It's an Enya Thing . . .

Just when you get the decks cleared
somebody turns off the power for the day.

That doesn't help much.
However finally all the parts come together and I have a new more compact winch for the generator. Can't see it here but all the pieces come apart for easier storage and assemble without tools.
It just does the job if I substitute a shackle for the big hook supplied with the winch. It's fitted with an eyelet which makes it non-detachable and I haven't decided to cut it off yet. I probably will - it only needs to annoy me one more time and it's history.






















I think it's time to start finishing things as I go. There are too many things which are 90% done but not finished off as I still have quite a bit more welding to go in the upper parts of the structure and I don't want weld spatter, of which there is quite a lot when you weld zinc-plated steel, to mark any of the finished parts. But a friend of mine has promised to give me some "chipboard" which he is going to throw away that I can use as temporary flooring so I can start to finish and fit things under the floor.

I have been debating the best way to finish up the gaps created underneath from the supports for the bin floors. There are two 50 mm wide spaces for the full length under the main beams.


















In the end I decided that I will just have to weld a plate over the full length on each side.
It will have to be about 75 mm wide by 5 mm thick. This is not too bad as it will actually provide a little bit of clearance for the rest of underside and stop the bin doors hitting on anything if it actually has to be put all the way onto the ground. It will also make it easier to provide an insect-proof underside, good for peace of mind with regard to creepy-crawlies and for customs etc as well if eventually sent overseas.

It's amazing how long it takes to prep., fit and weld a piece of flat bar in. Mind you it is 4800 mm long so it can't happen instantly.


















Now all I have to do is clean up the welds, degrease, prime, seal and paint and the underside will be done.
Then there's only the other 90% to go. . .

In Your Dreams . . .

Finally finished enough of "customer jobs" to keep them happy for a while so now it's my turn.

While feeding the machines and in between cycles I get to stand next to the camper and think about all the stuff still to do.

The list gets longer all the time.

I'm waiting at the moment to see if any of my friends can come up with a 24vDC windscreen wiper motor from which to make the bed winch.

One of the other things on the list (as mentioned previously) is getting the generator in and out of it's assigned compartment.

Suddenly today while doing the second last customer item I had a big "AHAAAAA".

I could use one of the lifting posts as part of the structure and just add on some bits for lifting. The same way the lifting leg structure fits into the camper cross-beams.
So a bit of cutting, welding and drilling and an hour later a prototype lifting winch was in position.


















This is at a height to just swing in under the door opening. It means the door has to hinge up 180 deg. but the hinge type being used allows for this to happen so that's no big deal.

The generator is too wide with the wheels on to fit in the compartment so off with the wheels. They are held on with just a couple of bolts so it's no problem. They can probably fit in a compartment somewhere so they can be re-installed if it's ever necessary to wheel the generator somewhere.














So now we have a generator minus wheels and stands ready to go.























Hook it on and start the lift.























Swing it inboard and "Voila".


















Yeah !!

In your dreams.

Doesn't show it here but there are a number of problems.
I'm sure all of them are solvable but this quick prototype doesn't really cut it.

. The support post is not stable enough. As there is relatively little weight on board at the moment this may improve as more stuff gets added.

. The tube sliding over the lifting leg has just a bit too much clearance and takes up a "lean" when the weight is put on it. Not too much of a problem as this can be designed out by tilting the arm pivot bearing.

. The arm pivot bearing (at the moment) is just a bolt through a couple of drilled holes. While this is plenty strong enough and swivels fine there is way too much slack allowing the arm to droop. Will need to fit some proper bearings to correct this.

. Using a load strap on the generator to hook the lifting wire to is not really optimal. The length of the hook and the stretch in the strap etc. etc. mean that the lift height is about 30mm too low and the generator needs to be juggled into position for final placement.

. This is compounded by the use of the 75 x 50 mm RHS as the arm. I used this to test it as I knew it was overkill for the load but it means that it just wont lift high enough. But I can change this to something like 50 x 25 RHS when I change the pivot bearings and changing the attachment mechanism will give another 30 mm so it will just fit.

And the lifting hoist is usable at 10 points around the base of the camper.
That may be useful as well.

So given this was just a quick prototype I think it will all work fine.

Famous last words. . .

Another Eyesight Test . . .

Another weekend come and gone.

It was one of those "chasing stuff" kinds of weekends.

Having satisfied myself that the bed lifting mechanism was now actually working quite well I needed an "actuating" mechanism.

As the power requirements were quite low I guess I could just put in a small manual winder of some sort.

I have a "brake-winch" already which I intend to use for lifting the motorbike (and maybe the spare tyres) up tracks on the back of the accommodation unit (I think I mentioned this previously).


















I will probably use another one to lift the generator out as well. This is because the generator enclosure will make it very difficult to refuel and/or do any maintenance while the generator is inside as it is only just big enough and it is 1500mm off the ground.

Brake winches look like boat winches (and can be used as boat winches if they are big enough) but are different in that they can be wound both in and out under load. Boat winches will wind one way and freewheel the other which is not good if you are trying to lower something gently to the ground. Actually they are not supposed to be used for dead lifts anyway whereas a brake winch can be.

They are not even very expensive at about $180 for a 200kg 3:1 ratio version.
But with the bed system it was difficult to find the right spot to put it without tripping over the handle or having to use 5 pulleys on each corner to get the ropes in the right spot.

Hmmm.
Maybe I could use a truck windscreen wiper motor to drive it?????

. It would be 24vDC which is what the house battery system is going to be so no conversion required.
. It is a DC motor which is easily switchable for direction.
. They are quite powerful (try holding your arm out the window at 110kph!! On second thought don't!!)
. They are small enough to mount almost anywhere.
. Driven electrically I can put the switches anywhere I like.

Better ring the truck wrecker and see what a second hand one will cost.
"WHAT??? The cheapest one is $200 and they go up to $600!! No Thank You!!"

I know I've seen trucks laying around in yards just rotting - I guess I'll just have to keep an eye until I find one where I can buy a windscreen wiper motor CHEAP!

In the mean time finish welding in the tracks for the bed frame and start to put in a few of the roof supports.























Another of those spot the differences photos !!

Material Progress - Periodically !

What to do about the bed frame lifting mechanism ? ? ? ?

One thing I really don't like doing is spending too much
time on an idea just to have it NOT work!

So best to set up another customer's simple job and let the ideas sort of roll around in the background.

These discs need drilling in a particular pattern.
They are laser cut from 10mm thick mild steel and then pressed in the centre.
There is a fixture I made previously (we have done this job a number of times) which goes on the CNC milling machine and the discs are clamped to it with a simple mechanism.
The drilling operation takes 6 minutes and the changeover takes about two minutes.
If I average 6 of these per hour it earns me about $80 per hour.
The customer provides the discs, all I have to do is drill them.


















So I spend approximately 15 minutes per hour to earn $80 per hour.
The rest of the time I can think, work or play tiddlywinks.

I might as well have another look at the bed lifting mechanism.
Hmmm.
One of the ropes is twisted around another, may as well straighten that out.
And another one goes in front of the rollers, should be behind,
may as well put that in the right place.
Oh. That "D-shackle" is scraping on the inside of the roller guide.
May as well clean that up and the other three as well, just in case.
The adjustment seems just a little tight on the rollers.
Wonder what happens if I slacken that off a bit.
The frame is not exactly "square" between the guides.
Better adjust each of the rollers to square that up properly.
Now if I just give a gentle pull on all of the ropes at the same time . . .
Whoo Haaa.
It all goes up in the air !!!
I might just tie it all off and leave it there for an hour while I have lunch.
(Well I was only using about 50% of the time, I was "WORKING" the rest).
.
.
.
So after lunch.

I was partially right.
The different lengths of rope have all stretched proportionately and the bed frame now has a distinct lean to one corner.

So maybe I can use this idea after all.

All I really need to do is find some non-stretching rope.


















You know. The stuff made from unobtainium.

A Good Plan Goes Astray . . .

I hate it when a good plan goes astray.

Set up the machines to make 11 of these little shafts.

(I know I have to fix that lens distortion - they are actually straight!)






















Only 25mm diam. and 265mm long.
They go in a high-speed fan in a harvester.
No problems. Done them before.
They take about 20mins. each so I can
work on the camper while they are being done.
Only really need to pay attention every 20 mins.

OK.

Finally rig up the pulleys in the bed frame lifter.
Give it a test.
(ie Yank on the rope!!)
Hmmm.
Feels a lot harder than I thought it would be. . .
Damn . . .

Fit a spring in temporarily to see how that goes.
Doesn't seem to want to work at all.
Damn . . .

Rearrange the pulleys (trickier than it sounds)
to give a 2 x 1 advantage
(ie reduce the pull required by 50%)
Feels a little lighter but not 50% !!
It must be losing about 20% mechanical advantage
for each pulley it goes around.
Better but not "YeeHaa" better.
Damn . . .

Now of course the rope requires twice as much movement
at the pulling end to get the bed fully up.
That means the spring idea is out the window!!
Damn . . .

So now I'm going to have to resort to some complicated winching system which will require all the ropes to be brought to one central position to wrap around a drum.
Damn . . .

That means each rope will be a different length.
And while the rope didn't stretch under test at the shop
it sure as hell is stretching now.
Different lengths, different amounts of stretch, different amounts of lift . . .
Each corner moves differently and the bed not level.
Damn . . .

Will have to try a different rope "guaranteed" not to stretch.
If that doesn't work will have to resort to wire.
Wire rope however will cut the nylon pulleys, so
will have to change the nylon pulleys to steel.
Damn . . .

Oh well.
So much for that plan.
Time for a new plan.
Damn . . .

Get a Life . . .

Saturday didn't start out so good.

Thursday I took my car back to the people who fitted the gas system some time ago.

I had been avoiding them.

Why??

They had my money ($4000) and my car still didn't work properly.

"Sorry Mate. We forgot all about it."

"Look. Just fix it!"

"We'll come and get it at 8:00 am tomorrow and have it back at 4:00 pm"

Of course come 9:30 I was a little pissed-off when they hadn't turned up so I drove it around there again.

Went back to work and forgot it until it was returned at 5:30 . . . .

"Goes great now mate. Lots of power. You'll really notice the difference."

"Actually you may remember I said I wanted it tuned for economy not power?"

"Oh. Sure Mate. Just don't put your foot down."

"Hmmmm . . ."

So of course going out Friday night all the control lights kept flashing on and off and the system kept cutting in and out making the car surge all the time.

And it wouldn't turn off. The switch didn't work.

Just to make sure I wasn't going to damage it I went round Saturday morning just to see if someone was there who could at least turn it off until Monday and then I could get it sorted out AGAIN.

Apparently the guy who was there was really really really annoyed with people interrupting his Saturday hot rodding.

I have to admit he did look at the problem.
He said the wiring was not done correctly.
And was really angry about that too.
So much so that in a fit of pique he threw his $500 multi-meter about 50 metres down the driveway when it wouldn't stay put on the bonnet of my car.
I don't know why he thought anyone would be impressed by other than his stupidity.

I must admit however that by about 1:00 it seemed to be fixed and he seemed to be calmed down a bit.

But by then I had a headache and didn't feel like working all that much so I read a book.
That's always good therapy.

Sunday I was determined to make a better day.
Beautiful day. Cool and crisp morning.
Took my motorbike for a ride to a nice little cafe for breakfast.
Great way to start the day.

Now some work on the camper.
Cut, shape, weld all the brackets for the bed lift.
Like this one.























YES!

Then the phone rang and somebody suggested there was a real life out there where people go out to the movies etc. and would I like to go?

Out for Recess(ion) . . .

Not my favourite week so far !!

Customers!

They want their jobs back the next day!

Suppliers!

They send the wrong stuff!

And when you tell them (and I was polite)
they forget to send the right stuff!!!

Whatever . . .

And I still haven't got to work on the camper yet this week !!

I spent it finishing off the dozen bearing housings I started last week!!
Well almost finished, I still need to drill some holes for mounting in the flange.




















Then there was the emergency for a couple of simple shafts that had to go by Thursday.









Then 4 each of the bushes to match the pins made last week.
150 mm OD x 50 mm and 100 mm long.













Then square up all the sides and edges of these plates and drill them full of holes.
They are about 1000 mm long x 350 mm wide and 25 mm thick with 25mm holes.
Heavy and awkward to get a good grip on but not enough to make me move the camper to get a crane or forklift in there :)
A couple of these please.











Some profiles to be machined, from the same sized pieces as the drilled plates, to weld the bushes into.












Did I mention the drawings I received so that everything would fit accurately.

A F***ing cardboard template !!!

I'm sure that's NOT how they built the D9 !!

There goes another half a day making sure that everything will actually go together.












Then some nice simple plates 400 mm x 250 mm x 25 mm just to be squared off.

Nice to get some easy ones too!













Then just as closing time comes around a couple of deliveries . . .

Good news and bad news . . .

The good news is the water tanks have arrived :























With very nice multi-tank gauge for monitoring:
















The bad news is word is leaking out that I might still be doing a bit of work.
Hence the pallet load of parts to be machined.


















And to make matters worse
the courier tells me he couldn't fit the other bigger pallet
on the truck today so he will be back tomorrow.

What's wrong with these people?

How am I supposed to work on my camper if they keep sending work.
Next thing you know I'll have to employ someone again!!

Don't they know there is a recession ???

The Customer's WHAT ????

I forgot how customers are!

Monday morning first thing : Ring, Ring ... Ring, Ring

"Hello".

"Hi. It's Phred Knurks here. How are you going with my parts?"

"YOU ONLY SAID TO START ON FRIDAY !!!!"

"What? You don't work on the weekend??"

"Well I do on two conditions.
1) You have to be here while I am, and
2) It costs three times as much!"

"Fair go mate. I gotta play footy on the weekend!
And I've got some other things to do too."

"SO HAVE I !!"

I suppose the quickest way out of that sort of misery is just to get it done.
I guess that's what they count on.
So set up the lathe and the mill and get going.

The mill part is quite easy - just some big slabs of steel (1000 mm x 350 mm x 25 mm ) which need squaring up first and some more machining later - so set that running and start on the lathe.

Four large pins ( all this stuff is for a D9 bulldozer so it's all quite heavy ) about 300 mm long and 60 mm diameter.






















All that takes care of most of the day.
Just time to rush out and see if I can get the necessary bits for the bed lift.
I've got the springs so it's pulleys, eyelets and rope.
I'm going to try rope first as it's easier and these days there are special ropes which are actually stronger than steel, don't stretch and are supposed to be very wear resistant.
$140 for the pulleys (Stainless Steel) and $20 for the rope.
Amazing.

Gyro Gearloose Strikes Again . . .

Sometimes you don't see anyone for weeks at a time and then all your friends drop around.

This weekend was supposed to be a catchup weekend as the week was spent "out of retirement".

Never mind - you can't have too many friends (and besides they don't mind if you tell them to either help or piss off - in the nicest possible way of course :) ).

Lots of brackets to go under the floor joists which were put in last week.
You can't see them unless you know where to look and even then it's not very impressive but they have to be done.

Finally got to the bed guides and decided the tracks by themselves were probably not strong enough.
They don't do much other than guide the rollers, but will require a pulley at the top to lift the bed up with a wire rope pulled from underneath the floor. This will apply a fair amount of compressive load so it was decided to attach them to some 50 x 25 mm tube to help keep them straight. Hard to see but there they are welded into position at each corner of the bed frame.


















Now of course the rollers needed to be attached to the frame and be able to run in the guides.


















Hmmmm.
Not that hard to do!
Can't be!
Can it?

Well it can be put together without to much trouble but it had better never go wrong or need maintenance!
OK. Better go the long way round.
There goes another hour or two working that one out.
Finally : that ought to do it!















Now it can all be taken apart if it needs to be.
So all in all not too bad a weekend.
Progress is progress.



































It was interesting actually to weigh the bed frame as it is now.
20 kg.
Will probably end up about 50 kg. with trim, mattress and bedding etc.

Thinking . . .
There are some springs in the workshop left over from a previous project which will provide about 300 mm of travel with 50 kg compression.
Two of those on each corner will provide 600 mm of movement with a total 200 kg lift force.
Combined with a 3 to 1 pulley system that will provide about 65 kg of lift for 1800 mm of travel and I only need 1200 mm lift.
The springs will probably tend to weaken a little over time so it will only need about 5-10 kg to pull the bed down from the ceiling and it will lift up by itself when released.
A lot cheaper than electro-mechanical drive and controller.
Might have to give that a try. . .

The More It Changes - The More It Stays The Same.

Well it looks like its back to the old regime for a little while.

Put in 5 hours in the morning on customer work like a dozen or so of these fan bearing housings and then 3 hours in the afternoon on the camper.

These are made from laser cut discs welded to extra-heavy wall pipe and then machined all over for an internal bearing and circlip in each end. There are matching shafts to do when these are finished and then a whole raft of other stuff as well like 200 spring guide and adjusting rods. These have had all the parts made and "just" need welding together.


















You don't seem to get much done in three hours these days.
That's one of the signs of getting older (I think (that's another one)) everything takes longer and costs more!

Never the less all the main floor supports are in now apart from the bathroom area.


















I rang the people making the tanks today and they now say "the end of NEXT week".
I think that's a bit more than the 10-14 day lead time I seem to remember.
They better be good!!

I don't think I can avoid the bed and generator lifting mechanisms for too much longer so I think they'll have to be next.

1 Corinthians 13

Slowly it's becoming clear.

The tubing arrived finally so I could fill in the bits around the seating area.
This was all a bit vague I now realise.
It's not always convenient to make tubing frames when everything will be covered with one or more layers of ply of varying thicknesses and perhaps finishes.
In the end you just have to bite the bullet and do it.
I'll probably change my mind about 3 times for how to do the covering while I'm doing it anyway.
At least now the seat frames are in place and the flooring supports under the table area.
The floor here has been raised 50mm above the rest of the floor for a couple of reasons:
. the seat is the top of the generator bin bay so it's height is set by the room required for the generator.
. the height of the seat needs to be about 400mm above the floor plus about 50-75mm padding to be comfortable so that's where the floor needs to be working down from the seat.
. the extra 50mm of raised floor makes the underfloor area more useful.
This underfloor area is accessed only from the inside by moving the table out of the way (it will be hinged to the back wall on it's rear edge) and lifting up the floor (which will be also hinged to the back wall at floor level).
Safe to say that only items which will be required on an infrequent basis (eg depending on the season) will be kept here.


















I've also managed to make it possible to remove the floor panels over the two main fresh water tanks if necessary but will probably make that a screwdriver job as I hope never to do it once it's all installed.

It's moving toward the bathroom end fairly quickly now.

"Sich" has made a mould for a fibreglass shower base and is going to take a couple of mouldings from it, one for his bus and one for me.
Mind you he's going on holidays for a fortnight next week so I don't know quite which way to go yet.

Still there are all the doors for the bin bays to keep me going for a while . . .