The Transamarobird swallows another victim!

[A_Pmech]

Here is the connection diagram for the motor. It does not show the coil group connections as it would become impossibly complex, but it does show the twelve leads necessary to connect a dual-voltage star motor and their relationship to the coil groups. Also shown are the instantaneous poles on phase A, complying with the left hand rule for electromagnets. This shows how the motor has four poles.

I drew this from memory. I'll print it out later and go over it for errors. I don't think I made any but we'll see...

 

[SiGmA_X]

Dead thread? Come on John!

 

[TheGrooveking]

What does this grinder look like now? Pics...

TheGrooveking

 

[A_Pmech]

Not dead!

I got a new size 0 manual starter for it a few days ago:

More supplies arriving tomorrow, then I'll get to work building the winding head and tension device to wind the coils.

 

[A_Pmech]

I'm finally getting back to work on this rebuild. The past couple weeks I've been making parts for a winding machine in my spare time.

Here's the winding frame right after drilling the last mounting hole. This will eventually hold adjustable UHMW plastic wire forms, onto which the magnet wire will be wound:

I used my Hardinge collet indexer to drill and tap four mounting holes in what will become the winding frame adapter. The winding frame will bolt to this adapter, which will then thread onto the spindle of the winding machine:

In this photo I've just finished turning and grooving the main housing, a piece of seamless tubing into which two ball bearings will be pressed and retained with circlips:

Before proceeding with the winding machine spindle, I needed to measure the final distance between the two seated bearings. This will ensure the snap ring grooves are correctly located to keep endplay to a minimum.

This is the completed main housing with the spindle installed. Next to the main housing is the finished winding frame adapter and winding frame. The winding frame adapter and spindle are made to the Jacobs 3/4-16 threaded chuck mount standard, so I could install a 3/4-16 threaded back Jacobs chuck if I wanted to for some later project:

 

[Travis E.]

Very nice. Are you winding it to the factory specs?

 

[Arne73]

John, have you got a stand for it yet?

 

[larry_g]

Damn I missed this thread till today. Sorry about the failure to heap grief about the transtruck. You are doing a hell of a job on this grinder. Keep up the good work. Speaking of lost threads, What happened with the Holridge?

lg
no neat sig line

 

[A_Pmech]

Very nice. Are you winding it to the factory specs?

Per standard practice. The manufacturer is long out of business so all of the specifications are arrived at by analysis of the old windings.

John, have you got a stand for it yet?

Not yet! I'm planning to copy the US Electrical Tool pedestal when I have the grinder itself finished.

Speaking of lost threads, What happened with the Holridge?

Thanks!

Summer came. I'll probably get back into it this winter when things slow down. I've run into a couple projects lately where I could have used a radius attachment!

 

[A_Pmech]

I got a little more work done on the winder today. I began by drilling and reaming a section of the same 1" bar stock used to make the spindle. This will become the crank handle hub which will be keyed and bolted to the spindle. Here, I'm measuring the finished length of the hub:

Here's the handle hub ready to receive a keyway. This will be done with a broach, which is the nasty-looking long toothed thing on the left:

This is the broaching setup. The broach guide is placed into the hub and the broach slid into place. Then, the hub, broach and broach guide are placed on a press block with a hole through it sufficient to pass the broach. The hydraulic press is used to push the broach though the hub. Each tooth of the broach takes a progressively larger chunk out of the inner wall of the hub, creating a keyway. It takes two passes to complete the keyway. When setting up for the second pass a shim is placed behind the broach in the broach guide to increase the depth cut as seen here:

Obviously, the spindle needs a matching keyway to mate with the hub keyway. This was milled on the Bridgeport. Here's the end result showing the keyways in both the hub and the spindle:

Back on the winding frame, I took a few minutes to finish countersinking the winding frame mounting holes and bolt the winding frame to the adapter:

In the next installment I'll be covering making the handle.

 

[Kenwc]

I've been watching this like reading a good book I can't put down....Though I'll probably never attempt a motor rewind I've been wanting to see it illustrated like this...thanks for taking the time to document it.

 

[amolaver]

A_PMech - you may have already done this, but can you give us some info on your schooling / educational background (i assume lots is OTJ, but still). I'm just consistently dumbfounded by the breadth of your expertise, never mind your exquisite attention to detail; the simple things like countersinking the winding frame mounting holes. i don't see any reason WHY they needed to be, but it is one of a million details i see that marks you as a craftsman (as in the old-world meaning of the word).

ahm

 

[A_Pmech]

thanks for taking the time to document it.

You're welcome, Ken.

A_PMech - you may have already done this, but can you give us some info on your schooling / educational background (i assume lots is OTJ, but still).

I really don't have an educational background, I'm an autodidact in the most extreme sense of the word.

 

[A_Pmech]

Earlier in the week I finished the layout for the crank handle:

Each corner was drilled out with a 3/4" drill to provide a smooth transition between elements:

I tapped a 3/8-16 thread for the handle:

Before removing the handle from the mill, I bored the center of the handle for the hub:

Skipping ahead a few steps, here's the handle after sawing out on the bandsaw, grinding smooth and brazing the handle hub into place:

Here, I'm coping the frame tube to fit the bearing tube by using the boring head:

The finished result:

 

[A_Pmech]

Moving along, I made the Nylon handle today. Here it is as I'm turning the outside taper using the compound slide. After turning the taper I used a custom-ground outside radius tool to radius the transition on the exposed end:

A 1/2" shoulder bolt makes up the axle on which the finished handle turns:

In this photo, I've just finished welding the spindle tube onto the frame:

Over on the drill press, I drilled two brackets which will become the bottom of the winding machine frame and part of the vise adapter:

Things are starting to shape up, I should be ready to paint the main components and assemble it for the final time shortly. Then, I can focus on installing the revolution counter and making the wire forms which will complete the winding machine.

 

[browntown]

Somewhat off topic, but you make me want to quit my job and study to become a machinist. You do quality work.

 

[A_Pmech]

Somewhat off topic, but you make me want to quit my job and study to become a machinist. You do quality work.

That's what I did. Well, sorta...

Thanks!

 

[justanengineer]

Very nice work as always John. I look forward to seeing this project finished and seeing the motor being rewound.

One question inspired by the broach usage...do you ever see a shaper in your future? Being that you enjoy machines of the larger variety, I think a hydraulic shaper would fit right in.

 

[A_Pmech]

Very nice work as always John. I look forward to seeing this project finished and seeing the motor being rewound.

One question inspired by the broach usage...do you ever see a shaper in your future? Being that you enjoy machines of the larger variety, I think a hydraulic shaper would fit right in.

Thanks!

Yes, I missed an opportunity to buy a perfect low-hour Rockford 28" Special Universal hydraulic shaper with all the options several years ago. I won't be making that mistake again! It was almost identical to this one:

 

[bad_idea]

you continue to astound me. you are almost to the point of being a show-off though.

 

[Arne73]

you continue to astound me. you are almost to the point of being a show-off though.

I'll subscribe to John's type of "showing off" any time.

 

[A_Pmech]

you continue to astound me. you are almost to the point of being a show-off though.

It's kinda hard to show how I did it without... showing how I did it.

I'll subscribe to John's type of "showing off" any time.

The UHMW stock to make the wire forms is here!

I did manage to order the wrong counter though. I'll have to rectify that on Monday.

 

[daveroy]

Please, Do not stop showing off! I am learning so much.

 

[cubfarm 1]

Plz keep going!

 

[trboxman]

bump for update...hopefully...

 

[Diesel_Crawler]

Stop machining so many darn hammers and get to work on that bench grinder!

 

[A_Pmech]

I've made absolutely zero progress on this since my last post. I was looking at it yesterday on the shelf and thinking "I NEED to get this done!". I'll see if I can get this project jump-started again shortly. I have about a dozen things torn apart around the shop and I need to get something finished.

 

[hammlm]

I have about a dozen things torn apart around the shop and I need to get something finished.

Amen. Although I operate in a different dimension and quality universe than A_Pmech, I need some closure on a few projectsmyself. Phew!

 

[Outlawmws]

I've made absolutely zero progress on this since my last post. I was looking at it yesterday on the shelf and thinking "I NEED to get this done!". I'll see if I can get this project jump-started again shortly. I have about a dozen things torn apart around the shop and I need to get something finished.

Why be different that any of the rest of us?

 

[bad_idea]

I have stopped looking at craigslist until I get a couple projects done. Here's hoping I can knock one of those projects off of my list today after church. Wish me luck.

 

[kidatari]

Any updates?

 

[-Brent-]

So you're self-taught? I admire that, truly. It inspires me to step my game up and get cracking on things I'd love to learn.

I've always wondered about the intricacies of the process. It'll be neat to see it done.

 

[dumbswede]

What the hell happened to this project? Let's get a move on....I am dying to see it complete..

 

[Diesel_Crawler]

I think he died.

 

[A_Pmech]

What the hell happened to this project? Let's get a move on....I am dying to see it complete..

I think he died.

I know... I know...

 

[Diesel_Crawler]

I know... I know...

You need to stop hanging around with so many women, its taking up fabrication time. Four wives is enough you know.

 

[A_Pmech]

You need to stop hanging around with so many women, its taking up fabrication time. Four wives is enough you know.

What are you talking about? I don't have time for women. Motorcycles and machine tools come first!

Actually, I just came in for a break. I've been cleaning up and repairing more dividing head parts this evening. That thing has so many parts I'm afraid if I don't get it back together soon I'll start losing parts.

 

[Strouty]

Anyone else wonder what is going on with the grinder?

 

[BigRed390]

^ ME!

(taps foot impatiently...)

 

[SiGmA_X]

Yes. John?