Now THAT'S the kind of project I like to watch being planned and manufactured. Being a retired Navy Molder I look back at all of the work I enjoyed in the foundry and all of the projects I watched being made in the Machine Shop and suddenly realized that I'm a manufacturing junkie! Keep the videos coming!
Hi Keith I was delighted when the cutout for the new fan fit perfectly the first time. This did not look like an easy pattern to get right but I knew your skill would carry the day. :-) I am looking forward to seeing the rest of the project come together :-)
This looks like a perfect job for your shop and talent. It's always jobs like these that push us to do more with what we have. That goes for all walks of life. I look forward to learning more from watching you do what you do. Cheers
I love it when different and interesting jobs like this get brought into work. When you get it done in a few days instead of 8-10 weeks, customers appreciate it more then you would believe. The break from the same ole, same ole is what keeps me happy to go to work in the morning.
I'm really enjoying the Rutland project, and am looking forward to more of this one as well. Thanks for all your sharing. It really helps people like myself. Keep em comin!!
Keith, super impressive. I am 71 and had the opportunity of going to a local FAB shop and looking over their shoulders a few weeks ago - guess what they were repairing that was also missing something :-) They also were taking into account the things you were pointing out.
I love watching your videos, I fire up the nuker and get the popcorn going and sit back and watch. I hope to retain a quarter of what you are teaching, my hobby machine "shop" needs all the help it can get. Please show the shaper in upcoming videos if you haven't made them already, there is something satisfying about seeing 100+ year old machines making money today. Thanks for the videos.
Nice , Answered a lot of questions I had as to why the whole thing was so robust. I will eagerly await the rest of the series. My respect for you continues to climb!
I've seen a few items like that destroyed in the mining industry and due to the same lack of maintenance as well. Always gets everyone's attention when they let go. :-) 3800 rpm would take some decent HP to spin that diameter and move that much air. From my perspective that project seems a bit more complex than it first looks like. Nice demonstration of just how versatile those plasma tables really are when the operator knows what there doing. Like Mikes (backyard machine shop) gang drill press table I'm more than a bit envious of yours Keith.
My brother in law has one of those sitting in his back yard. It was left there by the previous owner. We have wondered what is was for years. Thanks for posting!
Splendid new project! At first it seemed you were going to mend the old fan by creating a replacement ray, and, with miracle welding tacking it on. But, the problem of all that straightening loomed.... You'll be knocking this out in three--four tops---videos....
The opposing panels share the center line top to bottom. I think that accounts for the 1/4 off center. You not only have serious skills, but you got a great shop. Thanks again!
When that thing went into the housing at 3800rpm had to have been nasty! Being able to make one piece vs each fin sure will make it a lot easier to keep things true.
Great project, I just spent a week in the hospital and the WiFi was horrible, I'm trying to catch up on your videos and tis one looks ie a great series to watch while recovering. And the shaper will be a bonus! Thanks for sharing.
You know, that is a damn clean cut. It almost looks like it was done on a flow jet instead of a plasma cam. If it weren't for having seen it happen and the fact that there's a little heat discoloration around the edges I might miss that guess. Color me impressed...
Once again nice work..................I can only imagine the racket that thing made when she let loose lol. I'm looking forwards to part two and while I'm here I want to wish you and your family all the best in the New Year.
project forward to > 'get 'er done'. i been watching your u tube stream almost all of them and concur the busted part got sent to the correct place - turnwright machine shop. thnx keith mr. fenner, respectfully gerald.
Nice strategy for cloning the piece. Looks like you really enjoy your "new" 4-jaw. I bet that the missing impellor is somewhere in the next county.... and gave the dudes in the shop some new grey hairs.
The cover shot of the slug in the hole reminds me of the classic trivia question about why manhole covers are round. One acceptable answer is that they can't fall down the hole like other shapes could.
The accuracy of the plasma cam is a given, but the extraordinary preliminary measuring and laying out for the new piece to match the original, is where the real talent comes in. It would have been very educational to watch you going through your measuring techniques. Great video, looking forward to your next installment.
Wow - to my laymans eye it looks like a daunting task to cut, assemble & weld these all up to spin accurately and smooth. But I know your skill & years of experience will make it happen so im already impressed--lol
Nice road-runner and coyote on the wall there! Dang, those exhaust fans took a beating! Instead of re-in-venting this fan, you're re-out-venting it for them, eh?
No kidding. That is a hunk of steel to be spinning 3800 RPM or what ever he said it spins at. Rip two 1/2 thick webs clean off.... I'm guessing somebody noticed that when it happened. LOL
No doubt! I would have hated to have been around or even been in the building when this thing let loose. I wonder what actually stopped the whole thing? Breaker, thermal overload, or just binding and then burnout of the motor?
Keith Fenner what material are you using for the Hub? I hope it is 4140 ,not superior ground , the next failure would be awesome if you are welding up the wrong steel
Another great job Keith, cant wait for part 2. Just noticed your Clausing lathe is very nearly identical to my Colchester. I know there is a connection but not sure what it is.
Oof...that fan's shaft failed while it was still turning nearly 4000 RPM, and it was that sturdily built to begin with, it probably made some of the most horrific machine failure noises imaginable. And you likely could have heard the failure happen in the farthest reaches of the building it was in too, everybody in the building likely heard it let go and came running if they could. Apparently either the housing was salvageable, or they've either contacted a foundry to cast a new housing or they're hand-fabbing up a new housing for it to go in as you fab up the new fan.
"Separation". Some of the old timers told me about a time when one of the big fans we have kicked a vane loose. Punched it's way through the housing, missed one fella by about 2 feet, clipped a hillside about 50' away, skipped, and disappeared.
Nice project. Of course it depends on what the customer wants but if it was mine and the hub was good I would have repaired the original. The original lasted for years and was welded up, surely some weld repairs would have been fully serviceable. Straighten as needed and it would be good to go for another century. The cost savings would be substantial.
Love the videos. Thanks! The original wheel is truely a fine example of some workmans fine workmanship and tallent and functional thoughts for designs of the past.Modern machinery,like the plasma, sure can speed projects like this up a LOT! How will you go about getting this in percision balance?How many rpms does it rotate?Can static balanceing be "accruate enough?
A thought on the original stars and the way they were built. Perhaps it wasn't an equipment limitation limit that dictated the segmented construction. The segmented design seems like it would be much more efficient use of materials and the sheet of material you had could yield all the parts with material left over.
How is it that after all these years and all this great content the subscriber number is still under 100K? Think of all the total crap channels that are nothing more than entertainment that have numbers that are so high.
As far as I can tell, Keith isn't interested in garnering eyeballs for ad money, which means he can give us videos of literal boring work which the typical person would consider that other sort of boring.
Excellent point, great content on Keiths channel - years ago these videos would have been training gold for many going into the trade. Sadly we don't have as many young people these days interested in such jobs. I wonder if that's part of why subs aren't higher. Used to be trades were considered a great job opportunity, not near as many of the upcoming generations want to do actual labor such as in the trades. We sorely need to push the trades and generate more talented people like the ones that built this country from nothing.
So something like 70, 80 pounds of metal turning mach a lot stopped hard enough to come apart like that? That would be something to see, but from a distance!
I see enormous talent. And it looks like business is picking up. I've gotta ask this and I hope you understand I'm not tryin' to be a smarty here. Is there a master plan or vision of capital expenditure. Will your property size accommodate a new larger shop building? I mean I can understand either way, to expand or not. I know I get comfortable with how things are in my own environment and at my stage of life I just would not want any more overhead costs. I could see where you could really put more floor space to good use, and further more you deserve it. I'm interested in your thoughts/visions on expansion of your facilities.
Are you using the 9-8210... 60 amp tips @55 amps or the 9-8209... 50/55 tips @ 55 amps. The shielded cup really does work best on .500 ms.. (9-8237 cup) with the 9-8238 machine shield.. (50-60 amps) 80 psi..Hard to tell your setup, but there is always ways to improve the Victor machines, or arrive at the same place with slightly different setups. Even if it's just to improve the possibility of slag messing with your nozzle/(Victor call them tips) :)
Looking forward to the new series, Keith. Question: Considering how much material is wasted cutting the star, is it really that much better to cut a solid piece rather than to cut individual blades and weld them in a jig? Aside from how cool it is to be able to do that, I mean :)
When they were first manufacturing those, then, they had to save on material plus also had the jigs in order to make probably thousands of them, now you make one you save the time, F...K the material... Since it would take probably more material than the waste to make the jig itself... ;)
Hey Keith, how are you getting that heavy plate on your plasma table? Just man handling or you have a hoist of some sort that helps you load that heavy plate on the table?
I lay two rods length ways and slide plate, then lift one side at a time with heal bar and then just adjust the little bit left into place with heal bar and outside lip of table. ;{)------
That repair is typical of the stuff that comes into our shop (not my place, I just work there). Why maintain something that's working so well? When you can spend more to have it virtually rebuilt? Who knows what audible warnings the bearings were sending out? They were certainly complaining, but the change in volume and sound quality happens over time, and you just sort of get used to it. Add more oil and hope for the best.
Interesting I have a few questions - Why was the item fabricated in sections- obviousley it was fabricated before computer aided manufacturing era. So why was it fabricated in sections there must have been a considerable cost saving to cut sections or segements and weld components together. The potential risk of additional labour to reshaping after welding must have been a costly or risky exersise . Anyway I look forward to project end - Happy Newyear Keith
Tony Buck Possibly made in multiple parts to ensure that the segments are all the same. Stack them together and shape them to size. Though the distortion after welding would have been a painful tradeoff.
At 9:48 he explains why he starts the cut at the location he does. I would imagine leaving a bit of meat around the outside of the cutout would come down to the same reason.
Great videos. Can you tell what are the CFMs on the exhaust fan for your plasma? It does a great job of pulling out the smoke. Also did you build the computer cabinet for the plasma? If so do you have a video on that?
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Now THAT'S the kind of project I like to watch being planned and manufactured. Being a retired Navy Molder I look back at all of the work I enjoyed in the foundry and all of the projects I watched being made in the Machine Shop and suddenly realized that I'm a manufacturing junkie! Keep the videos coming!
Hi Keith
I was delighted when the cutout for the new fan fit perfectly the first time. This did not look like an easy pattern to get right but I knew your skill would carry the day. :-)
I am looking forward to seeing the rest of the project come together :-)
This looks like a perfect job for your shop and talent. It's always jobs like these that push us to do more with what we have. That goes for all walks of life. I look forward to learning more from watching you do what you do. Cheers
I love it when different and interesting jobs like this get brought into work. When you get it done in a few days instead of 8-10 weeks, customers appreciate it more then you would believe.
The break from the same ole, same ole is what keeps me happy to go to work in the morning.
I'm impressed at how well your star fit over the original fan. Your 4-jaw chuck centering is great to watch. I like part 1.
I'm really enjoying the Rutland project, and am looking forward to more of this one as well. Thanks for all your sharing. It really helps people like myself. Keep em comin!!
Keith, super impressive. I am 71 and had the opportunity of going to a local FAB shop and looking over their shoulders a few weeks ago - guess what they were repairing that was also missing something :-)
They also were taking into account the things you were pointing out.
I love watching your videos, I fire up the nuker and get the popcorn going and sit back and watch. I hope to retain a quarter of what you are teaching, my hobby machine "shop" needs all the help it can get. Please show the shaper in upcoming videos if you haven't made them already, there is something satisfying about seeing 100+ year old machines making money today. Thanks for the videos.
Looks like it's going to be another great project. Just to say the Caps arrived in time for Christmas- thanks Keith.
Nice , Answered a lot of questions I had as to why the whole thing was so robust. I will eagerly await the rest of the series. My respect for you continues to climb!
Well this is quite a switch from the delicate, small muscle project the Rut-land lathe had you in. This is a cool beast of a project.
I really like the idea of the plasma cutter table, draw what you want and it cuts it pretty much perfect. .
I've seen a few items like that destroyed in the mining industry and due to the same lack of maintenance as well. Always gets everyone's attention when they let go. :-) 3800 rpm would take some decent HP to spin that diameter and move that much air. From my perspective that project seems a bit more complex than it first looks like. Nice demonstration of just how versatile those plasma tables really are when the operator knows what there doing.
Like Mikes (backyard machine shop) gang drill press table I'm more than a bit envious of yours Keith.
"Welcome to Turn Wright Machine Works, my name is Keith and *today* ...." and I'm instantaneously excited :-)
That was great....And looking forward to seeing this project take shape. Very cool.
My brother in law has one of those sitting in his back yard. It was left there by the previous owner. We have wondered what is was for years. Thanks for posting!
Splendid new project! At first it seemed you were going to mend the old fan by creating a replacement ray, and, with miracle welding tacking it on. But, the problem of all that straightening loomed.... You'll be knocking this out in three--four tops---videos....
I again have to tell you how much I enjoy your videos. Also, the Cape Cod potato chips are extremely good !!!!
KEITH , GLAD YOUR BACK , GREAT JOB , LOVE THE VIDEOS...
Great job of explanation and set up. Looking forward to the up coming progress.
Very cool project Keith, Look forward to seeing this take shape. Thanks for sharing :-)
The opposing panels share the center line top to bottom. I think that accounts for the 1/4 off center. You not only have serious skills, but you got a great shop. Thanks again!
Awesome, Keith. So many things to learn from you. Was so disappointed when this episode came to the end. Looking forward to the next installment!
Awesome to see that you get jobs with the help of viewers
When that thing went into the housing at 3800rpm had to have been nasty! Being able to make one piece vs each fin sure will make it a lot easier to keep things true.
Wild how a simple bearing can cause so much damage .. Thumbs up Keith !
its not the bearing that causes the damage, its the lack of maintenance that causes the damage :D ;)
Great project, I just spent a week in the hospital and the WiFi was horrible, I'm trying to catch up on your videos and tis one looks ie a great series to watch while recovering. And the shaper will be a bonus! Thanks for sharing.
Looks like the start of a good project. Thanks for sharing it. ~ Cheers.
You know, that is a damn clean cut. It almost looks like it was done on a flow jet instead of a plasma cam. If it weren't for having seen it happen and the fact that there's a little heat discoloration around the edges I might miss that guess. Color me impressed...
Once again nice work..................I can only imagine the racket that thing made when she let loose lol.
I'm looking forwards to part two and while I'm here I want to wish you and your family all the best in the New Year.
project forward to > 'get 'er done'. i been watching your u tube stream almost all of them and concur the busted part got sent to the correct place - turnwright machine shop. thnx keith mr. fenner, respectfully gerald.
The cat's outta the bag. Adam will be ready for the 4 jaw belt in '17.
YOU ARE THE MAN. GREAT JOB KEITH
Nice strategy for cloning the piece. Looks like you really enjoy your "new" 4-jaw. I bet that the missing impellor is somewhere in the next county.... and gave the dudes in the shop some new grey hairs.
The cover shot of the slug in the hole reminds me of the classic trivia question about why manhole covers are round.
One acceptable answer is that they can't fall down the hole like other shapes could.
Interesting project Keith
Thanks for sharing ;)
Hi mate. A great project there. Nice that you gave reference to the old bloke that first made that.
Nice cut and probably a fun project.
I love that feeling when you realize something you made is going to fit. Right at 5:18.
This is going to be a great series!
Can hardly wait for the next installment on this one Keith.
Looking forward to the series.
Looks like a very interesting project, can't wait to see more.
Love that Plasma cutter., such a sweet cut. This job should be quite interesting. Getter Done Dave
Outstanding, Keith, a perfect gig for you. I can't wait for part 2!
The accuracy of the plasma cam is a given, but the extraordinary preliminary measuring and laying out for the new piece to match the original, is where the real talent comes in. It would have been very educational to watch you going through your measuring techniques.
Great video, looking forward to your next installment.
The new four jaw looks pretty.
Just found your channel and watched episode 4, great. Thankyou
Great work Keith
Looking forward to this one.
Wow - to my laymans eye it looks like a daunting task to cut, assemble & weld these all up to spin accurately and smooth. But I know your skill & years of experience will make it happen so im already impressed--lol
I wasn't even interested at first, but I couldn't stop watching...
Happy New Year Keith. I hope 2017 is good for you and your family. Thanks for the entertainment and education.
Bet that woke even the security guards when it came free :)
keith cool video, P. S.thanks for the tip on black silk coffee great.
Oh, nooo, you say I have to wait a year to see the next part, oooo
Nice road-runner and coyote on the wall there! Dang, those exhaust fans took a beating!
Instead of re-in-venting this fan, you're re-out-venting it for them, eh?
another AWESOME video.
You're having way to much fun..... :-)
I'll bet that made a little bit of a noise when it happened.
No kidding. That is a hunk of steel to be spinning 3800 RPM or what ever he said it spins at. Rip two 1/2 thick webs clean off.... I'm guessing somebody noticed that when it happened. LOL
if my guesstimation is correct it spins at around 600 kmh or 370mph
No doubt! I would have hated to have been around or even been in the building when this thing let loose. I wonder what actually stopped the whole thing? Breaker, thermal overload, or just binding and then burnout of the motor?
Probably shook all the dust off the roof girders...
That had to be the sound of "Hell's Bells" ringing to anyone close by it.
This is going to be good!
I think the shaper jig made a cameo on some of the Apron videos.
Imagine if the original maker, the "old timer" could see how this was redone. Sweet.
Doubtless, it would make him feel old.
Hey Keith, You're giving away your 4 jaw secrets. Don't forget Adam watches your videos. Lol.
I'm counting on it! LOL ;{)-------
Michael Marriam - I'm sure Top Lipton over at Oxtoolco and Keith Rucker at VintageMachinery.org probably watch, too!
Keith Fenner what material are you using for the Hub? I hope it is 4140 ,not superior ground , the next failure would be awesome if you are welding up the wrong steel
Another great job Keith, cant wait for part 2. Just noticed your Clausing lathe is very nearly identical to my Colchester. I know there is a connection but not sure what it is.
It is called a Clausing Cholchester ;{)-------
Oof...that fan's shaft failed while it was still turning nearly 4000 RPM, and it was that sturdily built to begin with, it probably made some of the most horrific machine failure noises imaginable. And you likely could have heard the failure happen in the farthest reaches of the building it was in too, everybody in the building likely heard it let go and came running if they could. Apparently either the housing was salvageable, or they've either contacted a foundry to cast a new housing or they're hand-fabbing up a new housing for it to go in as you fab up the new fan.
Oh boy a shaper episode: Ya Hoo
aha! NOW I see what the shaper jig is for! Kewl... ~8D
"Separation". Some of the old timers told me about a time when one of the big fans we have kicked a vane loose. Punched it's way through the housing, missed one fella by about 2 feet, clipped a hillside about 50' away, skipped, and disappeared.
Wszystkiego najlepszego w Nowym Roku
Happy New Year! ;{)------
I was gonna say Keith that looks a lot like bird strike to me.
Awesome Ninja star...
Nice project. Of course it depends on what the customer wants but if it was mine and the hub was good I would have repaired the original. The original lasted for years and was welded up, surely some weld repairs would have been fully serviceable. Straighten as needed and it would be good to go for another century. The cost savings would be substantial.
Looks like fun
I bet if the guy that originally made that saw the web cut out on your plasma table he would cry........LOL
Love the videos. Thanks! The original wheel is truely a fine example of some workmans fine workmanship and tallent and functional thoughts for designs of the past.Modern machinery,like the plasma, sure can speed projects like this up a LOT!
How will you go about getting this in percision balance?How many rpms does it rotate?Can static balanceing be "accruate enough?
Ooh a plasma cam.. Awesome.
A thought on the original stars and the way they were built. Perhaps it
wasn't an equipment limitation limit that dictated the segmented
construction. The segmented design seems like it would be much more
efficient use of materials and the sheet of material you had could yield
all the parts with material left over.
How is it that after all these years and all this great content the subscriber number is still under 100K? Think of all the total crap channels that are nothing more than entertainment that have numbers that are so high.
As far as I can tell, Keith isn't interested in garnering eyeballs for ad money, which means he can give us videos of literal boring work which the typical person would consider that other sort of boring.
Excellent point, great content on Keiths channel - years ago these videos would have been training gold for many going into the trade. Sadly we don't have as many young people these days interested in such jobs. I wonder if that's part of why subs aren't higher. Used to be trades were considered a great job opportunity, not near as many of the upcoming generations want to do actual labor such as in the trades. We sorely need to push the trades and generate more talented people like the ones that built this country from nothing.
So something like 70, 80 pounds of metal turning mach a lot stopped hard enough to come apart like that? That would be something to see, but from a distance!
Great video Keith. When will part 2 be posted?
I'll be dropping in a few in between the Rutland project! ;{)------
Nice project Keith, Does the plasma pierce the sheet on the waste side of the cut then move to the cut line?, Jus' wondered, Cheers, J.
Yes and the parameters can be adjusted to suit. ;{)-------
Got it, Fantastic machine, no-wonder the old fan was fabricated out of sections, would have been a pain to hand cut that whole!, Regards, J.
Holy shit 3800rpm!
I am thinking about the force needed to spin a fan that size at 3800 rpm.
It would have to be a 20 -30 hp.
I figure you could balance it just as good or better than whoever they're sending it out to.
I see enormous talent. And it looks like business is picking up. I've gotta ask this and I hope you understand I'm not tryin' to be a smarty here. Is there a master plan or vision of capital expenditure. Will your property size accommodate a new larger shop building? I mean I can understand either way, to expand or not. I know I get comfortable with how things are in my own environment and at my stage of life I just would not want any more overhead costs. I could see where you could really put more floor space to good use, and further more you deserve it. I'm interested in your thoughts/visions on expansion of your facilities.
I like at the end of the day, shutting the doors at the overhead I have now too!
Are you using the 9-8210... 60 amp tips @55 amps or the 9-8209... 50/55 tips @ 55 amps.
The shielded cup really does work best on .500 ms.. (9-8237 cup) with the 9-8238 machine shield.. (50-60 amps) 80 psi..Hard to tell your setup, but there is always ways to improve the Victor machines, or arrive at the same place with slightly different setups. Even if it's just to improve the possibility of slag messing with your nozzle/(Victor call them tips) :)
I've made that laugh at 15:17 before! Haha
hahaha! awesome! I wanted to ask whats that jig on your shaper , I spotted it on your last video :)
How come you didn't have that 4 jaw belt in the camera's field of view?
must have been a hell of a failure!
Looking forward to the new series, Keith. Question: Considering how much material is wasted cutting the star, is it really that much better to cut a solid piece rather than to cut individual blades and weld them in a jig? Aside from how cool it is to be able to do that, I mean :)
Yes it is when you consider the time it would take to jig the 12 segments together, the steel is cheaper. ;{)------
When they were first manufacturing those, then, they had to save on material plus also had the jigs in order to make probably thousands of them, now you make one you save the time, F...K the material... Since it would take probably more material than the waste to make the jig itself... ;)
Also likely chance the offcut material finds another use down the road too.
Nice work as always, Cutting it out in one piece yours is already have closer tolerance than the original. what is the 1/2" material you used?
yes 1/2" plate. ;{)------
What kind of plate is that? A36 A572? Great Job!!
Hey Keith, how are you getting that heavy plate on your plasma table? Just man handling or you have a hoist of some sort that helps you load that heavy plate on the table?
I lay two rods length ways and slide plate, then lift one side at a time with heal bar and then just adjust the little bit left into place with heal bar and outside lip of table. ;{)------
That repair is typical of the stuff that comes into our shop (not my place, I just work there). Why maintain something that's working so well? When you can spend more to have it virtually rebuilt? Who knows what audible warnings the bearings were sending out? They were certainly complaining, but the change in volume and sound quality happens over time, and you just sort of get used to it. Add more oil and hope for the best.
Interesting I have a few questions - Why was the item fabricated in sections- obviousley it was fabricated before computer aided manufacturing era. So why was it fabricated in sections there must have been a considerable cost saving to cut sections or segements and weld components together. The potential risk of additional labour to reshaping after welding must have been a costly or risky exersise . Anyway I look forward to project end - Happy Newyear Keith
I would have had to been or seen the originators shop to reason his design. ;{)------
Tony Buck Possibly made in multiple parts to ensure that the segments are all the same. Stack them together and shape them to size. Though the distortion after welding would have been a painful tradeoff.
goooooooooooooooood job
Keith I've often wondered why cut so far from the edge of the plate?it seems you have a lot of waste.
At 9:48 he explains why he starts the cut at the location he does. I would imagine leaving a bit of meat around the outside of the cutout would come down to the same reason.
Great videos. Can you tell what are the CFMs on the exhaust fan for your plasma? It does a great job of pulling out the smoke. Also did you build the computer cabinet for the plasma? If so do you have a video on that?