AGRKULTURAL

EQUIPMENT

AND

TOOLS

FOR FARMERS

DESIGNED

FOR LOCAL

CONSTRUCTION

Publications ? King street. irlrl WCZE BHN. Lnglancl TrieDhone 1 836 h370

Lfd

-l-

THE BELLOWSOPERATEDOIL DRUMFORGE Developed by the Intermediate Technology Project, Zambia Development Group

Introduction: The be made blacksmith blacksmith The or can ment be brazing be will used by Rural by as Oil a step then of in cause man, free will the the as Drum for in Forge use the forge being rural it to serve the particular It the give its good owner is is tend to forge trouble in is his designed of and does available. areas. to the the show is hoped and, foot owner. operated, work the and local of suitable to that of the local this not sell All As parts The so his the that or tools. forges. on welding Che components wear, forge leaving the fire. that As any trainscale an replace can the it by can a The

a farmer could facilities not one bands

own workshop

.lp.grading

manufacture

construction obtained

depend

Qperator's The he ing used The need progra will forge engineering industrial

Forge not

artisan sort. for small

depend exercise, e, with development.

on imported

items reference

techniques craftsmen. most

inventiveness service, money.

will maice

perhaps

important,

Project Farm

Project Engineer H S Pearson Leader R M Coombs Designed by the i'roject Engineer Machinery Research Unit, Regional Research Station, Magoye, Zambia.

THE RURAL OIL Tools Tools and Marczrials Required

DRUM FORGE for Construction of Forge

12 kg (2.75 lbs) Hammer - eve: Two shifting spanners 20 cm - (8) File steel tape .-de 183 cm - (6 ft.) 20 cm - (8) screw Iri-~-er Centre purch 6.3 mm - (:I11 Diameter Punch 12.5 mm - (A1t) Diameter Punch Drill 6.3 mm - (iIt) Diameter Drill mm - (3/16vt) Diameter 5 Pipe die mm - (1") Diameter 25 Hacksaw l.'ood saw ,lisel made from old L??(! Rover spring iand drill (if available if not, holes can Materials: Wood

be punched)

109 cm x 51 .mm x 75 mm (43

x 2" X 2" X 15"

x 3) X 1-t") X ?~II)

cm X 51 mm X 32 mm (lOTt x 25 CIUIIx 6.3 EU,, (7"

76 cm X 38 cm X 19 mm (30"

x 11~ x p)

(45

galls) mm diameter X 10" (e.g. (67" X $") X 13" X t-") mm (40" X 0.394) s~c!r labels) cm X 10.1 cm (Z$ll X 4")

cm X 12.5 X 1 mm (83 thin metal

X 38 mm X 6.3

cm X 25.5

Two pieces Pipes & Fittings Gas Four One One 'ho pipe,

6.3

114 elbows

cm X 12.5 12.5

mm nominal
nominal

bore bore 12.5

(45" IWII (3tv)

X *11)

900
socket female nuts

mm (3") 25 mm (1") elbow,

reducing X female X female 25 mm (1'") 12.5 12.5

to

25 mm (lfl) 25 mm (1")
bore
b0rO

bore

One male

elbow, internal

nominal

bore

TWO ~-~Lpples

25 mm (1'1)
mm (3") mm (s",

internal internal internal

T-do nipples One socket

bore bore

1-

Bellows

Material
109.2 cm X

Canvas Plastic Steel Nuts/Bolts 0.45 Screws

30.5

cm

(43"

X 12") bag) 109.2 cm X 30.5~cm

Sheet banding

(old (e.g.

fertilizer old packing

(43" 228.5
case banding) cm x 12.5 INTI (90"

12")
x -;*I)

kg

(1

lb)

of

38 mm X 6.3

mm (1$11 X $I)

nuts

and

bol

51 mm (2") 9.5
mm (Qql)

wood wood

screws screws

10 %ails One box

of

large

head

tacks

Pins One box of drawing pins

Other

Materials Old car or (44 cycle lbs) of tyre inner tube soil

20 kg

ant--hill

KEY .ITEM Ae Ab AC Ad Ae Af *g Ah Aj Ak Oil Rim Top Half Seam drum. of of of of Steel. made DESCRIPTION 194.5 concave of (old crushed centre diameter (Bx) of (13" Mild Mild 12.5 steel. outlet Sheet strips. Very Wood thin litres to (45 a depth is cut spring) ant-hill section steel pedal X 4") steel steel thick wide Mild attach (Ce) steel this part soil) (Ad) bar to arm (Bc) nuts & bolts. galls) of 12.7 away cm (5")

drum. drum centre drum cutting edge (made from made of 12.5 return of tool cutting from cut-away car tool section drum

Home-made Sharpened Fire Shield Piece support bricks

mm ($II) spring mm diameter

Be Bb BC Bd Be Bf 4 Bh

38 mm X 6.3 Pedal Pedal Pedal Bellows Banding. Pivot Pivot before Mounting Air Valve Valve Bellow outlet holding flaps. base. stand stand. fitting arm arm. arm top.

support Mild pivot Thin side Mild air box.

plate. steel bracket.

Wood steel

19 mm (Et') bracket. Note elbow metal Hard metal,

mm (3")

support

Bj
Bk Bl Bm BIl Bo BP

beam.

Wood 1 mm (0.0394") wood. must t:,ick 2 off be flat. 2 off thick

19 mm (m$ll,

Bellows fabric. 109 cm X 30.5 Bellows (21" x pieces

Leather/canvas/polythene cm (43" X 12") cm

base support. Wood. 53 cm X 5 cm X 7.6 Note length of these 2" x 3") 2 off. can be varied to suit size of oil drum base hooves of (Bq) hot) in or former rubber (100 in pivot box for inner along stand (Sk) bellows tube dotted for pedal pedal lines arm and (Oh) outlet bolt for pivot bracket (Bn) to bellows

Bq
Br Bs Bt BU Bv BW BX BY

Screws to attach bellows base support (Bp) Bellows Hole

air for for

inlet/outlet screws (metal hole

attachment

(Bd)

90 Air Return Bend make

twist outlet

Template air up

for spring

wire

(DC) (UC

arm

outlet box as shown

-4KEY .-

ITEM Ae Ab Ac Ad Ae Af *g Oil Rim Top Half

DESCRIPTION Steel. drum. drum drum cutting edge made from of (made tool cutting from cut-ansy (old car tool ant-hill sec'.ion steel pedal X il') steel steel thick wide Mild attach (Ce) steel this part soil) (Ad) bar to arm (Bc) nuts & bolts. centre spring) made concave of to a depth is cut of 12.7 away cm (5") centre section drum 194.5 litres (45 galls)

of of of

Seem of Home-made Sharpened Fire Shield

bricks

crushed diameter (Bx) of (l+" Mild

Piece of 12.5 support return Be Bb BC Bd Be Bf % Bh 38 mm X 6.3 Pedal Pedal Pedal Bellows Banding. Pivot Pivot before Piounting Air Valve Valve Bellows outlet holding flaps. base. stand stand. fitting beam. box.
arm arm. arm

mm (3") spring mm diameter

support Mild pivot

plate. steel

top. Thin

Mild bracket. Wood 19 mm (2") steel Mild air 12.5 steel. outlet Sheet strips. Very thin support bracket. Note e= metal Hard metal,

mm (3")

side

Bj
Bk 81 Bm BIl Bo BP

Wood 1 mm (0.0394") wood. must tT,i.ck 2 off be flat. 2 off thick

Wood 19 mm ($-")

Bellows fabric. 109 cm X 30.5

Leather/canvas/polythene cm (43" X 12")

Bellows base support. Wood. 53 cm X 5 cm X 7.6 Note length of these (21?' x 2" x 3") 2 off. pieces can be varied to suit sl:e of oil drum Screws to attach bellows base support (BP) Bellows Hole for 4 hales air for inlet/outlet of (El-j) hot) in in pivot box for inner stand (Uk) bellows tube for pedal pedal arm (OhI outlet screws (metal hole for spring wire attachment base hones bolt for pivot
bracket

(Bn)

to

bellows

(Bd)

iiCY twist
Air Return outlet Template

former

(UC)
(UC

ox- rubber

arm

"Yerkd air r,utLet box Ctlkj along make "p as SllOwn

dotted

lines

and

-5Bz ition pport of bolt bracket ich ( de fPcm Fire Fit hearth. bellows (top assembly of dru to drum 12.5 (3")
ered

attache

t stand

ride

Ca Cb cc Cd C@ Cf CSZ Ch C.i Ck Cl Cm Cl3 CO CP cq Cr CS Ct CU cv x 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 Pedal ($", (+*, (j") (%I*) (3") (3II, mm (+", (%'I) ($"I (&', Poop bore bore

bore
concave)

pape

a@ shown to attach the

4 ===~"* bellows 25 Air Holdiw 25 pass outlet

through the base support bore pipe nute for F.F. nipple outlet

side of drum pieces (BP) pipe elbow pipe in nipple drum

(1")

(1") diameter through (1") (1") bore pipe pipe (1"

hole elbow nipple to

for

pipe

to

bore

3") elbow elbow nippae elbow nipple elbow socket

reducing

socket

pipe pipe pipe pipe pipe pipe pipe pipa pipe pipe

b ore bore

bore
bore bore bore bore bore

-6-

-7-

6 3tm(Zv2213

i r--- 30.5C (\ ;?7

-8-

..0.......... . ......-. . . ---__------ ----- ---..-- -- L . ----..*.--.I -.-- .., .....

-9-

.-

0 %-I

+3=-m (P+)

- 10 -

- 11 -

6.3-w.. (4)

$6

it+-

38-(c-k) 6.3 mm..(%) $i

- - _1

;;--fII
6.3 -e* (/a> 12144q 2Sel,(l3

25.w..

(I)

-it-

- 12 -

--

------

_------

I ' 49.5cm (19%) -

t 50-m (2")

f833cm

(139

14 -

I l/---10.2cm(4"')

-----+

- 15 -

L63-w /2> I
(2

127.,,(5)
L. 76=M(39 ----I ---q

16

89mm (3h)

j59cm
.22)

82-5 cry\ (32y2u)

- 17 THE RURAL OIL CCNSTRUCTION Note: Abe key letters in DRUM FORGE DETAILS refer in FORGE TOP ASD CUT-Aiu'AY The bole even at and oil the drum bottom. straight in (Aa) If should the so that shape. fire lbs) Starting drum centre can However, the left on it's described hammer drum to top own work top is hearth in the is required, at the hakered at can with the the pour the (AC). lead care, is netal metal water the required drum using in to to top a ball pein the hammer face working a depth splitting without experienced to must 'red' hammer outof blows of having a fire heat; to metal). be fire hot will the to be rims the stood (Ab) drum upright are badly stands with bent firmly the they with filler should the top to the Items the drawings indicated attached.

brackets

be hammered

circular

To form the curved hammer of 1-i kilos (2.7j and wards in one not in the ball at must metal. is the enough then slowly above for end. the the circles, spot This the fire down

centre

and Heavy

11.7 cm (5)
metal. anneal can the cool After soft hearth. The drum half starting wrapped marks, laid out at the is the can to of next the

as shown as this be done. if to go out (do to heating form bring and not difficulty

be avoided

operation

be made in

be allowed metal

on the

treatment,

bowl-shaped

step

is for

to

cut use nark two

away the the the

the seam of

mid-section unit. (Ae) of or point ribs. drum With until is and use hammer. the

(Ad) drum by two

of

the

make room point, around one side the the

fitting with

bellows string

To determine as a tape chalk is held through mark cut 'the in (Ad) forge and between carried tool (Ag) chalk cut other mid-section on in dangerous drum a flexible The the the then the The later are

circumference and the drum, of and the the

a piece

half-way of tool the rib The seam the (Af). sharpened lines metal line marks. for

on each

intermediate

on its using 9o" to metal, reached ribs,

removal cutting hammer the ribs. the is drum the put edges using

mid-section edge

home-made drum seam, of along connecting and sharp inwards The

proceeding on each one line cut

along the

a straight construction. should

chalk aside left a small

now be removed, be turned

by cutting

- 18 THE BELLOWS UNIT Follow bellows SrS cut Sir-outlet does not from split the attached The (Br) between drawings bellows in top the comtruction Of the

components. holes

19 mm (t")

thick timber. must be drilled adjacent

(Be) and bellows base (Bn) Both the air-inlet and with care SO that the wood can flexible to The
(Bn)

be made of any thin sheet to lift out Snd allow the drawn used valve outlet the set flnps of in is valve and fixed valve holes strips as this Fix Make metal. box inside the to is can outlet and elbow the central Fit the flaps (Bt). (811, would pedal air air other pipe base the out sacks on the are during are on the on crop

metal, full 'bellows-volume' operation. The for side of care the the being

The valve flaps holes. but must be sufficiently of metal flaps. base to Sir label thin valve bellows taken

(ilm)
be tags inlet and that

suitable upper

the

underside, positioned The valve the tend zrm to pivot

enSure their place

to cover flaps are of which the buckle bracket box (Bk) securing of the onto that The solder to the

completely secured in must not sheet metal. the

respective by holdthe

ing-down

screws

go through

(Bd) of

to

bellows thick (Cf) one side.

top

(Be). sheet the on the the

up the the the bore aperture

outlet outlet (Ch) elbow upwards. (Bn), outlet using base (Dq) for can found with on the

1 mm (0.394") nipple (Cg), box the outlet of putty. bellows nipple outlet flap the nuts the pipe

25 mm (1") using (Ce) ensure outside

pipe

into nut Screw (Cf) box valve

25 mm (1")

so that (Bk) (Bm) box

end points within

When fitting the or

bellows

box.
soft (Bn)

edges

outlet

be made airtight Fix the fcxr material is of to types allow and Case Cut air bellows screws used

wooden

base

supports

(BP)

with The

as shown the this also the when bellows is

on Page 13. must the bellows lining make best but are be airtight. material if too to thin outside, plastic airtight. If use. they A satisfor (in

supple certain will factory support this

leather

available canvas escape was fertilizer of canvas of

be used,

compressed. on the

compromise strength, an old a strip and

by using an inner bag) to (Bo),

canvas

of strong the bellows

109.2 sheet

cm X 30.5 for the

cm (43"
lining

X 12") of the

in

size,

S piece

plastic

inner

same dimensions. Attach the bellows plastic inner liner to the outer edges of

19

both

the

bellows

top

(Be) is

and

the

bellows

base

(Bn)

with

drawing pedal

pins spaced approximately arm pivot bracket (Bd) bellows of the glue by inner strips holes steal arranged of the base plastic on the stitching. liner of bands that inner The are not supports liner

25 mm (1") apart, ensuring that the parallel to the centre lines Of the Make point s.veral where folds they and (Bo) top in of the two meet together

(BP). at the

edges
(smear

edges being folded together) The bellows outer canvas to steel held the plastic bellows built as this are to block the edges at place liner canvas of (Bf) with joint to the 12.5 bellows mm (3") banding in

secure the seem joint is fitted over the and being bellows with base, small the be that a minimum. flow is width,

made by a nail

25 mm (1")
seam

spacing, does reduce provide to not air

broad-head help to

tacks.

used, and It should with to

coincide leakage

Note: and should available

intended give high the in into view

a steady Therefore

air-stream no attempt pressure

pressure. damage the drum, on Page bottom, by the to

be made to

outlet

see how much the bellows.

may result unit on the

Fit outline supports supports side of positioned cut-away, AIR PIPES Join the iength length

the in (Bp) are the

bellows the rest secured drum.

as indicated
19.

by bellows of

the base

dotted base

section-plan

The the

and

ends

the

in position When fitting off-centre being

four screws bellows.unit the at the centre

(Cd) through the it should be line of the drum circumference.

mm (34-@)

from made

this

measurement

drum

up the of 12.5

air

pipes mm (4") for is

as shown bore at pipe each

on Page 27. required, end for the

When measuring 12.5 mm (-&'I) extra threads. bore (Ck), 12.5

should To the

be a&wed elbow by to 12.5

(Ce) $")

connected bore socket pipe pipe (Ct.). elbow pipe should the

a 25 nan (1") pipe (Cl), (Cn), (Cp), (Ch) elbow elbow the hole 12.5 (Ct.), socket other nipple a 12.5

pipe then

elbow a 25 mn bore bore bore side,

(Cj), to pipe pipe pipe

followed 12.5 nun (1'" (Cm), (C,o!, nipple mm (3"') 12.5 and The with

a 25 mm (1") reducing bore bore elbow pipe bore (Cal and

mm (3") mm (3") mm (3") the drum

mm (3") rrrm ($'I passing pipe bore man (3") nozzle end

(Cq) bore mm (3'") a 12.5 blower outer

through

in

(Cs). (Cu), CC=). long

nm~ (2") bore pipe nipple 12.5 mm (311) bore pipe (Cv) end to blower to nozzle fit
the

be made about threaded

102 mm (4")

closed

12.5 with and is mm ($I) about sides easily in bore 20 holes order replaced pipe each to when PARTS stand twist (Bh) being is it socket spread

20 (Cv). the air The nozzle diameter The blast. burnt out in should along blower use. be drilled the top nozzle (Cf.)

5 mm (3/16*t) becomes

through

BELLOWS PIMPING The Pageil, the point The beam base (Bj) pivot a 90 (Bu) pivot which

made on the

to

the

dimensions heating of

as sho~:n t!le metal

on at

made following drawing.

as indicated stand is (Bh) then in is

secured down view bracket (Bz) plate

by a screw in position !?. on Page (Be;) is

to

the

mounting bellows

screwed plan

on the

supports The pivot

as Shown stand as indicated

support at

bolted

to

the

side

of

the

drum

on Page 7. (Bb) is made to the dimensions

The given

pedal

arm support t3. construction (Bw) 254 pedal diameter dimensions bolted pivot is the to the

on Page To facilitate

of full-size from

the the bar, support (Bd1). the

pedal scale point

arm

(Bc),

first on Page by

make 15, made The the

a wire allowing arrow of 12.5 template, pedal stand

template an extra X for to arm (Bh) At (Bc) and the the mm (3")

as given indicated arm (Bc) to and (Bb) :3

mm (10") loop (X). mild with bracket above

The steel

pedal

is the !;. to

then wii-e the

matched plate

as given its

on Pages

pivot

a point the the drum to

89 mm (3-2") pedal arm, and the

support hole

bracket hole rod as the length return spring

(Bg) is (AK). return of old

and drilled

in side

line through of

with the If

a 12.5 pedal

mm (3") arm spring can The

d'lameter support be used

drum-side take

a similar

made on the

opposite

available, pedal inner arm. tube as shown HEARTH (Ah) soil. be laid slowly, in the for The

a metal can

spring

spring car is

for rubber

the

Alternatively be used. 7. on Page

a suitable pedal

(Bx)

positioned THE FIRE Bricks ant-hill should to dry

the bricks

fire of standing

hearth while in

(Cb) they the

can are

be made from moist The bricks and

crushed X -1") allowed should

50 mm X 50 mm X 19 mm (2" still shade.

X 2"

the

hearth

drum

21
if

be dampened too quickly. The covering pipe it

to

avoid

cracking

they

appear

to

be drying

out

(Cu) in clay. (AJ)

should

be protected

from

the

forge

heat

by

A 3hit.1,i centre Lut-away

l~or

the (Ad)

fire

hearth

can

be made

from

the

drum

section

THE FORGE IN USE The of paper The with long Once will being remain used forge and best firm the to can wood be started together are with obtained easily by using a small quantity

charcoal. by pumping the bellows slowly

results strokes. fire alight bring is for it

going several up to

with the

the hours,

charcoal

fully

ignited, on the heat.

it bellows

a few pumps working

required

- 22 -

ted Oil Dmm Fowe v for blank CBS* to a little forge. re equipnt

t.hs wo~shope

e the bellova forge my like to comes.3 their

possibilities are left vitk tie bellows fo * Solo as the be&c dimeatk ea hgenions d, there ie no reason wky tke builder ckonld not le, if ball racefJ are be used in prefereme to tke wed bear-i kxm=as to arc or gas we1 a larch easier if a t ie required, the capacity electric-till

23

TBEFAliOPERATEDOXLDRtBFORCE Tools rewired Metal drills

5/e,,)

Hand drill or prefembly electric drill Steel mle, protractor, aad compasses centre punch Clamp Rivet set Hammer Backsaw File Two shifting spanners 20 cm (El') r for 6 mta('/L$") bolts / 2" dia. Chisel Materials rewired Wood &antitp
2 2

DEscrilJtion

50 pm? 50 mi7i 25 mmhardwoo& (2" x 2" II 1") x x

1 1 1 1 1 Steal Quantity 1 1 1

110 mmI je m x 35 mmhardwood (4&'

x 1l/ 2" T 1v 2")

mmhardwood (2" x 2" x 3/4") pbood

355 Iplpdia. x 6 am

305 mmdia. I 20 m

plywood (12" dia. z 3/4)

Approx. 400 mmx 400 mmx 35 mmlumber (16 x 16 x 1I/ 2")

hSCriDtiOn

230

mmdia. x 3 mmthick,

flat

mild steel (Vu dia. I %) gg

850 DIPx 76 ma x 3 mmmild steel (33" x 3" x %)

steel (25 I. 4 x V,,t)

- 24 Steel mx 2 1 2 EesobDtion 300 m x 260 me I 1.6 mmsteel sheet (1113/16*1 x 101/41 x %6'9 855 mmx 102 DIDII 1.6 mmsteel aheet (335/ 8" x 4" I '/169 140 rm x approx. 350 nunx 1.6 mmsteel skeet (5 l/ 2" x appmx. 12" x '/l6'9 i25 m I 65 nm I 1.6 mmsteel sheet (5" x 2V 2" T '/16@9 280 rm of 6 ma - 8 ma dia. mild steel bar (11" of
3/10L1/4*@

dia.)

200 ILID 12 rm dia. mild steel bar ( 8" of '/2" dia.) of 2jj mmc~f 16 m dia. bright drawn steel shaft (10" x 5/81 dia.) 3Oj m of 16 mmdia. bright dram steel shaft (12" x 5/81t dia.) 520 mu of approx. 6 mmdia. x 1.6 mn tubing (21" of approx. '/4" ~16~0) 380 m of jo r&m y nm angle (1591x 2" x 2") x Ruts & Bolts Quantity 8 4 4 4 8 2 4 SescriDtion 40 nn x 6 m (1% 75 mu x 6 nm (3" x i/4") x l/p) dia.

65 mn x 6 m (2l/21* x l/4$')

90 m x 6 rim (31/2t* x l/4") 115 mn x 6 nm (4l/2" x l/4") 165 m x 6 m (6l/2. 75 mu xl2 Dm (3" x l/4**) x
V2)

Other Materials 4 mlts - 12 am (l/2") 12 r!!m(l/2") 16 ma (5/8t9

2washers 5waakers 3Q rivets 20 nails

- 12 nm x 5 mn dia. ( l/ 2" x 3/161') - 1~ mm(6)

25 (1 1: l/fp) ( 21i4ts x l/W*)

4 steel pine

25 rim x 3 mm dia. 55 mm x 3 mmdia. 65 m x 3 m dia. 36 mmdia. (11/2")

2 steel pine 2 eteelpins small pulley -

(21/21t x %) cast iron or alluminlum, or made from E

63 mm(2 l/ 2") dia. piece of hardwood. Veee belt tfetal boss 50 1(m3 dia. x 25 ll~~mild ateel (2" dia. x 1") assembly.

Old bicycle cb&.nvheel, crank and epiAle Cld bicycle reaz wheel spmcket Old bicycle chain.

26 -

blade Fan cowli.ng Left-hand fan side plate Right-hand fan side plate Tubular spacere
Es n

EC !a3 Ee H Eg
m Fb

Large pulley.sidee Large pulley oentre Large pulley hub L=i%e pullw be--=@ Laxge pulley axle Spmcket small pulley Front base angle Back base angle Leeband woodenupri#t Fight-band woodenupright Woodenspacer Support bar Air chute bir outlet. grill Vee belt Cheinvheel, crank and spindle assembly chain.

PC Fd Fe Ff Fg ii33 Gb GC Gd

27 -

centre clearlp v-itch the oeatm-pmoh

drur the oircleueisgr

tly at the oentre of the plate.

Make the f'iret onesae ehom in Eigtrt of these are reqdred. ing using the 850 mm(33) or 650 mm (25n) lewtb of 3 mm Uae this first blade ee a template and jig for the other eeveablades. Finally bend all eight blades at 90"

These are identical and are made from the two pieoee of 50 (2~) x 50 rdb (2") x 25 mm(111) hardwood. Mark the centre md dnw the 50 ien (2") dia. &role. Chisel to shape or turn on a lethe. mll the four 6 zm ( 1/ 4) dia. holes and the 5 nm ( v 8") dia. oroeehole es ehovn. Finally drill ,the 16 mm( 5/811) dia. hole thmngb the celltree.

Bend the 280 m (11") length of 6 m - 8 m ( 3/ 10" - 114) dia. bar into a p0 nun(3 l/ 2") dia. ring, and breze or arc weld the sade together. FARAXLE Use the 255 m (low) length of 1.6 mm( 5/ aw) dia. bright steel shaft..

- 28 FANBLBDN ASSf?BLY Line up the fan back plats and fan hub by sliding them together on the axle. Drill through the four 6 mm( l/ 4) dia. holes. Nowslide the axle so that its end just emerges fmm the wooden hub and carefully drill through the 3 mm( 1/ 8") dia. cross hole. Tap a 55 mm(2l/41*) x 3 mm(l/Stt) pin into the hole - it should be a good tight fit. Bemovethe back plate, set the back edges of the blades against grill tbmugh the 5 urn (3/~611) the marked lines and clsmp in plwe. dia. holes snd rivet the fan blades in position. The blade supporting ring can now be set in place and biased at each point it contacts the blades. Finally, reposition the beck plate and blade assembly on the Me, and fasten to the hub with the four 40 mm(11/ 2") x 6 mm( V 4) at.8 end bolts. s&N COWLING lend up from the 855 mm(355/S*) length of 102 mm(4") T 1.6 mu (%6*1 or 16 SIG) steel sheet into the shape shown in the drawing. This is dons by first making the 90' bend 50 mm(2") from one end of the strip. Kark the required shape on the large piece of wood using chalk. Knock 150 mm(6") nails into the wood at intervals of about 50 mm(2") along the chalk line, mking sue that the nails stand up at least 102 mm(4"). Hook the 90' bend mud the first nail and bend the strip mund the outside of the other nails. The bent cowling will spring out of shape but this will not hem. FANSIIEPLATES x 260 imo(101/41) x Cut from ihe two pieces of 300 mm(11i3/16) 1. 6 ran (1/16*f) steel sheet. Both plates should have the ssme finished shape - this csn be done by clamping them together for final filing. 'With the plates still clamped together, rark the oentre and using a pair of compassesdraw the 102 mm(4) dia. circle aad the 248 mm (y3/4*) dia. circle as shown. Locate the position of the ten 6 imn(l/4.) dia. holes end drill them through both platea. Inill a 16 mm(5/~1v) dia. hole thmu& the centre. Non unclamp the plates and out out the 102 mm (4) dia. hole which hss been marked out alresdy. This plate will later be referred to as the left-band fan side plate.

- 29 TiJBuLm SPACNFS ) 0lensule. by cutting the 520 are req~i*~~, . length of tubing into 101 PP (3 32"
Five of these

The fan oaae is assembled with the fan blade assaably iaside. Paas the fan tie thmugh the 16 m ( 5/ 8") dia. hole in 'the righthand fan side plate. Position the cowling so that it eurrounds the fan blades. E&w line up the lef+hand side plate with the right-hand (41/29 I 6 wit (l/49 bolts into plate, and push the eight 115 position, leaving holes 1 snd 5, end using the tubular spaoers for holes 2 - 4 - 6. These will atop any distortions of the efde plates when the n&a are tiateaed. The bolts and spaoers for holea 1 and 5 are i;ot positioned et this stage.

Use the 305 ma (12") length cf 16 PPPD (5/g") dia. bright drawn steel ahaft.

Hade fmm three aimular pieces of plyvood and the large pulley hub. Take cars when aahing these parts - the.~axle hole needs to be ae near the exact centre as possible for the pulley to ma true, so aa& the centrea clearly. The sides of the pulley are made by outt!.ng tvo 355 au (ye) dia. pieces from 6 ma ( I/ 4s) ply. The oentre of the pulley is asdo by outting a 305 mm(12") dia. disc fmm 20 am ( 3/ 4") ply. Hark the position of the four 6 mn dia. holes on one of the pulley sides as shwn. Bow drill a 16 ma (5/8l*) dia. hole at the exact centm of these three pieaee and pu..h then tcgether on the pulley axle. Drill the four holes that have alresdy been aarked aad together with four 40 aa (1l/ 2") r 6 ma ( 1/ 4") bolts. Nowslide the hub onto the axle, push it up agaiaat the pullay, and drill the four 6 ma ( V 4") dia. holes. Piaally bolt the hub JI place with the four 65 IUO(2 112") L 6 EQI( V 49') bolts and e the axle.

- 30 -

TWO these sre required. We them from the 110 mm(41/411) of length of je mu (1 1/ 2") x 38 mm(1 l/ 2") hardwood as shown in the drawing;. The 16 mmaxle hole should be drilled as carefully as possible to make a good fit.

If a cast pulley of alluminium or iron is available this would be ideal. If not, one will have to be madefrom wood by hand ( or turned if a lathe is available). TheW belt groove will depend on the type of belt that can be obtained. Turn the belt inside out so that its form is on the outside - it can t&en be wed as a pattern when cutting the groove i,n the pulley. BASEANGLBS Two required, made from the two 3~30 (15") lengths of 50 mm mm (2") x 50 mm(2") angle. Mark out and drill the front base angle as shown in the drawing. Place back to back with the back baee angle (see drawing of fan case and upright essembly) and drill through the four 6 mmdia. holes. Place base to base and drill through the two 12 mmdia. holes.

TWO required madefrom the two 585 PIP(23s) lengths of 50 mm (2") x 38 mm(1'/2") hardwood Clamp the two lengths oarefully to. gether with the 50 mmfaoes against each other and drill the 16 mm dia. and 12 mmdia. holes through both uprights. Now carefully reclamp the uprights together, this time with the 38 mmfaces sgainst each other & dtiil the 6 mmdia. bearing - mounting holes using one,of the large pulley bearings ae a jig to be sure of getting the holes to aatch up. Do not drill the bottom holes at this stage. 'r;ooDBN SPACERS Two required, madefrom the 50 mm(2") x 50 mm(2") x 20 mm (3i4") piece of bardwood.

e from the 200 mm(8") length of 12 s80( l/ 2") dia. mild steel ing eaoh end for a distance of 70 mm.

31 -

Position the large pulley baaringe on the upl%ghtn and 100ctx (l/4) bolts - do up the ats to finger (3l/2n) x 6 the four 90 tightaees. mana mtdovneaoh end of the support bar, then@teMt upright on followed by a uaaher aad nut oathe outside. Liar up the bearings by positioning the large pulley axle, aad adjust the iMer rmte on the support bar to give 89 mm(3 V 2") between the inside faoee of the uprights. Tighten the outside mta on the support bar. BOW clsmp the uprights in positionbetween the base a&es, ing eta-e that all is aqusre and that the distanoe between the uprights is 89 mm(3 v 2") at both the top and the bottom. Tighten the bearing bolts ard check that the tie will turn smoothly. dia. holes through the holea ia Ilrill the four 6 lea and thm@ the wood uprights. Position the four 75 x 6 mm( l/ 4") bolts in these holes aad fssten the nuts.

The fan case assembly and the upright assembly are now ready to be put togetner. The air outlet chute should be on the ssins side 8s the pulley beax%ngs. Fimt of all two holes must be looated aad drllled in the left-hand vocden upright. This is done by pushing the fan axle thmogb the 16 mmdia. hole in the left-hand upright and then thmugb the corresponding hole in the right-hand upright. Slide the assembly until the right-hand fan side plate is up against the lefth upright and boles 1 and 5 am on the upright centre-llas. Carefully mark the position of these two holes. Now ve the fan case assembly and fan ezle and drill two 6 m ( l/ 4) dia. holee strsight through the left-hand upright at the located positions. Fiaal assembly can mu begin. Tne fan de is pushed through the left-head uptight before. Row slide the small pulley onto the axle, boss to the right, followed by a 1.6 mmwasher. If the fan-belt to be ussd is without a join it will have to be slipped over the axle at this B e. Nowpushthe poeitinr axle the rest of the way, tbm the ldght-hand upti her on the outside. Do not drill the omee holeo yet. Locate the two 165 (114.) bolts 9 thm em, thmugh the the side platen

- 32 -

lly tbrou& the left-band uprighf. with the fan cese now mounted, rotate the fm catches inside the case, slide the e from side to side until Now drill the two turns freely. the fan cl the axle 88 close as possible t ~mss holes tbro Tap a 25 ES (I@*) x 3 mm( l/ 8") dia. steel pin into of theee holee. Bemovethe large pulley axle far enough to allov the to be placed in poeition. Nowpush the axle through the uprighte until upright. Place8 alZmm( %") length re rains outside the left16 nm wesher over eaoh aad of the axle net the e as cloee pulley bearilre;s. Drill 3 m dia. cros.e holea tbrougb the as possible to tne washere. Nowposition the large pulley mid-w&y between the upIi&ts and drill the 3 SUQ dia. crone hole t thehubandah&ft. Donotput pins in these holes yet. Slide the e 1 pulley 00. the fen e *o that it mm exactly in line with the large pulley, and drill tbrou6b the 3 dia. cross hole. Tap a 65 m (2 l/ 2") I 3 mm ( V 8") pin into tus hole. Tne large pulley and axle met now be removed before the assembly om be positioned inside the drum. x!lount as follove: (1%") in the cut a slot 102 InIn(4") x 38 top centre of the dram, place the aesembly on the two wood eupporta in the base of the dmm so that the fan outlet ie in lim with the hole cut in the top o* tm3 drum. With the cutaway in front of tk!! d you, the pullet aseembly ebould be on yam ri down with the four 75 mm(31) x 12 m (l/2") 16s e support timbers. semble the axle aad pulley, (reaembering to poeitfon the far belt if it is without a join) and push the axle through the b u&PI it touches the inside wall of the dm. At this point drill or punch a 16 mmdia. hole thma& the drum wall and weld a t&ok 16 nun washer in position to support the pulley axle. The axle can now be pushed into its previous position, the waehera iooated and the pins
tapped into the case holes. up the two piecee of I the slot in th

33 -

bend eaoh piaoe rlmm hearth. Cut the piecee to the co a box section into En @L shape, 102 (4) bY 38 when they are put together. push the chute up through the underside of the drum hearth then bring down over the faa outlet sad tack weld in position. (2%) x 1.6 mke a grill fmm the 125 USI(5) I 65 (1/~6*@) steel sheet to cover the a$r chute outlst in the top of the drum. The boles should be 3 mm( 8vv) dia. Tine BVi belt being used will probably hsve to be joimd. NeaaUm mund the two pulleys with a length of striag as a mu& guide and add a little to this length. If the belt is not tigtrt out a small piece off rejoin.

3 bicycle, Cut the canplete chainwheel assembly from an old or d leadng about 75 !a (3) of the frame tubes. Removethe crank from the side opposite the chainuheel. N&e a hole in the side of the dmm, above a& in line with the pmtmding large pulley tie. The bole should be large enough to take the spindle beariw housing. Jeld the assembly in place st the points where the short lengths of fra!se tube contact the dmm. It w be necessary to make a bracket if the crank does not feel rigid a F&e sure that the chainwheel runs as near aa possible at 90 to the large pulley axle. The small sprocket will have to be welded to a metal boss drilled with a 16 m (5i8tf) dia. hole. It oan then be fitted and lined up on the lezge pulley axle 8nd cmss drilled for securing with ~3pin. Measw mund chainwheel and sprocket to get the oorrect ohain length and re~;ove links to obtain the best fit. 0PE3EI0Fz Tse craak is turned AMY-CLOCKWISE operate the fan. to Keep all netin& parts WELLOILED, especially the wood beerings for the fan and pulley ties.

34 .

35 -

FAN CASE B UPRIGHT ASSEMBLY

/-q
LDJ
Fe-

Fb Fa -----A.

FAN BMDE

(HALF SIZE) Db

USE AS JIG BEFORE BENDINGAT 90 ALONG LINE AA.

RYE PULLEY

HUB

(HALF SIZE) DC/L

E ASSEMBLY

37 -

FAN COWLING (QUARTER SIZE) Df

FAN

SIDE PLATES

@uAR~~

SIZE) Do AND Dh

16Mmm DIA.

r-l\,

10 HOLES,/

38 -

FAN

CASE

-TUBULAR

SPACERS FOR BOLTS

AT

l-2-4-5-6

LARGE PULLEY

(QUARTER SIZE)

39 -

E PULLEY

BEARING

(FULL SIZE)

Ed

1 L PULLEY

(FULL SIZE)

E9

- 40 WOODEN UPRI@iT ( QUARTER SIZE) Fc/Fd

5t35m (23-l

\ \tinr~~~. (33

WOODEN SPACER (HALF SIZE) Fe

k-i*
_z . 25mm (i') SUPPORT BAR (HALF SIZE) Ff

20, 2) _..__