_b.jpg
https://c1.staticflickr.com/1/603/22449677686_6bc7c03695_b.jpg

I also installed the motor and a separate small gear motor to lift the counterweights. This needed a bit of thinking, since room was very limited. The 2 pictures show it both in lowered as in in raised position.
https://c1.staticflickr.com/1/569/22462321632_eaec9a5938_b.jpg
https://c1.staticflickr.com/1/658/21852960594_f72fba56b9_b.jpg

Kerst

[kerst]

In the past couple of months I did all kinds of little things, including optimizing the steering, working on the space in front of the third axle, the levers of the gearbox and some other details.
https://c1.staticflickr.com/1/646/23284079655_48d30aefff_b.jpg
https://c1.staticflickr.com/1/707/23201453451_0150c62a4c_b.jpg
https://c1.staticflickr.com/1/642/23201454871_fdf5fe382a_b.jpg


Here is a short video of the steering in action: https://youtu.be/ObYaSMiSlfU

I also made a box for the crane with space for the crane itself and the boom sections.
https://c2.staticflickr.com/6/5727/23792628460_203ce6abc0_b.jpg
https://c2.staticflickr.com/2/1597/23792628870_ab88bf795e_b.jpg


I wish you all a Happy New year and see you at the Cabin Fever Expo!
Kerst

[sparkycuda]

This is a super build! With limited space you have still figured ways to make things work. Love all the mechanisms that make this crane tick and the detail.
Ken

[kerst]

I started work on the outriggers. here you can see the structural parts of the outriggers, steel, brazed together. I will use hand operated screw jacks for the vertical movement. there is too little space for a motor.
https://c2.staticflickr.com/2/1491/24853395036_438121c8c4_b.jpg

kerst

[Bo Wallen]

Looking Good Kerst.
The box is a work of art for sure.

[kerst]

I finished the outrigger boxes. The vertical movement is hand operated with a screw thread inside, very simple.
https://c2.staticflickr.com/2/1529/25321055132_1d8f3ddc1e_b.jpg

Kerst

[kerst]

I put the FAUN carrier together again. Apart from a few details (never ending!) the carrier is done.
I have started with the drawings of the upper works.

https://c2.staticflickr.com/2/1682/24956023934_7cdbfa80e4_b.jpg

Kerst

[sparkycuda]

That is one great piece of work! I'm sure the upper works will be awesome, as well. I've really enjoyed seeing this come together.

Ken

[kerst]

I made some good progress with the upper of the crane. It is based on a ¼” piece of AL with the two main frames of brass. I found some nice small gear motors to drive the 2 main winches, boom hoist and the winch for the luffing jib.The motors fit nicely underneath the winches. It looks like I even have room to spare.
https://c2.staticflickr.com/2/1635/26440018512_91bf51fae4_b.jpg
https://c2.staticflickr.com/2/1448/25929407943_1dec90f1f5_b.jpg
https://c2.staticflickr.com/2/1582/26259434970_cbb096e75d_b.jpg
Kerst

[Mikem]

Thanks for posting more ideas for projects

[kerst]

The past week I worked on the swing gear. There is plenty of space for the whole assembly, so that was no problem. I added a spring-loaded clutch. I tried it and it seems a bit fast, so I might add a reduction later.
https://farm2.staticflickr.com/1480/26757254255_64365876d6_h.jpg

Kerst

[Jared]

I like the slip clutch!

[kerst]

This is better. I added a reduction , so now the swing speed is perfect.
https://c2.staticflickr.com/8/7209/26810411735_9f28ed1f43_b.jpg

Kerst

[modelman]

That looks like a nice set-up. I enjoy seeing gears on anything. Good looking gears also. What is the purpose of the clutch? Great work so far!!!

[kerst]

The winches are taking shape:
https://c2.staticflickr.com/8/7244/26586063134_bd7b67e4f1_b.jpg

Kerst

[kerst]

It is summer and I haven’t had too much time for the hobby. I worked a bit on the enclosure of the upper. It proved to be more complicated than I expected, mainly because I couldn’t agree with myself which method to use. It turned out to be a combination of brass and AL. There are quite a few angles that make it complicated. But it is getting somewhere.
So far:
https://c1.staticflickr.com/9/8151/28325867572_90af8a60fb_b.jpg
https://c2.staticflickr.com/8/7773/27814114394_f0d16c8893_b.jpg

Kerst

[Bo Wallen]

Kerst. It's looking good ! I keep follow you're build for sure. Next event i might need lifting help......:D

[kerst]

The summer has been slow. Too many other distractions. And often it was simply too hot in the workshop.
I continued working on the enclosure of the upper and built the cab. I am quite happy with the cab. It came together nicely. I am still not really happy with the enclosure. The idea is to be able to remove the side panels easily. The interior still needs to be done. The door is ready, but the front window not yet. There are still lots of details to be done. The next step is connection the electric wiring.
https://c2.staticflickr.com/8/7484/29326332786_78ab3293cd_b.jpg
https://c1.staticflickr.com/9/8493/28736549054_31506e6705_b.jpg
https://c1.staticflickr.com/9/8345/29359866085_afb629e139_b.jpg

Kerst

[9W Monighan]

Can you put some of those tiny neodymium magnets on to hold the panels?
I want to try to use them on my 9W someday to hold the house panels on that need removed easily.

[kerst]

I used them for some smaller panels like the one on the truck just in front of the first rear axle.

kerst

[kerst]

During the past month I worked on the sheaves. They are the same size for the boom hoist and for the boom tip, 22 sheaves total. The difficulty was reproducing the spokes. After a couple of trials I figured out a way to make them. Basically there are 3 parts, the outer part, the spokes and the center core. I made the outer part from brass tube.This was pretty straightforward. The spokes were very labor intensive. I made them from 1/16” brass sheet, turned them to size and then milled the spokes out, 4 at the time. Then I soldered the parts together in a simple jig and finally finished them on the lathe in specially made chuck.

https://c2.staticflickr.com/6/5490/30153073261_e8fbc39902_b.jpg

https://c2.staticflickr.com/6/5304/30153072671_0b35abc572_b.jpg

https://c1.staticflickr.com/9/8279/29608199634_a8114c3dc8_b.jpg

https://c2.staticflickr.com/6/5632/29608902683_b024da8768_b.jpg

Kerst

[Cooper]

Love the detail!! That's one thing I usually get too eager to finish and skimp on detail stuff. But that is what separates good work from awesome work. And love to see your ideas in set up jigs and customs tooling. I keep forgetting to complement you on your models when I see you!! I guess me starring at them speechless probably says more :). And also at a very small scale!!! I remember you saying about why the scale you build, realizing most rooms don't have high enough ceilings for larger scales!! Great work kerst!! Always enjoy any posts you share!!

[9W Monighan]

I know the pain in making several sheaves alike. I made 18 for my boom support cables. I showed step by step how I did them.

[TRUCKMAKER]

Those sheaves are incredible!

[Jared]

Nice work!

[kerst]

After a little break I continued with the Demag crane.

https://c1.staticflickr.com/1/582/32344053545_917cb2c103_b.jpg

I started working on the boom. I plan on making the longest main boom available, which is about 250 feet for the real one. It will result in about 10’ for the model.
This took some preparation, setting up jigs and so on, making the joints.
I use square brass and turn them to fit in the brass tubes. I connect them with silver solder.

https://c2.staticflickr.com/4/3939/33537229855_b2f2c320c5_b.jpg

Then the holes are drilled.

https://c1.staticflickr.com/3/2896/32722581213_c5a050b44b_b.jpg

I made a very successful setup to create the female joint on my old little Unimat. It works beautifully.

https://c2.staticflickr.com/4/3933/33408440901_ddf01c5a58_b.jpg

https://c2.staticflickr.com/4/3734/32693456214_53f77ab418_b.jpg

In order to get the distance between the pins right I made a jig. I first drill the hole on the one side, then pin the chord on the jig and drill the other hole.

https://c2.staticflickr.com/4/3780/33538612155_f77db23bab_b.jpg

And this is the jig for the final assembly. It should guarantee proper alignment. We will see.

https://c2.staticflickr.com/4/3804/33537230005_cc074fd7ee_b.jpg

I think I have everything ready to start producing all the boom sections.


Kerst

 

[jack van]

very nice keep up the great work

[frizzen]

Thats so impressive! Your skills are amazing.

I can't wait to see how the lattice boom comes together

[Jared]

When I did my lattice boom on my quick-and-dirty build I drove nails into a 2x4 in a zig-zag pattern and bent the rod around them. Worked for what it was but I think your method is better :D

[jffhrvstr]

That is looking good. Your doing an amazing job on your crane, it is very impressive how you have hand built everything. I can't wait to see more pics on the progress of this build!

[jack van]

if it is possible i would like to see you makeing a boom section on video hehe

[DADSGARAGE]

Nicely done!!! Looking forward to seeing more of this build!!
KP

[Grainfarmer]

:jaw: Great job! I still can remember these cranes from my childhood days...

[9W Monighan]

While driving North on I99 near State College yesterday; I passed Kerst on his way to to some secret location to get the TC500's carrier ready for the upper works. :D

http://imagizer.imageshack.us/v2/1024x768q90/924/7YS3cq.jpg

[Doggy]

Great project! I always loved crane trucks.
Never looked too much in to details but I wondered how the real cranes extend the boom? I guess big telescopic hydraulic cilinder?

[kerst]

While driving North on I99 near State College yesterday; I passed Kerst on his way to to some secret location to get the TC500's carrier ready for the upper works. :D

http://imagizer.imageshack.us/v2/1024x768q90/924/7YS3cq.jpg

I wish it was me!

This looks like the Liebherr LTM1500 without the upper. Nice!

Kerst

[kerst]

Great project! I always loved crane trucks.
Never looked too much in to details but I wondered how the real cranes extend the boom? I guess big telescopic hydraulic cilinder?

The Demag TC500 is a conventional crane. The boom sections are explained in this picture:
https://c2.staticflickr.com/6/5477/12730987965_df30ace248_b.jpg


Kerst

[kerst]

Some progress on the boom.
These are the ends for the boom sections. It took some work to get them straight, square, parallel and true, etc. , but the preparatory work paid off.

https://c2.staticflickr.com/4/3929/33154896060_54fcf17ef7_b.jpg

These two pictures show the setup for the assembly of the boom sections. Once set up it was a matter of fitting the laces in and soldering them. I made five 12 meter (40’) sections. With the butt and the top I will reach 72 original meters, which translates in roughly a scale length of 10 feet.
My little cutoff saw was great for cutting the 3/32” laces.

https://c1.staticflickr.com/5/4187/34402780832_70a9034f67_b.jpg
https://c1.staticflickr.com/3/2874/34166128066_79dd86f120_b.jpg
https://c1.staticflickr.com/3/2902/33364558754_73ee2036d2_b.jpg

Each section took about 3 hours to solder together.
This is the result. They are not perfect, but good enough and the boom is pretty straight.

https://c1.staticflickr.com/5/4180/34523235376_870dac5555_b.jpg
https://c1.staticflickr.com/5/4157/34564282265_e7eefc18c8_b.jpg

Next the butt and top section.

Kerst

[sparkycuda]

Kerst, amazing planning and workmanship, as usual. It takes a lot of patience to this kind of fitting and soldering - great job!

Ken

[JAMMER]

Very nice job Kerst how much weight do you think you will be able to pick up when you get done? Ed

[TRUCKMAKER]

Kerst, did you chamfer the ends of the laces or just cut them square prior to soldering?

[Mikem]

Stunning

[frizzen]

Those look great!

I love the jig solution you used

[kerst]

Kerst, did you chamfer the ends of the laces or just cut them square prior to soldering?

I cut them at an angle to fit the main chords, but I didn't mill them round. it worked pretty well this way.

Kerst

[kerst]

Very nice job Kerst how much weight do you think you will be able to pick up when you get done? Ed

Thank you!
With a short boom it should lift around 20 lbs max, but with the max boom that will be reduced to a couple of pounds I think.

Kerst

[Cooper]

This is one of the most eye catching parts, and it definitely is going to do that!! As always kerst, your work is above and beyond. Keep the pics coming.

[kerst]

Another step in the right direction:

https://c1.staticflickr.com/5/4285/34962851660_342d85c91e_b.jpg

Kerst

[sparkycuda]

As usual, a giant step toward great detail with excellent craftsmanship. That's a lot of parts to keep in alignment while soldering!
Ken

[kerst]

As usual, a giant step toward great detail with excellent craftsmanship. That's a lot of parts to keep in alignment while soldering!
Ken

Thanks!
I used this setup for the soldering and I prefabricated the hinge points, brazing pieces of steel together.
https://c1.staticflickr.com/5/4263/35194603172_3aa4c888c7_b.jpg

Kerst

[kerst]

The past couple of months I worked on the boom. By now most of it is ready. I am still working on the head and there are many details to be done, like the rigging, etc.
This morning I took the basic boom and fitted it to the crane for the very first time and it fits like a glove. That is a relief!

https://c1.staticflickr.com/5/4306/35276321283_f807573dfc_b.jpg

https://c1.staticflickr.com/5/4321/35276318193_fafbddaffc_b.jpg

https://c1.staticflickr.com/5/4297/35695328390_fbd5ebd79a_b.jpg


Kerst

[TRUCKMAKER]

Outstanding!

[frizzen]

Wow, thats looking amazing.

[egronvold]

Looking very nice.

[kerst]

First try reeving:

https://c1.staticflickr.com/5/4332/36958154575_f71946d3dc_b.jpg

Kerst

[JDH429]

Too notch skills you have. Love all the brass work.

[kerst]

I rigged her up yesterday and tested her with 12 and 48 m of boom.

https://c1.staticflickr.com/5/4348/36938257210_e8179ff410_b.jpg

https://c1.staticflickr.com/5/4391/37153533066_4bd94c85c6_b.jpg

https://c1.staticflickr.com/5/4401/37201126921_5da18a505e_b.jpg

Kerst

[Bo Wallen]

Fantastic !!! So beautiful model. Showstopper right there Kerst. i see big lift in the future.......:D

[9W Monighan]

Very nice. I see you didn't add any extra counter weight. Where you able to boom up from zero degrees?

[kerst]

Very nice. I see you didn't add any extra counter weight. Where you able to boom up from zero degrees?

Thanks! That is right. there are no counterweights yet. It booms up without, but the outriggers are needed.
I have 2 more boom sections to add, turning it into 10' of main boom. Then I guess I will need some counterweights.

Kerst

[JAMMER]

Very nice job kerst. You sure have a lot of patients to do these models. Ed

[Panther F]

Oh wow... what? I missed this thread completely!

What a beautiful truck and that boom is TALL! Super nice work... I've never seen such a project like this in brass. ;)

[frizzen]

That's beautiful!

[kerst]

I finished the remaining pendants and rigged her up with 72 meters of boom. This turns into about 10' for the scale model. It needed 7 lbs of extra weights on the back to raise the boom. Otherwise it worked fine. I am pleased with the result. When finished the counterweights will be around 5 lbs, so I will need to make the extra outriggers on the back for raising the boom.

https://c1.staticflickr.com/5/4402/23562545868_8e428b3d87_b.jpg

https://c1.staticflickr.com/5/4413/37157231770_93f4beebfc_b.jpg


This is how the extra outriggers will look like:

https://c2.staticflickr.com/4/3785/12760740244_54f672dfc5_b.jpg

Kerst

[kerst]

My project for the Thanksgiving break: the 6-sheave hook block:

https://c1.staticflickr.com/5/4533/38567019502_807234de9d_b.jpg

https://c1.staticflickr.com/5/4558/38542704086_3568b1fee8_b.jpg


Kerst

[JAMMER]

Great job Kerst you haven't lost you touch keep up the good work. Ed

[kerst]

Hook block done!

https://c1.staticflickr.com/5/4569/37757666815_632aae78bd_b.jpg

https://c1.staticflickr.com/5/4547/38612760102_ac68b85959_b.jpg

https://c1.staticflickr.com/5/4570/38589144846_fc7d30e40e_b.jpg

I will make 2 more hook blocks, one with 3 sheaves and on with a single sheave.

Kerst

[frizzen]

That hook block looks amazing!
How hard was reeving that since it controls the lines that effectively?

What are the 2 ears at top of the block for?

[skeeter]

Now it makes sense to me. When I saw a cylindrical part, with notches cut into it, I was like,..............WTF is that for. Great work!

[kerst]

Auxiliary outriggers
I spent the past couple of weeks fabricating the auxiliary outriggers. They are clearly needed for raising the more than 10’ of boom.
https://c1.staticflickr.com/5/4662/39167565995_39f11860bb_b.jpg
https://c1.staticflickr.com/5/4625/40066318961_e4fbecf246_b.jpg

Machining the pads:
https://c1.staticflickr.com/5/4656/40066319041_a25baf2871_b.jpg

And it works! See the attached video.
https://youtu.be/meyH0aCXr8U

Kerst

[sparkycuda]

Kerst, amazing work, as usual! I have never seen auxiliary outriggers like these before. Very interesting.

Ken

[Stefan]

Totally missed this thread till now, so just read it completely through. Love every part of your work, Kerst!! Cool seeing first the cab raising slightly and then the boom going up with no visible play between the carrier and the upper of the crane. :jaw::jaw:

Stefan

[kerst]

Totally missed this thread till now, so just read it completely through. Love every part of your work, Kerst!! Cool seeing first the cab raising slightly and then the boom going up with no visible play between the carrier and the upper of the crane. :jaw::jaw:

Stefan

Thank you!

Kerst

[liftmys10]

Love that short video! The extra outrigger sure works! Can't wait for your next pictures.

[kerst]

The next step is building a trailer for the counterweights and the boom. I choose a typical trailer used in the 70’s and 80’s for this purpose. It is a 4 axle Scheuerle trailer. I started a month ago and made some good progress.

https://c1.staticflickr.com/1/965/28027248398_d63f47069d_b.jpg

https://c1.staticflickr.com/1/903/27028352037_a15510029b_b.jpg

https://c1.staticflickr.com/1/910/41195346684_1bed2d5bbe_b.jpg

https://c1.staticflickr.com/1/957/40105725340_79ef300eab_b.jpg

https://c1.staticflickr.com/1/869/40105725540_f11e633923_b.jpg

Kerst

[Zabco]

That is going to be a real interesting trailer. Is the rear self-steering or is it controlled by the front somehow?

[kerst]

That is going to be a real interesting trailer. Is the rear self-steering or is it controlled by the front somehow?

The front and the rear are connected and steer together, but opposite. The trailer is bi-directional.

Kerst

[Lil Giants]

The front and the rear are connected and steer together, but opposite. The trailer is bi-directional.

Kerst

All mechanical linkages? Look forward to see how you make that work.

[Zabco]

How old is that trailer design? Got to looking around the internet to see if I could find some info on it and there is almost nothing. Found one picture on the Scheuerle company web site on a history timeline that says it was introduced in 1949!

Found a guy on a german modeling forum who built one in 1/16 scale and it appears his has crossed chains running underneath the trailer to connect the front and rear bogies. Is that how yours will work?

Looking forward to seeing more photos of this build.

[kerst]

How old is that trailer design? Got to looking around the internet to see if I could find some info on it and there is almost nothing. Found one picture on the Scheuerle company web site on a history timeline that says it was introduced in 1949!

that is correct. The design is from 1949, but most were produced in the 50's 60's and 70's


Found a guy on a german modeling forum who built one in 1/16 scale and it appears his has crossed chains running underneath the trailer to connect the front and rear bogies. Is that how yours will work?
This is how the original works, but I will use steel cables.



Looking forward to seeing more photos of this build.

Thanks!

Kerst

[kerst]

All the main parts are there, now it is time for the details.

https://c2.staticflickr.com/2/1755/42472806542_86bd6f8012_b.jpg

https://c2.staticflickr.com/2/1760/42472805882_28d371bdca_b.jpg

Here with a Manitowoc #27 boom section:

https://c2.staticflickr.com/2/1726/42472805132_81ddedc73e_b.jpg

Kerst

[skeeter]

Looks excellent, sir.

[kerst]

A short progress report. I worked on the steering mechanisms of the bogies. It works fine now. next is the connection between the front and rear.

https://c2.staticflickr.com/2/1828/29046604158_3d9c4f1eb8_b.jpg
https://c1.staticflickr.com/1/880/42918910841_42f19d3912_b.jpg
https://c2.staticflickr.com/2/1786/29046604348_c44f8d6e0e_b.jpg

Kerst

[Bo Wallen]

Wellcome to the heavy haul side.......i'm sure you'll like it :) I like your work and always looking forward to see more.....and more.

[frizzen]

This just keeps getting more and more wicked!

Will the mobile crane be able to transport the boom trailer, or is there going to be a tow-rig for that?

*looks at your crane, back at my crane, at your crane again* Maybe it's a good thing i don't have better tools yet... i don't think i could handle this much awesome.

[Zabco]

Awesome work! Must have taken a lot of work to get all those rods adjusted to the proper lengths so all those wheel sets will turn to different radiuses simultaneously. Were you able to scale off your drawings or did you have to calculate all of them?

[kerst]

This just keeps getting more and more wicked!

Will the mobile crane be able to transport the boom trailer, or is there going to be a tow-rig for that?

*looks at your crane, back at my crane, at your crane again* Maybe it's a good thing i don't have better tools yet... i don't think i could handle this much awesome.

the crane could tow the trailer, but it gets very long and is rarely done. I am still thinking what to make to pull the trailer.

This pictures shows the counterweights and 4 boom sections of the Demag on the trailer:
https://c1.staticflickr.com/1/883/42925054002_475e721382_b.jpg

And here with a boom section of the Liebherr LTM1800:
https://c2.staticflickr.com/2/1797/42925054332_473e909837_b.jpg

Kerst

[kerst]

The whole combination:

https://c2.staticflickr.com/2/1829/42270562964_66e793571f_b.jpg

kerst

[kerst]

Done!
It took me about 4 years altogether!
I spent the summer painting it. This was quite a time consuming job, taking it all apart and spray painting every part, then putting it together again.

https://c2.staticflickr.com/2/1947/43105836560_d437bd86cc_b.jpg

https://c2.staticflickr.com/2/1944/29981501737_842b128014_b.jpg

https://c2.staticflickr.com/2/1905/43105835910_294e73d306_b.jpg

https://c2.staticflickr.com/2/1947/43105837330_01551763f4_b.jpg

https://c2.staticflickr.com/2/1904/43105838570_b3ac8de20d_b.jpg


Kerst

[Bo Wallen]

Gorgeous Crane. Well done indeed Kerst Hope to have a closer look at Cabin Fever.

[PrimeRigg]

very nice work

[9W Monighan]

Outstanding Kerst!

[Zabco]

A truly beautiful piece of craftsmanship! Congratulations!

[frizzen]

That's amazing! Congradilations on getting it done!

Any chance of getting some action videos?

[Wombii]

Beautiful work! How is it controlled? Would love to see more info on the electronics.

[kerst]

Here is a video: https://youtu.be/dzHC31NVI8k

Kerst

[Lil Giants]

Exquisite craftsmanship Kerst :cool:

Do you ever do weight lifting tests with your model cranes?

[kerst]

Exquisite craftsmanship Kerst :cool:

Do you ever do weight lifting tests with your model cranes?

I did. This crane lifts more than it is supposed to do. The whole crane turned out to be a bit heavier that it should be, but that results in better capacities. The extra weight is useful when erecting the full 10' of boom.

Kerst

[sparkycuda]

Kerst, as usual, you have made an unbelievable operating model! Excellent planning, workmanship and detail...just awesome. I'm looking forward to seeing it at Cabin Fever.

Ken