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.

 

[Slava Yorish]

Today, I made some progress with yhe flywheel. It is assembled along with crank, clutch bearing caps and rotaiting ring. Fork will follow.

 

[strength_and_power]

Impressive

 

[yhprum]

Looking good!

 

[Slava Yorish]

I was fitting two arms that will drive a ram. No spring yet.

 

[Slava Yorish]

My milling machine is operational again. I mill the V-slot for the ram. First pass with 1/32" end mill to clear the corner. Then 90-degree mill to make sliding surface.

 

[Slava Yorish]

Ram is installed. Links are next

 

[Slava Yorish]

I made a spring on my lathe.

 

[Slava Yorish]

It is stiff but it is already reciprocating

 

[Slava Yorish]

Here is a picture

 

[Dodgeboy2020]

Absolutely impressive work. If you had to guess how much time do you have into this project when it's all done?

 

[Slava Yorish]

I checked my files and found that first pictures of Little Giant I downloaded back in January. Probably in February I started working on CAD files. It was not continuous work since I had another projects running in parallel. Roughly end of April when files were ready and wax models creation started. 2 weeks ago it was cast in bronze and since then some machining started. With all attention to details it can not be done fast. It is not finished yet although it starts looking like a working power hammer. Just a miniature one.

 

[Slava Yorish]

Today, I made a pedal from thick gauge copper wire. Round part is bent while two straight sections I rolled flat using rolling mill. I also fitted two dies. It comes snug and it can be wedged in the future. I will pin the clutch in the future and start adgusting everything to make a smooth operation.