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Emerson S60SEP-2783 Restoration  Rate Topic 
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 Posted: Thu Sep 19th, 2019 03:12 am
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Trevor Soundararajan
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Belt driven fans are without a doubt my favorite type of air mover to watch in action.  I'm not 100% sure what it is about them, but I find them aesthetically pleasing to cool with.  Perhaps it's the mechanics of them.  Who knows.

I came across this Emerson and had actually planned to give it to my mother to use for her husband's shop, but things weren't so simple.  When I arrived to pick up the fan, I noticed that the original Levolier switch was present and worked perfectly.  The reverse worked as well.  There wasn't any dent or ding on the cabinet to suggest that it fell with any notable force.  It even had the large Emerson badge still intact on the rear guard and nearly scratch free.........It was way too nice to be put to work in a shop.  I didn't care that it was 30"- one of the perks of being a bachelor.  I wasn't sure what I wanted to do, but I can tell you, I hated that paint scheme.  The inside was nicely decorated with rust, but the bottom of the cabinet was where the worst of it was, further propelled me towards the decision to restore it. 


By the way.


.........
The 100 pounds plus change was a real joy to load up a flight of stairs.   But see, us short people-we got a low center of gravity.  I made it look easy.











The wiring is almost finished, but I'm still waiting on the new motor mounts to come in.  I had to take a dremel to remove the old ones.  As you can see, they contain inner and outer steel rings that were very happy staying pressed on the end bells of the motor.





After spending the better of an hour in searching, I settled on a color that could stand out without being an eyesore.  In it's current state, all parts have been bead blasted, etched, and powdercoated.  The more work I do, the more I love this thing.  Will update when everything gets put together.  And no worries, the Emerson decal is on its way to me.















-Mr. T

Last edited on Thu Sep 19th, 2019 12:09 pm by Trevor Soundararajan

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 Posted: Thu Sep 19th, 2019 05:31 am
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Levi Mevis
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Nice work, so what about the old Emerson Decal, are you going to find a repop of that and put that on the cabinet or are you going to just leave it as is without it?

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 Posted: Thu Sep 19th, 2019 12:07 pm
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Trevor Soundararajan
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Levi,

Thanks-I have a reproduced decal on the way.

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 Posted: Fri Sep 20th, 2019 01:55 am
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Steven P Dempsey
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I had one of those beasts & don't recall what I did with it. Had the 3 wing overlapping blade

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 Posted: Fri Sep 20th, 2019 01:58 am
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Steven P Dempsey
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Not a belt driven, but pretty hefty



Attached Image (viewed 510 times):

Emerson House Fan3.JPG

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 Posted: Fri Sep 20th, 2019 01:59 am
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Steven P Dempsey
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 Posted: Fri Sep 20th, 2019 06:13 pm
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Zachary Parr
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Steven P Dempsey wrote: Not a belt driven, but pretty hefty



I have 2 of these and they are awesome. Great air movers. One is a two speed that needs a new switch but no one has made a wire diagram for it. 

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 Posted: Sat Sep 21st, 2019 03:55 pm
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Trevor Soundararajan
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Today, I have the motor cracked open for some inspection and cleaning.  I must say, these things are usually beaten and abused, but this one is very nice!  Centrifugal switch snaps nice n' clean.



I realize that the front of this fan is rather large.  My goal was to get something that would look as close to "original" as possible.  Plus, this is staying indoors.  I didn't want to use chicken wire, and after a good few hours of searching I sourced a 36" guard which I have trimmed down to be an exact fit on the front of the fan.  I figure I'll fasten it using some clips to avoid any hole drilling.



I like that it's non-OSHA because I wanted to feel confident for this to run with people around without a notable sacrifice on performance.




-Mr. T

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 Posted: Thu Sep 26th, 2019 02:52 pm
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Ryan Lemke
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Wow, that's looking great! Can't wait to see the finished product...

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 Posted: Sun Sep 29th, 2019 07:13 pm
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Trevor Soundararajan
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Status update: 9-29-19

I'll look for any excuse I can to replace the pillow blocks on a belt driven fan if they are sleeve.  I prefer ball bearings, but honestly, the ones on this fan were in perfect condition.  Also, the center height of this shaft bearing is low (roughly 0.620), virtually eliminating every ball-bearing  option, unless you want to make your blade off-center from the venturi ring.  I just ain't about that life.......


The stock pillow block on this fan is composed of two 5/8" ID flanged sleeves, with 1-1/4 depth.  Impressive amount of contact area, which I'm guessing is to deal with the weight of the 6 wing STEEL blade.  The pillow block originally had a couple of fiber washers on each end to account for thrust.  There was about 1/2" of back/forth movement on the fan blade shaft, and I didn't just want to add a bunch of washers to take up the slack.  I decided to try needle roller bearings from McMaster-Carr and installed them on each end.  I wasn't finished, because I also wanted to absorb shock and vibration, so I added a curved disc spring washer on each end.  The result was an exceptionally smooth, low-friction rotation for the fan shaft, even when pressure was applied backwards or forwards.  This gives me confidence when I install the blade.











I want to credit Emerson on their design.  The 5/8" shaft is keyed on both ends and steps down so the 2nd of 2 blade bolts locks the blade to the shaft. Additionally, there are 3 points where the shaft is cut for retaining clips to be installed which further secure the blade and pulley.  I bet this shaft would not be cheap to re-machine......



I gave a test run of the newly rewired motor, new belt, and updated bearings.  Smooth as silk.  I also installed new rubber feet to the bottom of the frame.  There are no motor harmonics present anywhere on this fan.









For now, I wait for the badge to come in the mail to put on my custom-fit guard.  I am also waiting for my decal, which one of my buddies is taking care of.  More to come soon! 




-Mr. T

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 Posted: Sun Sep 29th, 2019 08:44 pm
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David Kilnapp
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Wow, what a fabulous restoration. Looking forward to seeing it finished! Thanks for sharing these great photos Trevor. Mighty impressive work so far!!

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 Posted: Mon Sep 30th, 2019 06:35 pm
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David Allen
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This one looks as good as new. Very impressive!

You know I'm partial to the large direct-drive industrial fans; however this belt drive looks great. I'm sure the rubber mounted motor base helps a lot with the motor hum often heard with this sort of fan.

Sincerely,
David

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 Posted: Mon Nov 11th, 2019 09:01 pm
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Richard Daugird
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Very impressive indeed. I got started on belt driven fans, but never put in as much effort as you did on this one.

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 Posted: Tue Nov 12th, 2019 01:28 pm
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Tom Zapf
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IT REALLY CAME OUT BEAUTIFUL! 

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 Posted: Tue Nov 12th, 2019 07:27 pm
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Ryan Blazei
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I 100% agree that belt drive fans are great. They provide more mechanical wonder with a spinning belt and pulleys than a direct drive fan can. Also, impeccable job restoring this beast, love the finish and the mechanical improvements! Keep it up.

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 Posted: Wed Nov 13th, 2019 04:40 am
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Trevor Soundararajan
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I guess it's only right to conclude this post properly.  It doesn't seem THAT long ago that I started this project, but we were still having 90+ degree days here in St. Louis when I made up my mind to restore this.  We had a strong 12 degrees this morning.


This wasn't an easy project or was it cheap to support, but then again, I didn't really care.  I loved that sense of childlike anticipation in getting each stage of the process done.  It was satisfying to know that I completed each step to the best of my ability and with 0 regrets.  I fully admit there were parts I grew impatient and had to remind myself "I'm going to do this right, not quickly"  I now have a giant box fan I'm proud of, which will keep me cool and be a solid conversation starter for guests.  Thanks again to all for the support and apologies for the double post.  




























-Mr. T

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 Posted: Wed Nov 13th, 2019 02:59 pm
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Brad Hughes
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That is totally awesome!  Great job :clap:

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