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Mini Lollipop Project  Rate Topic 
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 Posted: Sat Jul 31st, 2021 05:43 pm
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Louis Luu
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Will be drawing up the back portion to the motor housing...should be interesting. The back portion is the most interesting part to the 8" R&M open commutator fan. Let the sparks fly!

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 Posted: Sat Jul 31st, 2021 09:52 pm
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Louis Luu
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Roughed out the back today.  Will need to double check all measurement before sending it out for printing.  The main feature of the 8" R&M open commutator is the ability to see the commutator while it spins and it will spark slightly.  









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 Posted: Sat Jul 31st, 2021 09:55 pm
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Louis Luu
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The struts will be next.

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 Posted: Sat Jul 31st, 2021 10:36 pm
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William Dunlap
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Which CAD software are you using, Louis?
Cheers,
Bill

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 Posted: Sat Jul 31st, 2021 10:45 pm
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Louis Luu
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Fusion 360...it is the program I had from years ago while at college...but never had the time to mess with. It does get bog down if using too many vector lines.

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 Posted: Sun Aug 1st, 2021 08:05 pm
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Louis Luu
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I started printing out the base/stem, commutator holder, brush holder, bearing assembly. Motor measurements need to be double check before sending out for printing...most likely next week.

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 Posted: Mon Aug 2nd, 2021 03:26 am
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Louis Luu
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I started to print out the bottom base and motor housing.  Picture is the actual one being printed.  Base has been shortened as the proportions were wrong...need to keep it short and stuby.  Motor housing showcases the open commutator.
I will be putting on the bearings...it all checks out...the struts will be next and off the the caster.






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 Posted: Mon Aug 2nd, 2021 05:18 am
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Louis Luu
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I made sure to keep the window large so the commutator can be observe while running the fan.  I remember seeing one run with the beautiful spark.  The fan once done can be converted from a mini-lollipop to a mini-vane. 




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 Posted: Wed Aug 4th, 2021 02:50 pm
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Louis Luu
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Both the motor housing and the stem/base should be here by this weekend. When I get them, I will post a picture side by side of the printed parts and the original 8" R&M open commutator. I did make slight modification to the window opening in the back of the motor...larger opening on the top.

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 Posted: Wed Aug 4th, 2021 03:55 pm
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John Smalley
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Amazing craftsmanship

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 Posted: Wed Aug 4th, 2021 04:37 pm
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Louis Luu
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Thanks John....I am trying.  I don't have the talents like some of the master restorers I admire...I do what I can.  The strut will be a lot easier to do than the base and motor housing...learned quite a bit from practicing.



I did however had to add 20 mm to the stem section to accommodate the bearings...there was no way getting around this unfortunately.  I did my best to keep it stubby.  The original total height of the stem is 100 mm.  I increase the diameter section from 34 mm to 37 mm to maintain the look/proportion "stubby".  I did make some personal modification design by adding the feet to keep it from tilting over during rotation...bottom is actually heavier than the top and opened up the view of the back portion for the commutator.  The unique features of this fan is watching the sparks...not too much...just enough for fun.



I will also make personal modification to the struts...just the portion where the cage is clipped on.  The original holders for the 8" R&M did not use any clips or screws...just a "U-shaped" bracket to hold the back square cage.  I will post pictures later on this week when I do the struts.  The goal for the struts is to maintain the curvature...that is what makes the original lollipop unique.  The only thing I will be doing is making adjustments to hold the cage size for the mini-lollipop.



There will also be a miniaturized blade hub designed after an original one...just shrunken down for the 8".


I will try to keep the cost down for the casting...these will be done as kits allowing others to modify them for either lollipop or vane oscillation.

I am debating on the badge.  I received a small 8" R&M open commutator from Daniel...it is too beautiful to mess with.  I am only taking spare parts open commutator for modification.  Now, the unique thing about Daniel's open commutator it is a rebadge with a miniaturized "Hunter" badge which I have never seen before.  I will probably cast a few for myself unless there is a demand.  Otherwise, the original 8" R&M flag emblem is still being made...just need the rope and letterings drawn up....can not be casted...must be printed.  I do have the option of printing in bronze or brass.  The expense is under $50 for the 8" R&M flag.  The mini-Hunter badge will need to be casted because the amount of metal used is too expensive to print.  I can make the mold off of Daniel's fan.


John Smalley wrote: Amazing craftsmanship

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 Posted: Wed Aug 4th, 2021 04:44 pm
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Richard Daugird
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Anxious to see the castings! I need to find a parts fan so I can have one of these. Are all 8" R&M open commutators the same?

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 Posted: Wed Aug 4th, 2021 05:22 pm
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Louis Luu
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No!  Please don't use the rare or good condition ones.  I wish I had a DC...I would have kept it original.  The ones I'm using are the regular stumps (non-DC, missing switch).  If it is unique...I say keep it original.  I am definitely keeping the one Daniel sent me...a Hunter rebadge.  That fan is way cool!  I will take pictures when I get home this weekend.

The basic model came in two styles...straight stem and the other with a knuckle between the stem and motor...both had the same motor housing. What you should be looking for is to make sure the commutator is in good condition.  If the stator is bad...that is not a big deal....just a basic rewind.  The coils are very simple....so simple and yet I can not do it....there are people around who can do this.  If the motor is crack...I would say that is a perfect candidate.  I am using bad ones for this project!

Richard Daugird wrote: Anxious to see the castings! I need to find a parts fan so I can have one of these. Are all 8" R&M open commutators the same?

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 Posted: Wed Aug 4th, 2021 05:51 pm
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Richard Daugird
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Louis Luu wrote: No!  Please don't use the rare or good condition ones.   If the motor is crack...I would say that is a perfect candidate.  I am using bad ones for this project!

Richard Daugird wrote: Anxious to see the castings! I need to find a parts fan so I can have one of these. Are all 8" R&M open commutators the same?
That is what I'm looking for, parts fans.

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 Posted: Wed Aug 4th, 2021 05:54 pm
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Louis Luu
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This project would not be possible without the volunteer of some of the restorers and machinist here I admire! The casting will need new wings for the hub and cage and the casting will require drilling and some tapping for screws to fit the plate for the base and switch and new brush holders and brush holders for the motor housing and mounting the motor. That is a lot of "and". I am very grateful for the help!

Last edited on Wed Aug 4th, 2021 05:55 pm by Louis Luu

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 Posted: Wed Aug 4th, 2021 06:00 pm
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Louis Luu
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I could cast the motor housing and base with the holes for screws...but that would present quite a challenge for the lost wax mold and flaws during casting. I am trying to minimize the amount of things that can go wrong during casting. Holes in single direction is fine but holes perpendicular causes a headache!

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 Posted: Wed Aug 4th, 2021 08:08 pm
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Louis Luu
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I did talk to Mike Petree who did the previous mini-lollipop. After talking with him, I realized the amount of machining that is required and why it was so difficult to make these. He told me that while these fans may look the same, there are minor differences...enough that he had to make it one at a time. I am solving this problem by doing this from a single casting and all the bearing parts would be off the shelf including the middle long screw that holds the motor and allow wires to run through it. I am basically using a lamp tube that already has the thread. Since the stem will be short and the bearing portion will be supported with internal part for the bearings...the use of lamp parts for the stem screw will not be a problem.

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 Posted: Tue Aug 10th, 2021 03:38 am
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Louis Luu
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Got home from a long day and forgot my base was coming today.  I opened the box and the base is gorgeous.  I immediately dried fitted everything.  There is plenty of clearance for the commutator and the bearing is perfect...still spins.  Unfortunately, the motor casing was not here yet so I dried fitted my motor.  The motor casing I drew up is actually modified slightly with a larger window opening into the rotor.  It is squat and gorgeous.  I love the feet.  The feet even has rubber bumpers.  The only thing left is the struts and hub design. 





I am in such a rush I don't even have time to trim the pictures or put them in order.  It is gorgeous and I am picky!












































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 Posted: Tue Aug 10th, 2021 03:39 am
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Louis Luu
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Also, the motor casing on mine has a lip at the base just like the vane oscillator to give it a little class.

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 Posted: Tue Aug 10th, 2021 03:54 am
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George Durbin
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Louis Luu wrote: Also, the motor casing on mine has a lip at the base just like the vane oscillator to give it a little class.
All I can say is HOLY FREAKING COW!!

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 Posted: Tue Aug 10th, 2021 03:56 am
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Louis Luu
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I am going to make the commutator holder into a swing door.

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 Posted: Tue Aug 10th, 2021 04:04 am
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Louis Luu
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Also, I will keep the top portion "half rib". The rest will be primed and smoothed out.

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 Posted: Tue Aug 10th, 2021 04:11 am
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Louis Luu
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I like the look of this so will keep.  The rest will be smoothed.




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 Posted: Tue Aug 10th, 2021 04:43 am
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Louis Luu
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The bearings are rated for "Static load rating of 5000 newtons and dynamic load rating of 2350 newtons" I am using one on each end of the stem. I know it is overkill.

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 Posted: Tue Aug 10th, 2021 04:59 am
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Rob Duffy
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What is that base and motor housing made out of? That looks impressive!

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 Posted: Tue Aug 10th, 2021 05:04 am
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Louis Luu
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Printed ABS plastic for now.  I am using it as a pattern for making a mold for casting in bronze.  The entire base/stem/motor housing/struts will be cast in bronze.

Rob Duffy wrote: What is that base and motor housing made out of? That looks impressive!

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 Posted: Tue Aug 10th, 2021 03:36 pm
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Louis Luu
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There are various plastic available...that was the cheapest. Once finalized, the small parts will be printed in good quality plastic. Large objects can not be printed in metal yet as this is relatively new technology. Small parts like gears can be printed. I will be experimenting with that when I have time. Spur and Worm gears can be design in CAD with great accuracy. Still, the quality does not hold up to a talented machinist! You can see the difference under a microscope.

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 Posted: Sun Aug 15th, 2021 01:12 am
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Louis Luu
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All good to go.  I checked for motor clearance and commutator clearance and fit.  Next will be the curvy stylish strut.  I will begin work on it next week.














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 Posted: Sun Aug 15th, 2021 12:47 pm
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John Smalley
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Amazing craftsmanship

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 Posted: Sun Aug 15th, 2021 01:17 pm
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Louis Luu
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Goal is to have one auction and proceeds go to a great cause...must be fan related. This project would not be possible without the help of numerous people helping out.

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 Posted: Sun Aug 15th, 2021 01:56 pm
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Louis Luu
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Nope...this is just drawing on computer and parts printed...minimal craftsmanship.  I am still jealous of some of the amazing restoration posted.

John Smalley wrote: Amazing craftsmanship

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 Posted: Wed Nov 24th, 2021 02:49 pm
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Louis Luu
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Have not given up. I am pushing forward with the struts in December when I have time off. The Demott motor was a quickie project since there is no weird curvatures to draw. I have been practicing on drawing spider hubs for members free of charge.

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 Posted: Wed Nov 24th, 2021 02:55 pm
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Richard Daugird
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Looking good Louis.

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 Posted: Wed Nov 24th, 2021 03:10 pm
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Louis Luu
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Good morning Richard and Happy Thanks Giving. I have not forgotten about your fan...It will go out. I have several items to mail out. George, William and you.

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 Posted: Wed Nov 24th, 2021 03:12 pm
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Louis Luu
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Richard...check the Demott motor project. That was a quickie since there is no weird geometry to draw.


https://new.afcaforum.com/index.php?/topic/291-demott-bipolar-fan/

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 Posted: Wed Nov 24th, 2021 04:57 pm
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Ron May
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That sure takes the hard work out of building one of these! I had to make and remake several of my pieces until it was fine tuned and working properly. Unfortunately I only took a few snapshots of it before it was picked up but here's a few shots of it.

Attached Image (viewed 52 times):

IMG_20210816_200729937.jpg

Last edited on Wed Nov 24th, 2021 08:51 pm by Ron May

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 Posted: Wed Nov 24th, 2021 05:00 pm
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Ron May
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.

Attached Image (viewed 51 times):

IMG_20210816_200721067.jpg

Last edited on Wed Nov 24th, 2021 08:52 pm by Ron May

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 Posted: Wed Nov 24th, 2021 05:01 pm
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Ron May
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Attached Image (viewed 50 times):

IMG_20210816_200656532.jpg

Last edited on Wed Nov 24th, 2021 08:53 pm by Ron May

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 Posted: Wed Nov 24th, 2021 05:01 pm
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Ron May
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Attached Image (viewed 49 times):

IMG_20210816_200630741.jpg

Last edited on Wed Nov 24th, 2021 08:54 pm by Ron May

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 Posted: Wed Nov 24th, 2021 05:28 pm
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Louis Luu
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Ron...that does look nice. I am aiming at making it a mini...as close to the original as possible. It does take a little bit more work but in the end it will be worth it.


The strut holder reminds me of the Veritys holder.

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