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William Dunlap
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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

Louis Luu
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Dang!

George Durbin
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COOL!!

geo...

Geoff Dunaway
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Bill , you are one incredible metal magician !! :up: :up:

Mel Lagarde
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Holy cow.  Impressive work, Bill. 

Alex Rushing
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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

David Kilnapp
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Impressive work by both Bill and Alex!! Most impressive

Sean Campbell
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I can’t even begin to describe how impressive the work by both the above artisans is. A big thanks to both of you.

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

Sean Campbell
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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.

William Dunlap
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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

Richard Daugird
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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?

William Dunlap
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The set screw goes through both the fingers and hub.


Cheers,
Bill

Richard Daugird
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Oh, I see. That seems like a good design, helps keep the hub from coming loose from the spider.

William Dunlap
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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

William Dunlap
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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

Michael Rathberger
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Very nice. Doubt anyone could have done better with all the tools in the world at their disposal.

William Dunlap
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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

Sean Campbell
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You have done an absolutely amazing job! :clap::clap::clap:

Evan Atkinson
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Wow Bill. Incredible work. Makes me think of a job I have, just for you   :light:

Tony Clayton
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WOW Bill I'm blown away. I can't wait to see the end result.


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