Category: Workshop

I have been in negotiations to acquire a 1944 portable generator for a few months now.  Finally, this weekend I went to pick it up.

From the looks of it, it has not seen much use.  The generator case had some welds on top but other than that, it looked brand new.  It still had the first use label on the front and the parts box in the lid had all the original parts.  The motor would not turn so I guessed it was just “glued” together given there was little to no oil and the gas tank was completely clean inside.  I was just going to look under the cover panels and that quickly turned into an almost complete dismantle.

Update 30-Apr-2012

• Mechanical
  • After checking out the major parts, everything was in good working order…with the exception of 3 of the lifters.  They were completely “glued” to the block with old fuel.  Some gentle persuasion (dead-blow hammer) and Corrosion-X finally freed them up.
• Electrical
  • Wanted to make sure there was good spark and I have had good luck with sealed electronic ignition conversion kits so I removed the points and converted to electronic ignition.  Tested and there was still no spark.  I put all the original components back and got it to fire with some starting fluid in the cylinders.
• Fuel
  • The mechanical fuel pump leaked as soon as gas was poured in the tank.  Removed the carburetor and fuel pump and began a quest to replace the main diaphragm in the pump.   After a few weeks and dozens of calls, I decided to make the part myself.  A stove bolt and a heavy nitrite glove were donated to the project and appeared to work fairly well.

Starting

1. First attempt
   • Belt to Bosch drill
2. Second attempt
   • Direct drive to retainer nut on generator shaft – bolt un-screwed
   • Direct drive to retainer nut on motor flywheel – tightening while starting.  Was working until motor fired and reversed retainer nut of the end of the shaft.  The nut backed off and snapped off a cooling fin on the flywheel.
3. Third attempt
   • Found a pulley and shaft that would fit in the drill and tried the belt again.  It almost worked however it seemed to never fully fire.
4. Fourth attempt – success
   • Was thinking of how I could get more power to start the generator and happend to look over at the snowblower.  A quick removal of the pulley cover and belts and a long belt made for an efficient and strong starter.  After a few seconds, the motor finally started and ran for about a minute and stalled.  It looks like the fuel pump fix is not keeping up with the motor.  Back to the drawing board..

If anybody has any experience with this type of generator, please drop me a note.

WF

The following math formula results in another project:

A friend’s Rottweiler wasn’t getting roughage and she developed a taste for wood…especially their oak dining room chair spindles.

1st attempt – the tried and true method is to turn the spindles by hand.  It is definitely a task that requires some practice.  My first attempt looked like a spindle from a completely different style of furniture.

2nd attempt – I decided to update my wood lathe with a duplicator attachment.  I didn’t like the way the commercial ones looked so I decided to build my own.  Mounted a piece of plywood to the lathe bed and then made a block out of a stack of plywood so that it was even with the wood blank.  I used a carbide cutter from a metal lathe and it was working good…until it caught an edge of the blank and got pulled under the turning.  The end result was a partial spindle in 4 pieces.

3rd attempt – replaced the carbide cutter with a 1/2″ Sorby gouge.  I figured I would have more control with a long handle tool.  I was wrong.

4th attempt – didn’t even get to the testing phase…

5th attempt – it’s not a real project until the welder is turned on…hehe.  Using steel from a bedframe, handles from a junked Bridgeport, parts from a basketball arcade game and a vintage trim router, it is now able to make a round blank.  With the added profile track above the center line, I can now reproduce just about any profile.

Future improvements

• Calculate the rotation and linear distance to create spiral designs.
• Add a Deflector to keep the chips from flying all over
• Replace handles with computer controlled stepper motors and use the system to create intricate designs programmed on the computer.

I shall name it DUPLI-FORGE!

WF

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It is that time of year again when the garage changes from summer storage to winter luxury accommodations for the car.  I decided to take much of the useable items to the new ReUse Action building at 980 Northampton St, Buffalo, NY 14211.

If you are looking for great bargains in doors, windows, wood, insulation, old tools, hardware, cabinets, tile, antiques, restoration art…and a bicycle, then you need to check it out.

I picked up a couple interesting items and had a discussion about rust removal and tool restoration.  This is the process I go through to cleanup old tools.

1. Get some old tools
2. Brush off any loose dirt and look for any makers marks.  If the “Made in” is followed by anything other than USA, then go to the end of this post… 🙂
3. This triangle didn’t look like much; buried in a box of rusted tools…
4. In the same box was a couple odd tools, I small breaker bar and a thin wrench that despite its rusty exterior, was still a quality tool.  After scraping some of the rust away, I could see it was stamped “PROTO”…score!
5. I also found a military sorter cabinet that was supposedly used for ammunition and thankfully, it was empty.
6. The steel tools go into a 6 gallon bucket with 2 gallons of “Evapo-Rust”.  Previously, I had taken another bucket and cut it into a “basket”.
7. Set the timer for an hour
8. For the sorting cabinet, I used Oil Eater cleaner which is my primary cleaner.  You can watch the grime just wash off.
9. I have never had paint react like this; It washed off with cleaner and warm water.  It was almost like it was temporary paint.  If anybody has experience with military finishes, please let me know.
10. The tools right out of the bath, already look better.
11. They all get a wash with Oil Eater
12. The remaining residue can be removed with a brass wire wheel and the bench grinder.
13. Once cleaned, I like to use some CorrosionX spray to coat the steel.  Wipe it down with a clean shop towel and let dry.
14. Tools that have a ball bearing detent, I put a couple drops on the ball and then use something flat to push it in to allow the oil to get to the spring.
15. This tool needed to be put in the vise and worked back and forth; working the dirt and corrosion out.
16. The finished tools.  Better than new; now with character!   WF

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On one of the old tool collecting groups in Facebook, Don posted an old planer that was available.  I have been looking for a suitable upgrade to my Dewalt portable and thought it might work for me.

Work done so far:

1. Disassemble entire unit
2. Brought motor to United Richter for evaluation
3. Separated top and bottom sections
4. Scrapped the provided cart and kept the handles and wheels
5. Casting that will get painted was stripped to the metal
6. All other parts were degreased, dried and polished with a brass wheel
7. All 17 bearings were removed and inspected
8. Buffalo Bearings provided 11 replacement bearings
9. Realigned posts and adjusted chain tension
10. Wired motor and switch
11. Installed new 2 speed transmission
    1. Re-drilled mounting holes in casting

       

    2. Replaced roller height adjuster with new bar stock and tapped casting
    3. Extended drive chain
    4. Tapped drive gear (post for locknut was stripped)
    5. Modified drive gear
    6. Clearance chain cover for drive gear
    7. Filled with Napa synthetic gear oil
12. Final adjustments and testing

Future Upgrades

1. Power height adjustment
2. Digital height display
3. Electronic lockout in main circuit panel

How much was the new one again??? lol

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I needed to bind a manual and didn’t feel like punching holes every 10 sheets so I came up with my version of a hole “punch”.  I used some pre-finished plywood and 4 bolts to clamp the paper together.  The bolts also act as guides to make sure the holes are the same.

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It has been a busy month so far; cleaning up the shop and finishing projects that have been neglected.  Instead of posting about each project, I put them in one gallery…enjoy!

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