Above 1200 Sq/FT 86's 20HP shop

[86turbodsl]

Amazing I bought one of these Dremel drill presses and made a 12 thou hole in some brass. Should be able to make the burner ball!



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[86turbodsl]

And the doorknobs are ready for drilling. Need to get a fixture made so I can clamp em down.

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[86turbodsl]

Also cut an inch off the bottom of my burner tube to allow more Ash to build up between cleanings. Seems to light better too. Already up to 130f in an hour and a half. Was able to turn up the supply to burner too.

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[Strouty]

Most interesting use for a door knob, ever.

 

[86turbodsl]

The principle for a babington is pretty cool, you flow a thin layer of oil over a curved surface, and the oil flowing over the tiny hole makes a spray / atomized like a whale's blowhole. The smaller the hole, the finer the spray. You blow air into the doorknob, and nothing can clog up. You can use it for dirty oil. I avoided it for a long while, but i think i'm ready to try.

 

[OldSoldier]

Why did you avoid it for so long? I forget...

 

[86turbodsl]

I didn't really want a science fair project for my main heater, but the turk style drip burner doesn't burn as well as I had hoped. Waaay more Ash than I expected. I'm cleaning it out every other night now.

Also I did not expect the gas burner for lighting to be such a pain but the packaging was too difficult on this boiler.

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[86turbodsl]

Mounted this Hoffman box tonight. I figured since I only paid a dollar for these boxes I should probably use em.

Supposed to be rainy this weekend. Sounds like a perfect time to do some controls work. Gotta get the greenlee punches out.

Thinking I should move the Honeywell controller inside too. Any thoughts?

Would clean the wall up a bit too.
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[Perrorojo]

I didn't really want a science fair project for my main heater, but the turk style drip burner doesn't burn as well as I had hoped. Waaay more Ash than I expected. I'm cleaning it out every other night now.

Also I did not expect the gas burner for lighting to be such a pain but the packaging was too difficult on this boiler.

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So the oil washes over the doorknob and the holes "mist" the fire with oil? Is it a steady stream or a slow drip of oil?

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[86turbodsl]

So the oil washes over the doorknob and the holes "mist" the fire with oil? Is it a steady stream or a slow drip of oil?

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The oil washes over the ball, not a drip. Excess goes down a hole back into the sump. The air inside the ball blows the oil off the surface into a mist. The smaller the hole, the finer the atomisation.

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[86turbodsl]

Started working on Burner 2.0. Making it modular so i can change parts to change operating characteristics and tune it as needed. Goal is full automation, no gas lighting, and fully safe. I picked up the steel tubing this afternoon and dropped off a nice big chunk of steel at the CNC plasma so i can get started cutting.

Also found a guy on facebook who has 400 gallons of used oil for me to pickup tomorrow morning. That should put me near 900 gallons in the shop this winter. I still have a ton more outside if needed, but with the current consumption, i can't see it happening. I'm only burning about 2 gallons a day right now to keep the shop over 50F and it's been running 20-25F at night and 30F-32F during the day.

Also closed up the last panel on the shop over the garage door tonight. I was short a couple bales of insulation, so i bought a couple and broke them up by hand and spread em around. It took 2HRS! to do that.

 

[86turbodsl]

So while i wait for drill bits to show up, i started working on the controls by running some conduit. I did eventually decide to move the Honeywell controller inside the big box. Cleans the wall up a bit, and that controller isn't really something that needs monitoring anyway. It's not benefiting anybody to stay out. Did i mention i freaking *LOVE* greenlee punches???

I also took half of saturday to go get another 250 gallons of waste oil for free of course, and he's got another 275 gallons for me as soon as i can upgrade my waste oil pump with a bigger motor to pump the heavy diesel oil he's giving me. I think i have a "contract" to keep getting his oil. I pickup and he gets rid of it when he wants it gone. Many semi trucks there. And they are careful with the oil.

Also finally got the building attic sealed up by screwing the panels all down. Sunday was nice for about 1hr before more rain hit. After that the temp started dropping. It sure is nice working inside though! Shirtsleeves on Sunday for a while. I am under the gun a bit to get the controller back installed where it was, so i can run the floor again. I'll add to the controls after that point.

The burner design continues, almost done and ready to start cutting parts though.
Last photo is a shot of what I have to clean off every 2 burns. Right now that's about 4 to 6 hours run time.

 

[Strouty]

Those drill bits are cute, how do you not break them?

 

[86turbodsl]

It's kinda amazing really, the dremel runs at like 20,000 rpm, and you just tap the handle down with your fingers. Feel a bit of resistance, see a little brass, let go and blow it away. Repeat. I drilled a 12 thousandths hole in a chunk of brass a 1/4 in deep without breaking even one.

 

[Strouty]

I would be buying ten, I can break anything.

 

[86turbodsl]

Lol. You have to buy packs of 5, so i think they assume you'll break em.

 

[Strouty]

My buddy was talking about using some really tiny end mills to machine some intricate stuff, can’t remember how small, but I couldn’t believe you could make them cut anything without snapping off.

 

[86turbodsl]

It's all about feeds and speeds. Slow enough and low enough chip load and you can machine anything.

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[86turbodsl]

Yesterday, i had to go to the doctor and have a piece of metal removed from my eye. It happened Sunday night, at some point, and i noticed a burning when i took my shower on sunday night. I figured it was an eyelash stuck under my lid or something, it's happened before, and passed. Monday was a little better, but i took some pain meds. Tues, it was worse. I called my eye doc and scheduled a noon appt. He found a chunk of metal and some rust underneath. Now i'm taking eye drops and wearing sunglasses indoors. I am thinking i might buy some prescription safety glasses now. Can't be too careful!

I also was not able to take the night off from the shop because it's gotten cold again, of course, and the shop has not been heated in 2 days. Since i had removed the injection controller from the wall, i had to rewire that and move it into the box temporarily. Somehow i crossed the floor pump with the injection pump, so i was dumping 120F water into the floor for a bit. Yikes! Also, as i fired up the boiler i noticed that the metering pump had lost prime, and nothing i was doing was fixing it, so i moved back to the needle valve for now. Since burner 2.0 is on the way, i figured i could monitor it like it is for now.

Pic for attention.

 

[jbmatth]

Eye infections are nothing to mess around with, but glad you caught it sooner rather than any later. There was a 6 month period were I was getting them constantly and one so bad I couldn't even stand to open my eyes indoors with the lights off wearing sunglasses for almost a week. I changed two things I now use hydrogen peroxide contact cleaning solution and wear goggles anytime I'm working around dust and metal shavings. No problems since, I wish you the best with the eyes and heater.

JB

 

[86turbodsl]

Thanks JB.

Yeah, it's no fun for sure. I'm glad i was able to get to the DR appt without crashing. Usually this time of the year its cloudy in Michigan, yesterday on my drive, it was bright and sunny. I could barely see. And it was a 45 min drive. I'll keep on the drops.

 

[Strouty]

I got some **** from a grinding wheel in my eye a week or so ago. I was wearing safety glasses and it did a bounce ricochet thing, got it all out with no issues though. The only true way is goggles, but I tend to fog them up really quick. A full face shield with glasses is probably the closest thing to goggles.

 

[86turbodsl]

Man, you dodged a bullet. **** in your eyes is no joke. You only get one set. I've been a little cavalier about it up to now, but not anymore. I'm looking for wraparound prescription goggles now.

 

[86turbodsl]

Here it is, the diy oil burner kit.

Also working on a rebuild of my waste oil pump with a new MUCH larger 66 frame motor.

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[86turbodsl]

Finished the waste oil pump this weekend, had to do it 2x, as the thickness of the 2 mounting plates was different, so when i got it cut and assembled the first time, the shafts didn't line up anymore. Welded the 2 pcs to some angle and then reset the position, and it lined up. The sealer is drying now and i should be able to use it tonight. Getting lower than i like in the oil tank, so will add to the oil level tonight with a little luck. I added a passthru/airlock in the common wall with the leanto last night, so i can keep the mess in the leanto and fill the tanks remotely from the other side. I have 150 gallons stored in the tank on the other side. Plus the 250 gallons on the trailer still.

The tractor starter bit the dust, so i have to order a new one of those. Yay. Spending money right at christmas. Yay.

On the plus side, i kept the shop at full operating temp most of the weekend, and it's SOOOOO nice out there. Just dreamy. My feet have never been so comfortable.

Floor supply temp about 95F, exit temp about 75F, air temp about 60F. Just wonderful. So far i've burned about 50 gallons since the start of operation. Not too bad really. Wife has started asking about running a line to the house...

 

[Perrorojo]

Finished the waste oil pump this weekend, had to do it 2x, as the thickness of the 2 mounting plates was different, so when i got it cut and assembled the first time, the shafts didn't line up anymore. Welded the 2 pcs to some angle and then reset the position, and it lined up. The sealer is drying now and i should be able to use it tonight. Getting lower than i like in the oil tank, so will add to the oil level tonight with a little luck. I added a passthru/airlock in the common wall with the leanto last night, so i can keep the mess in the leanto and fill the tanks remotely from the other side. I have 150 gallons stored in the tank on the other side. Plus the 250 gallons on the trailer still.

The tractor starter bit the dust, so i have to order a new one of those. Yay. Spending money right at christmas. Yay.

On the plus side, i kept the shop at full operating temp most of the weekend, and it's SOOOOO nice out there. Just dreamy. My feet have never been so comfortable.

Floor supply temp about 95F, exit temp about 75F, air temp about 60F. Just wonderful. So far i've burned about 50 gallons since the start of operation. Not too bad really. Wife has started asking about running a line to the house...

I think the best thing about the floor heat in our wood shop is that cast iron machines are warm from sitting on the floor. There aren't any cold surfaces and it just is so nice to walk in to a comfortable room that doesn't have air moving around.

 

[86turbodsl]

Agree 100pct. Warm tools, warm feet. What can be better when it's cold out?

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[Strouty]

I remember that feeling, but then it all went away the second we opened the big door and then it was cold for a while. We had a forced hot air furnace to help with recovery. It was really nice to bring a wet or icy vehicle in at night and have the vehicle and the floor dry the next morning.

 

[86turbodsl]

I don't remember, was your floor broken?

And I have to report success! The transfer pump works great. Just put 200 gallons thru the pump into the first oil tank. That motor from pre 1952 wasn't even breathing hard. Torque baby!
The water separator works as designed too. I pulled a couple gallons water out seeing it on the sight glass and the boiler never burped at all. As long as I monitor the tank a bit after a fill, water should never be a big issue.

I'm much happier with this much oil rather than the little bit before.


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[86turbodsl]

An update on burner 2.0: I was successfully able to drill a 0.010" diameter hole in the first doorknob, without breaking any drill bits.

I then mounted the doorknob on the little diphragm vacuum pump/compressor i have, and it generated 30psi through the doorknob. Exactly the pressure i wanted to start testing.

I then ran water over the doorknob and validated the babington ball effect. It's going to work as advertised with this curved surface. Now i just need to complete the burner assembly and begin testing with oil.

I also had a little time left to run some more conduit for the automation. The plan is to be automatic on burner 2.0 by sometime during Christmas break.


I have a video of it atomizing but I can't post it here sadly. It's pretty cool though.

 

[Strouty]

Maybe upload it to youtube or something, then give us a link?

 

[86turbodsl]

I don't have a YouTube acct. I'll set something up and upload for you.

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[86turbodsl]

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[Strouty]

It seems so simple, yet looks so sophisticated.

 

[86turbodsl]

It is pretty simple. You can build em out of junk. I'm being fancier than most.

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[Strouty]

I will say, the one thing that I would never do, is use a brass door knob, that is soooo 1980s.

 

[86turbodsl]

Ha, i'm old. what do you expect? ;P I remember Reagan fondly.

In reality, i needed something with a curved surface and drillable reasonably easily. The doorknob from Lowes was the first thing i found.

Incidentally, i was working on the burner last night and had to clearance one of the plasma parts i cut out. It became clear that a file was going to take all night and wear me out. So i did what i try and avoid and break out the die grinder and a burr. What do normal mortals do to protect themselves from the blizzard of needles/splinters just waiting for a careless moment in 6 months to make my life miserable? I got the shopvac out immediately and cleaned up the best i could, but i'm sure i missed some. I put the hoodie i was wearing in the washing machine after i spent 1/2 hour pulling splinters off it.

The fun part - 5 minutes with the die grinder and 1 hr cleaning... [facepalm]

 

[Strouty]

That is the worst part of a die grinder. I usually put on my leathers so I don’t have to deal with it in my sweatshirt.

 

[86turbodsl]

Yeah I've never been able to figure out a good solution. Thought about putting the shop vac right next to the burr but don't know if that would work and probably need a 2nd person. So that becomes tough. I usually work alone. My family doesn't share my interests.

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[Strouty]

My family is usually too busy to help me, it drives me bananas, I would drive ten hours to help them, but getting them to drive 30 minutes is the end of the world. Rant over.