Miniature Little Giant power hammer

[Slava Yorish]

I start a new project. This time a miniature working Little Giant power hammer. Unlike my previous projects this time it will require a large number of parts cast.
Little Giant power hammers have a very recognizable shape. The one I decided to make is a miniature version of 50lbs model.
As usual, it all starts from the CAD model.

 

[Slava Yorish]

After CAD is complete next stage is choose the scale and 3d print all components.
I 3d printed a version with 6 inch tall base. But if I cast it after I could only position 5.5 inch tall part in the flask. So it determins the scale my miniature will be built.

 

[yhprum]

Looks like a good start to a great project! Following

 

[Slava Yorish]

Original power hammers were sand-cast. The company also made about a dozen of salesman items- fully functional miniature hammer. The base of that hammer was 18 inches tall and it also was sand cast. They used wooden patterns in the foundry. My model is much smaller. I can not get fine detailes with sand casting therefore I use wax models and investment casting or lost wax process. First step is to get waxes. For such a small project waxes can be 3d prin on resin printer from special wax resin. Such a resin is expensive and for mass production is better to make molds and inject molds with a regular casting wax. Once parts are printed I assemble it in trees for casting.

 

[Slava Yorish]

Now I start machining parts. Flywheel machined inside and outsode. Clutch hub and a sleeve. Everything should fit to the body between two bearings.

 

[Slava Yorish]

Drilling and tapping #0-80 threads in bearing pillow blocks

 

[Slava Yorish]

Some progress with the front shield. Now it is attached on #0-80 screws. Bearing pads installed as well.as the main shaft. The ram installation requires milling the slot in the body. I will make it when my milling machine will back to operation.