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Emerson 1510 Circa 1906 Antique 12" Fan - Restoration Complete.  Rating:  Rating
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 Posted: Wed Apr 7th, 2021 07:58 am
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Alex Rushing
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 Restoration of 1906 Emerson 1510. My first ornate piecrust Emmy! Woohoo!
A small grommet is on the way to screw in the motor to finally complete it.


The fan I bought, and keep in mind seller made it right after I showed him the issues. Seller pics:
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The other photos don't show the extent of problems apparent when I received the fan.




After Resto Photos:
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Video of fan running, and me running my mouth, in HD:



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So, story began when a fellow member was liquidating some fans, and listed this 1510. At the time, we thought the cracks were in the Japan, so I had planned on repainting the motor case.
Well, when it arrived, that is when things went sideways big-time. I figured this to be an easy fix and have a nice restored first early Emmy in my modest collection.....Wrong.


I noticed oil coming out of cracks around the shaft press-in on the back, poor running (lots of extraneous noise), and used my fingernail to pick the paint from the front after suspecting it wasn't cracked Japan. Didn't seem like Japan. Just some decent black paint over a grey primer over cracks in the iron itself. There was flex in the top, sponge flex in the shaft visible from inside/outside the motor case.
So, I picked the black goop out from inside the case and front bell, which was easy as oil seeped under it. I traced every crack with a red marker and devised a method of attach. I consulted Paul G.(the man to go to with this stuff), and my father(who is a good welder); and both concurred my plan would be the best course of action. Brazing can cause shaft drift from overheating. Used my Mig to complete the welding attack plan, cleaned it up, and painted the welds/iron inside the case and bell. Kept the metal slightly warm with a propane torch to avoid fast expansion. I'm not a good welder, but am patient and tenacious! Haha


I then cleaned the outside visible hairlines and filled with cyanoacrylate. Dried and sanded smooth as silk. Wire wheeled and sanded the entire fan as well. The clear coat bubbling and lifting on the base was unsightly, so just restored the whole fan. Motor tag was in acceptable condition though, and I had removed before welding to avoid burning it. Funny it was the only thing holding two HUGE wedges of iron in the top. Haha
So a couple of less significant issues included a stripped wingbolt, but Steve Hankes was kind enough to send one out to me!


The rear plug threads were junked, so I put an o-ring between it and the motor case, which sealed well when motor was assembled(tightening the front rotor retainer bolt).


Switch was in good working order, so I patched a broken cloth insulation cover on one lead and varnished the crap out of it. Also re-pooled the skimpy solder.
Stator is definitely Sydney Lamb's work and was the nicest thing about the fan. One of the best rewinds I've ever seen. The blade being second, and switch/rotor third.


I rebuilt the start plate assembly in the rotor, because all the oil flying around from a marred rotor seat made it filthy. I then used fine sandpaper and the edge of the rotor switch end to make it perfectly flat. A thin o-ring now resides in the conical space between the rotor rear and back fiber washers I replaced with new ones. No oil leak anymore.


Black paint is my go-to Rustoleum Advanced Formula Gloss Black rattle can, and I used an oil based paint marker(gold) to hand paint the letters and vent holes front bell and rear case. I clear coated the motor tag, after cleaning up, to give it a better shine.


Two strut screws were stripped, so I tapped for 10-32 on all four and replaced with identical head 10-32 brass screws cut-off and polished.


After the paint came out aces, the blade was out of balance and had spotting on the back now glaring at me, and scratches on the front. Had to actually remove some trailing edge on the patent stamped wing to get it smooth as silk. I gave it a good polish front and back, then painted the iron hub(had some sort of red and black faux rust paint job on it) semi gloss black. The cage was bent up and wiggly, so straightened that as well, then high polished it.


So, without anymore chapters of this book being written, here are the insane number of process photos - slightly smaller than normal so it won't take 200 years to scroll through.
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New case/yoke spacers cut and colored.

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Thank y'all for checking this one out! Definitely a new favorite, because of the situation of expecting someone else's work, but then getting to make it my own!

Last edited on Sun Apr 11th, 2021 10:25 am by Alex Rushing
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 Posted: Wed Apr 7th, 2021 11:16 am
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Allen Bennett
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 Fantastic!  I know you spend a lot of time preparing and loading the photos, but they are a testament to the your incredible work.  Reading your posts encouraged me to try your paint of choice. I just painted a customer's 79648, and I've have been very happy.  A couple of coats left to dry and then a wet sand followed by a two more coats and it's beautiful.  
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 Posted: Wed Apr 7th, 2021 11:22 am
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Geoff Dunaway
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  Great save on that one :up:, I've had to have motor housing cracks repaired before. That fan must have been knocked off the table at some point over the past 115 years
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 Posted: Wed Apr 7th, 2021 11:34 am
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Anthony Lindsey
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 Extremely nice!
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 Posted: Wed Apr 7th, 2021 11:49 am
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Bobby Gaines
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 What a job! Nice work. Beautiful Fan.

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 Posted: Wed Apr 7th, 2021 12:00 pm
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Michael Rathberger
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 Nice work. Your paint work is turning out really nice. Congrats
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 Posted: Wed Apr 7th, 2021 12:19 pm
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Patrick Ray
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 Those early Emersons are one of my favorites and you have yet another fantastic save! Lots of tedious work went into your fan, and the stunning outcome shows that you went for perfection!
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 Posted: Wed Apr 7th, 2021 01:17 pm
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Gary Buchanan
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 Another example of a talented restoration person in the AFCA. Superb job Alex
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 Posted: Wed Apr 7th, 2021 01:35 pm
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David Kilnapp
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 It doesn't get any better than this Alex. You certainly do outstanding work - really excellent. Thanks for the photos and the explanations. This is an excellent primer for beginners!
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 Posted: Wed Apr 7th, 2021 05:13 pm
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Noah Britt
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 I gotta say, this time you really knocked it out of the park even more than usual! All that welding, wow!! And the blade work; I've had experience with bad blades, and it is not an easy task getting them fixed. Also, that paint is so deep and glossy!! I don't know how you do that without it dripping. Amazing job!!
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 Posted: Wed Apr 7th, 2021 06:45 pm
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Alex Rushing
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 Allen Bennett wrote: Fantastic!  I know you spend a lot of time preparing and loading the photos, but they are a testament to the your incredible work.  Reading your posts encouraged me to try your paint of choice. I just painted a customer's 79648, and I've have been very happy.  A couple of coats left to dry and then a wet sand followed by a two more coats and it's beautiful.  Thank you very much, Allen! 
It is enjoyable being able to document the process, because so many have told me it has helped!

Glad the paint is working out for you. Once you get the hang of fast heavy coating, you won't ever need to wet sand and polish. Just takes some practice to keep it from pooling and running.
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 Posted: Wed Apr 7th, 2021 06:47 pm
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Alex Rushing
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 Geoff Dunaway wrote:  Great save on that one :up:, I've had to have motor housing cracks repaired before. That fan must have been knocked off the table at some point over the past 115 yearsThank you much, Geoff!
It is definitely a sinking feeling not knowing if a hard-to-find part is reparable. Had mentioned to someone wanting to be a fly on the wall when the fan first took a spill! Bet there were some four letter words flying around.
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 Posted: Wed Apr 7th, 2021 06:48 pm
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Alex Rushing
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 Anthony Lindsey wrote: Extremely nice!Thank you Anthony!
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 Posted: Wed Apr 7th, 2021 06:48 pm
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Alex Rushing
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 Bobby Gaines wrote: What a job! Nice work. Beautiful Fan.
Many thanks Bobby! Definitely a new favorite. :D
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 Posted: Wed Apr 7th, 2021 06:51 pm
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Alex Rushing
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 Michael Rathberger wrote: Nice work. Your paint work is turning out really nice. CongratsThank you Michael! Has been fun working on perfecting the rattler can method. Can't say the fans-n-heavy method is for everyone, but it is a budget alternative to the less monetarily endowed members. Been thinking about some ways to possibly emulate the slightly uneven asphaltium paint look with spray cans. Possibly on a project in the near future.
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 Posted: Wed Apr 7th, 2021 06:52 pm
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Alex Rushing
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 Patrick Ray wrote: Those early Emersons are one of my favorites and you have yet another fantastic save! Lots of tedious work went into your fan, and the stunning outcome shows that you went for perfection!
Thank you so much, Patrick! There are a couple of things I'll deal with another day(the one larger OD s-wire on the cage and solder clump wrap on another her), but couldn't be happier.
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 Posted: Wed Apr 7th, 2021 06:53 pm
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Alex Rushing
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 Gary Buchanan wrote: Another example of a talented restoration person in the AFCA. Superb job AlexMany thanks Gary! 
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 Posted: Wed Apr 7th, 2021 06:54 pm
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Alex Rushing
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 David Kilnapp wrote: It doesn't get any better than this Alex. You certainly do outstanding work - really excellent. Thanks for the photos and the explanations. This is an excellent primer for beginners!Thank you very much, David!
Always willing to share things that work, and learn new stuff. :)
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 Posted: Wed Apr 7th, 2021 06:57 pm
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Alex Rushing
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 Noah Britt wrote: I gotta say, this time you really knocked it out of the park even more than usual! All that welding, wow!! And the blade work; I've had experience with bad blades, and it is not an easy task getting them fixed. Also, that paint is so deep and glossy!! I don't know how you do that without it dripping. Amazing job!!Thank you kindly, Noah!
Definitely not a fan of resorting to removing blade material, but sometimes it is the only thing that fan be done that looks good. 

The welding was tedious, but ot was good practice, as I see broken fans for sale here and there. The Dayton base, and the 1510 motor case taught me a few things that will carry to the next challenge.
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 Posted: Wed Apr 7th, 2021 06:59 pm
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Alex Rushing
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 The shelf was feeling mighty lonely with the 1510 in surgery.


Problem solved this morning.
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 Posted: Wed Apr 7th, 2021 07:06 pm
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Tristan Crider
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 wow.. Very nice! I have to get one of those Emersons! Love the pie crust Emmy's and the fact that I live near STL makes it a must!
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 Posted: Wed Apr 7th, 2021 07:36 pm
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Alex Rushing
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 Tristan Crider wrote: wow.. Very nice! I have to get one of those Emersons! Love the pie crust Emmy's and the fact that I live near STL makes it a must!Thank you much, Tristan!
They're getting very hard to find, so as soon as you can find one, the better. When I began, my poor-man bucket list included pre-1910 Emmy, Westy, and GE. The GE was filled by the early ornate case 1906 16" cake. Westy was filled by a 1908 Tank. And finally the Emmy spot is filled!

The smooth step base stuff is becoming the new early standard.
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 Posted: Wed Apr 7th, 2021 07:42 pm
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Darrell Koller
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 Nice save, Alex!
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 Posted: Wed Apr 7th, 2021 09:18 pm
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Alex Rushing
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 Darrell Koller wrote: Nice save, Alex!Thank you Darrell! 
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 Posted: Thu Apr 8th, 2021 02:57 am
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Mike Petree
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 Very nice work Alex. You're certainly not afraid to tackle some challenging restos.  :up:
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 Posted: Thu Apr 8th, 2021 04:22 am
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Russ Huber
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 Mike Petree wrote: You're certainly not afraid to tackle some challenging restos.  :up:
Ya. I second that. You should go to school and study to be a brain surgeon.  :D
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 Posted: Thu Apr 8th, 2021 05:46 am
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Alex Rushing
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 Mike Petree wrote: Very nice work Alex. You're certainly not afraid to tackle some challenging restos.  :up:Thank you kindly, Mike!
As long as they're not needing machine parts(gears, castings, etc), I'll take em on. I've gotten my butt handed to me a few times, but jump right back up and approach at a new angle. :imao

So far, there are no fan shaped holes in the garage door. Came pretty close with the 8" 12-wire BC, Dayton knuckle fabrication with capped knuckle, and some other stuff.
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 Posted: Thu Apr 8th, 2021 05:54 am
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Alex Rushing
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 Russ Huber wrote: Mike Petree wrote: You're certainly not afraid to tackle some challenging restos.  :up:
Ya. I second that. You should go to school and study to be a brain surgeon.  :D
Thanks Russ!
Lets be real; ain't nobody, in their right mind(though could be argued thay weren't, seeing as they're needing brain surgery) is gonna let me operate on their brain.  :hammer::imao

Alex's Antique Fans and Brain Surgery Emporium: Step right up!


*Guaranteed not make no mistakes!*



Last edited on Thu Apr 8th, 2021 05:59 am by Alex Rushing
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 Posted: Thu Apr 8th, 2021 11:05 am
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Mel Lagarde
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 Alex

What a gorgeous outcome from incredible work.  Thank you for carefully documenting your work and posting for us. 


Mel
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 Posted: Thu Apr 8th, 2021 11:58 am
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Chris A. Campbell
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Amazing work. Curious in this photo are you checking clearance of centrifugal screws against edge of rim?

Attached Image (viewed 274 times):

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 Posted: Thu Apr 8th, 2021 02:49 pm
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Steven P Dempsey
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 super well done
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 Posted: Thu Apr 8th, 2021 08:30 pm
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Alex Rushing
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 Mel Lagarde wrote: Alex

What a gorgeous outcome from incredible work.  Thank you for carefully documenting your work and posting for us. 


Mel

Thank you much, Mel! And you're certainly welcome.

These photos seem to be coming in handy for folks, so will keep on doing them. Kind of second nature to snap photos now, bit have forgotten stuff.
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 Posted: Thu Apr 8th, 2021 08:33 pm
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Alex Rushing
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 Chris A. Campbell wrote:

Amazing work. Curious in this photo are you checking clearance of centrifugal screws against edge of rim?

Many thanks Chris!
Ahh. The back of the rotor, where it meets a rawhide washer, was leaking. Noticed some marring the oil could sling our of. Used the rotor edge as a flat surface to take the marred area down. Seems to have worked very well.

As you noticed, I used it to clean the heads of the Centrifuge screws at the same time. Now all is flush and was able to back the rotor up on the shaft a bit to get some play out, but not scrape the solder points.
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 Posted: Thu Apr 8th, 2021 08:36 pm
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Alex Rushing
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 Steven P Dempsey wrote: super well doneThank you very much, Steven! And again, I appreciate you helping out to make up for the repair time involved.
Couldn't be happier with the fan now. Plus, welding less cost what? So always consider lessons learned as part of the work. :imao

She is ready to run again for a very long time!
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 Posted: Thu Apr 8th, 2021 10:47 pm
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Jim Roadt
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   Maybe I should give up on Pontypool and Black Dragon.  Your paint technique looks spectacular
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 Posted: Fri Apr 9th, 2021 05:05 am
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Alex Rushing
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 Jim Roadt wrote:   Maybe I should give up on Pontypool and Black Dragon.  Your paint technique looks spectacular
Thank you very much, Jim!

For authenticity's sake, I'd say you're well to master the Japan work like Rick Powell has.

However, if the fan was a serious lemon and needed a resto, and isn't an ultra rare specimen, no rattle can paint can come close to the results I've had with Advanced Formula. Even spray gun jobs don't look much better from my personal experience.

Soon, I promise, I am going to do a video on the exact methodology I use. It will be boring, it will sound Alabamian, but might help show how I'm getting paint like that for $4-$5 a fan. One reason I've not done so already (well, two, because I don't like hearing my own voice), is because the line between thick/deep gloss, and a case of the runs(or pooling at the edge), is very fine. You almost have to think of yourself as the paint. If that makes any sense.
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 Posted: Sat Apr 10th, 2021 05:48 pm
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Sean Campbell
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 I saw this late, but wow Alex what an amazing job! All the welding and that paint! The gold around the vents is stunning! I may just have to send you my 1510 sometime! :D
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 Posted: Sat Apr 10th, 2021 08:46 pm
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Alex Rushing
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 Sean Campbell wrote: I saw this late, but wow Alex what an amazing job! All the welding and that paint! The gold around the vents is stunning! I may just have to send you my 1510 sometime! :DThank you much, Sean! It was definitely a test of will to take on the motor case. But, I generally don't stop once getting started. :imao
The gold painting was really the most fun part of the project. I had only done the letters on a member's 12648 before. But, recently saw a 11666 with the vents highlighted. Even though the 1510 motor is much small in diameter, the vent highlights look just as good I think.
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 Posted: Fri Apr 16th, 2021 01:48 pm
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Alex Rushing
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 A friend was kind enough to send me a motor grommet that I'll send a replacement back later.
While at it, replaced the two large grommets with new ones. The originals went into the unrestored 19646, since the ones in it weren't great.

Motor case small grommet.


Base with new grommets.
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