AFCA Forums Home
Home Search search Menu menu Not logged in - Login | Register
AFCA Forums > Antique Fan Collectors Association > Pre-1950 (Antique) > 1900 Sprauge Lundell blade set reproduction

 Moderated by: Steve Cunningham, Stan Adams, Rod Rogers
New Topic Reply Printer Friendly
1900 Sprauge Lundell blade set reproduction  Rating:  Rating
AuthorPost
 Posted: Wed Sep 2nd, 2020 04:20 am
  PMQuoteReply
1st Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
I've been tasked with reproducing the above mentioned blade as accurately as possible. Normally a project like this would include dismantling the sample blade and having the hub cast by Cattail or other casting services.That's not possible with this one. There simply isn't much demand for these, perhaps 5 in ten years, something like that. So the project involved keeping the sample intact and using it for a guide.
I don't have a water jet, plasma cutter, CNC machine, or even a mill or a lathe. Not to worry. It can be done with simple tools and techniques and the end product will resemble the original under inspection in every way and be perfectly balanced and functional.
I first started on the wings as the material was available at a local Ace hardware. I've already ordered a sheet brass disc .250 thick and 5 inches in diameter in 260 brass for the hub. This stock can be difficult to source from the usual outlets like McMaster- Carr. I chose 260 brass because it is formable. 360 brass would fracture when twisting the fingers to put the pitch in the spider. But that's for later in the week. 
Today I made the wings.


I made a stencil from stiff construction paper and traced the wing shape straight onto the 6x12 sheet of brass.This is also 260 brass .025 thick or 22 gauge.
Then I used my high speed cut-off wheel to rough cut the wings out. The sheet of paper was used to determine the size of the sheet brass needed for four wings.


Next, I carefully laid out the holes for the rivets and drilled them into one wing, which I used as a template to drill the rest. Then I riveted the four wings together, colored the edges with a large black Sharpie and used my disc/belt sander to make all four wings exactly the same size and exactly the same weight.



After that a polish with tripoli to remove burrs and scratches. The wings are now ready to be riveted to the hub which I will finish later this week after the stock arrives. In this last pic, you can see the tube brass I had on hand which will be the center of the spider. It is fabricated to be dimensionally correct for this type of application. The ID is right at .375 and the rotor shaft is .373. This is nominally 3/8". Outside diameter is .625 or 5/8" nominal and exactly the same as the sample.



More later this week, hopefully.
Cheers,
Bill

Back To Top PMQuoteReply  

 Posted: Wed Sep 2nd, 2020 06:32 am
  PMQuoteReply
2nd Post
Louis Luu
AFCA Member
 

Joined: Sat Oct 2nd, 2010
Location:  
Status: 
Offline
Dang!

Back To Top PMQuoteReply

 Posted: Wed Sep 2nd, 2020 07:07 am
  PMQuoteReply
3rd Post
George Durbin
AFCA Member


Joined: Fri Nov 2nd, 2012
Location:  
Status: 
Offline
COOL!!

geo...

Back To Top PMQuoteReply  

 Posted: Wed Sep 2nd, 2020 11:34 am
  PMQuoteReply
4th Post
Geoff Dunaway
AFCA Member


Joined: Fri Dec 23rd, 2005
Location:  
Status: 
Offline
Bill , you are one incredible metal magician !! :up: :up:

Back To Top PMQuoteReply

 Posted: Wed Sep 2nd, 2020 12:08 pm
  PMQuoteReply
5th Post
Mel Lagarde
AFCA Member


Joined: Sat May 21st, 2016
Location: New Orleans , Louisiana USA
Status: 
Offline
Holy cow.  Impressive work, Bill. 

Back To Top PMQuoteReply  

 Posted: Wed Sep 2nd, 2020 12:49 pm
  PMQuoteReply
6th Post
Alex Rushing
AFCA Member


Joined: Thu Dec 14th, 2006
Location: Montgomery, Alabama USA
Status: 
Offline
That is awesome work, Bill!  :shock:
I've got a few pieces of the fan in question held hostage in my shop at the moment as well. Gonna be a gorgeous fan! Not to mention, a multi front effort restoration, for a cool dude!


Was tasked with some fun...errrmm....work to reprofile the damaged screws and polish the bits and doodads.



Badge after a fine surface polish.



And after paint and clear coat. Shop lighting doesn't do it justice.



Had to use my drill press to reprofile these pliers marks out.




Reprofiled with clear coat.


Oilers drying with Nikolas 2105 after polishing.


Showing screws, nuts, bearings, and 2 washers polished and clear coated.

Last edited on Wed Sep 2nd, 2020 12:54 pm by Alex Rushing

Back To Top PMQuoteReply

 Posted: Wed Sep 2nd, 2020 01:10 pm
  PMQuoteReply
7th Post
David Kilnapp
AFCA Member
 

Joined: Tue Apr 17th, 2018
Location: Pembroke, Massachusetts USA
Status: 
Offline
Impressive work by both Bill and Alex!! Most impressive

Back To Top PMQuoteReply  

 Posted: Wed Sep 2nd, 2020 02:16 pm
  PMQuoteReply
8th Post
Sean Campbell
AFCA Member


Joined: Fri Jul 6th, 2018
Location: Indianapolis, Indiana USA
Status: 
Offline
I can’t even begin to describe how impressive the work by both the above artisans is. A big thanks to both of you.

Back To Top PMQuoteReply

 Posted: Fri Sep 4th, 2020 12:35 am
  PMQuoteReply
9th Post
Richard Daugird
AFCA Member


Joined: Tue Sep 12th, 2017
Location: Texas City, Between Hou. & Galveston, Texas USA
Status: 
Offline
This has been a long project Sean. Great of these guys to help out.

Back To Top PMQuoteReply  

 Posted: Fri Sep 4th, 2020 01:42 pm
  PMQuoteReply
10th Post
Sean Campbell
AFCA Member


Joined: Fri Jul 6th, 2018
Location: Indianapolis, Indiana USA
Status: 
Offline
Definitely! And yeah, it’s been a long one. I started it up in January of this year. It’s definitely going to be worth the wait though. It’s also really special since a lot of our great members collaborated on it. The finish line is in sight!

Richard Daugird wrote: This has been a long project Sean. Great of these guys to help out.

Back To Top PMQuoteReply

 Posted: Tue Sep 8th, 2020 02:59 am
  PMQuoteReply
11th Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
Well, hand it to the post office. They delivered the last piece I needed on Sunday to my PO box.So I got back on this one today.
This is a 5 inch disc, .250 thick of 260 brass I bought off ebay.


I darkened the brass using Van's gun blue in order to see the scribe lines better.





This is how I find the center of the disc using my calipers. Set the caliper to the radius minus .020 and scratch all around the middle. 




Carefully drill the center hole for a press fit of the hub center.


Several hours with hand tools to remove the unwanted material until I have this.




That's as far as I got today. I still have to thin the fingers as they are supposed to be 3/16" while the center is to remain .250. That will all be done mainly with a file. Hopefully by tomorrow I'll have the hub finished. I still have to press in the hub center, set the pitch in the fingers, drill the rivet holes and silver solder the hub center in place. Then I'll drill and tap for the set screw, fab the set screw, polish the spider, prepare rivets and rivet the wings on. I will balance the spider before I assemble the wings. A final balance and polish and it will be done.
Cheers,
Bill

Back To Top PMQuoteReply  

 Posted: Tue Sep 8th, 2020 03:15 am
  PMQuoteReply
12th Post
Richard Daugird
AFCA Member


Joined: Tue Sep 12th, 2017
Location: Texas City, Between Hou. & Galveston, Texas USA
Status: 
Offline
That's some nice work without machine tools. I'm just curious, but why would you not drill ant tap the hub BEFORE pressing it on?

Back To Top PMQuoteReply

 Posted: Tue Sep 8th, 2020 03:21 am
  PMQuoteReply
13th Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
The set screw goes through both the fingers and hub.


Cheers,
Bill

Back To Top PMQuoteReply  

 Posted: Tue Sep 8th, 2020 03:24 am
  PMQuoteReply
14th Post
Richard Daugird
AFCA Member


Joined: Tue Sep 12th, 2017
Location: Texas City, Between Hou. & Galveston, Texas USA
Status: 
Offline
Oh, I see. That seems like a good design, helps keep the hub from coming loose from the spider.

Back To Top PMQuoteReply

 Posted: Tue Sep 8th, 2020 03:28 am
  PMQuoteReply
15th Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
I believe the hub spider was originally cast, then machined. It appears to be one piece. By the time I'm done, mine will also look to be one piece.Cheers,
Bill

Back To Top PMQuoteReply  

 Posted: Wed Sep 9th, 2020 01:43 am
  PMQuoteReply
16th Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
Getting close. I thinned the fingers, (hard work) pressed in the center hub and silver soldered it, set the pitch, drilled the rivet holes and balanced it today. I'm confident it will be finished tomorrow..




Cheers,
Bill

Back To Top PMQuoteReply

 Posted: Wed Sep 9th, 2020 01:51 am
  PMQuoteReply
17th Post
Michael Rathberger
AFCA Member


Joined: Tue Nov 15th, 2005
Location:  
Status: 
Offline
Very nice. Doubt anyone could have done better with all the tools in the world at their disposal.

Back To Top PMQuoteReply  

 Posted: Wed Sep 9th, 2020 11:21 pm
  PMQuoteReply
18th Post
William Dunlap
AFCA Member


Joined: Fri Jan 31st, 2014
Location: Kula, Maui, Hawaii USA
Status: 
Offline
I've finished the blade, It's polished, balanced, trued up and ready for installation.













I like to balance the blade after just two wings are installed. Saves some time finding the heavy one. This blade need almost no balance adjustment.
But it needs to be very balanced. If you'll notice, there is very little pitch on this blade, so the fan has to spin fast to move any air. I've also balanced the entire blade and armature assembly since I had it.
Time to pack it up.
Cheers,
Bill

Back To Top PMQuoteReply

 Posted: Thu Sep 10th, 2020 12:32 am
  PMQuoteReply
19th Post
Sean Campbell
AFCA Member


Joined: Fri Jul 6th, 2018
Location: Indianapolis, Indiana USA
Status: 
Offline
You have done an absolutely amazing job! :clap::clap::clap:

Back To Top PMQuoteReply  

 Posted: Wed Sep 16th, 2020 06:03 am
  PMQuoteReply
20th Post
Evan Atkinson
AFCA Member


Joined: Tue Apr 18th, 2006
Location: North Hollywood, CA (LA), California USA
Status: 
Offline
Wow Bill. Incredible work. Makes me think of a job I have, just for you   :light:

Back To Top PMQuoteReply

 Posted: Thu Sep 17th, 2020 01:01 am
  PMQuoteReply
21st Post
Tony Clayton
AFCA Member


Joined: Tue Sep 25th, 2012
Location: Exmore, Virginia USA
Status: 
Offline
WOW Bill I'm blown away. I can't wait to see the end result.

Back To Top PMQuoteReply  

Current time is 04:27 am  
AFCA Forums > Antique Fan Collectors Association > Pre-1950 (Antique) > 1900 Sprauge Lundell blade set reproduction Top



Beige Theme By: Di @ UltraBB
UltraBB 1.17 Copyright © 2007-2008 Data 1 Systems
Page processed in 0.1847 seconds (9% database + 91% PHP). 27 queries executed.