Open Source Ecology - User contributions [en]

Talk:Chris Reinhart Log

2013-10-03T20:46:38Z

Justin Kurtz: Created page with "Way to go everyone! Glad to See Chris got a good team together. WHen I talked to him week before it didn't sound like there would be a lot of help. YOU DID IT. What are ..."

Way to go everyone!

Glad to See Chris got a good team together. WHen I talked to him week before it didn't sound like there would be a lot of help.

YOU DID IT.

What are you using for the outside plaster.

In North Texas here there is a lot of clay soil, but my concern was moisture deteriorating it. Chris mentioned the plaster dealt with that.

Is there a recipe?

Congratulations on doing such a great job!

Chris Reinhart Log

2013-09-23T21:48:32Z

Justin Kurtz: /* Brick Stacking Patterns */

=Sun Sep 22, 2013=

==Chris Discussion==
*Use Materials Requisition Form template - critical to track Ordered/Shipped/Tracking #/Received/Accepted chain - [[Material,_RFQ,_and_Work_Requisition]]
*Sensors - for hard data, $500
:*Surface mount sensors - [[Open Source Temperature Sensors]], illuminance, relative humidity, temperature reading, [[Open Source Infrared Camera]] from Public Lab
*2 rebars per side - 16' from 20' section, 1 foot stub out
*Pay fuel costs only for travel
*Kitchen - 2 outlets -
*Extend loft over kitchen by 1.5 feet

==Materials Lists per Module==

[[File:Window_Mod_Materials_List.jpg|400px]]
[[File:Door_Partition_Mod_Materials_List.jpg|400px]]
[[File:Elec+Plumb_Mod_Materials_List.jpg|400px]]
[[File:Loft_Floor_Mod_Materials_List.jpg|400px]]
[[File:Upstairs_Carp_Mod_Materials_List.jpg|400px]]
[[File:Roof_Mod_Materials_List.jpg|400px]]

for final Microhouse v1 documentation, add sheets for materials already ordered (door frame, foundation)

==Plywood and OSB Counts Determined for Minimal Waste==

In order to ensure maximum efficiency with cutting sheet material, sketchup model was sheathed with different colored 4x8 sheets to track number of pieces needed. Totals for upstairs wall carpentry is 5 interior sheets (3/8" plywood in this case) and 5 exterior sheets (5/8" OSB).

[[File:Upstairs_plywood_osb_cut_sheets_abstract.jpg|600px]]

==Exploded Assembly Diagram for Final Animation In Process==

[[File:Exploded_upstairs_with_roof.jpg|600px]]

=Fri Sep 20, 2013=

[https://docs.google.com/spreadsheet/ccc?key=0ArpE5Y9PpJCXdC1KNG80OWRmdk85TlBQTVA3YWhRbEE Organization Spreasheet]

[[Microhouse Development Board]]

==Meeting with Walter Grondzik, PE==

Walter Grondzik is the author of Mechanical and Electrical Equipment for Buildings, the "bible" on building MEP systems and passive design, as well as The Green Studio Handbook, a reference for incorporating sustainability into schematic design. This afternoon, he graciously donated an hour and half of his time to the project. We talked about small design details regarding thermal performance, as well as ways of gathering some solid data on building performance.

[[File:MEEB11-Cover.jpeg|150px]][[File:GSHcoverfinal.jpeg|150px]]

Here's a video of Walter discussing the uses and rationale for adding sensors to a building - then we'll look at some details that were discussed.

(Add video - need to convert and reduce file size)

Walter gets excited about building science. I wish I had captured on video our conversation about the different types of data collection he recommends. Here is the list:
1. Sensors, like the ones recommended in the video for ambient temperature, relative humidity, and illuminance.
Plug-ins to the sensors that are thermal probes.
2. Infrared (IR) Camera study
3. Blower door test.
Ball State has this equipment, but it needs to be looked into if it could be brought to the site at a later date during building operation.

One item we discussed was getting the best performance from the direct solar gain heating system (heating of the CEB floor by sun shining through windows). Walter highly recommended putting in a thermal break between the floor and the foundation. Without this break, there heat will travel easily from the floor to the foundation. He suggested a 1" thick piece of foam, but he agreed that a 1/2" piece would be acceptable. Even at 1", the plaster and a trim board would cover it.

[[File:Foundation section w thermal break.jpg|750px]]

Walter reviewed the window design including the indirect gain solar heating system, and thought it was an idea that would work well. He also felt that the amount of glazing to floor area seemed appropriate.

[[File:Window_frame_labeled.jpg|750px]]

This modular system - combining both direct and indirect gain systems - balances the quick warming felt with a direct gain system and the time-lag heat release experienced with an indirect gain system.

We spoke quite a bit about air sealing the building - a critical component when maximizes passive gains. He liked the idea of using a foam gasket (referred to often as "sill seal," in the field) between the window and door frames and the blocks stacking up next to them. Also, between the block wall and the top plate.

(More to come soon...)

=Mon Sep 16, 2013=
==Utility Module Design==

[[File:Microhouse_utility_module_full.jpg|750px]]

The utility module contains all the connections for the electrical and plumbing, and doubles as a partition wall separating the kitchen from the bathroom. This particular location allow all the plumbing connections to be inside a single wall.

[[File:Microhouse_utility_module_no_framing.jpg|750px]]

==Interior Partitions and Loft==
<span style="color:red">Chris - remove power outlets above kitchen?

<span style="color:red">Extend section above kitchen about 1-2 feet to expand loft size / fit king-sized bed?

[[File:Microhouse_utility_module+loft+partition.jpg|750px]]

Interior partition walls and loft panels shown with sheathing/decking removed to view electrical and plumbing.

[[File:Microhouse_full_electrical.jpg|750px]]

=Sun Sep 15, 2013=
==Precise dimensions for pipe layouts==

[[File:Pipe_layout_dimensions.jpg|750px]]

Notes:
1. Measure and mark opposing interior form boards with dimensions listed.
1a. Measure from outside of inner form board (in other words, from what will be inside of concrete).
2. Put small nail into form top at location of mark - string between similar mark on opposing form board.
3. Run designated pipes under foundation formwork and make sure vertical pipe is directly under
proper intersecting strings.
4. 6" chase for future hydronics does not need to be at any slope.
5. 2" graywater and 3" blackwater lines MUST BE AT 1/4" slope per 1' of length.
This is required for proper drainage, otherwise liquids will outrun solids.
6. Pipe layout shows 6" chase running over 2" and 3" lines, however, it is typical to conserve as much
elevation as possible when exiting graywater pipes... best practice will be to run 2" and 3" pipe
out just below bottom of foundation formwork. 6" pipe will most likely run beneath level of 2" and 3" pipes.
7. Run pipes past foundation forms by roughly 5' and cap with cardboard/duct tape or old rag, etc.
Leave vertical pipes at a length of 1' taller than foundation forms. Cap this end, as well.
Staking the vertical pipe in place with rebar will prevent it from getting disturbed.

Pipe Elevations:

<html><img src="https://docs.google.com/drawings/d/1KIMEWAJFuE8S1S1-wGtM4NfuQ9uzMFMDqyh4qefkYUM/pub?w=700&h=720"></html>

[https://docs.google.com/a/opensourceecology.org/drawings/d/1KIMEWAJFuE8S1S1-wGtM4NfuQ9uzMFMDqyh4qefkYUM/edit edit]

=Sat Sep 14, 2013=
Microhouse site cleared:

Total Labor Hours: 1 hour mowing with string trimmer and metal blade; 1.5 hr leveling with tractor including removing former goat fence on west side.

<html><iframe width="420" height="315" src="//www.youtube.com/embed/eX5e5A0v32w" frameborder="0" allowfullscreen></iframe></html>

[[Image:mhcleared.jpg|300px]][[Image:mhtrac1.jpg|300px]][[Image:mhtrac2.jpg|300px]]

=Fri, Sept 13, 2013=
[https://docs.google.com/spreadsheet/ccc?key=0ArpE5Y9PpJCXdC1KNG80OWRmdk85TlBQTVA3YWhRbEE#gid=5 Foundation BOM]

Revised pipe and chase diagram - future thermal hydronics only going to east module because west module will be sharing a wall. Also, proposed [[North Utility Line]].
[[File:Pipe_and_chase_diagram_final.jpg|750px]]

Updated bracing for concrete forms. Almost all bracing will occur with threaded rod, placed through holes drilled in the forms, and secured with a washer and a nut. Pattern for installation is shown in below photo. Staking can be kept to a minimum... 2 stakes per corner... just to keep forms square and in place.
[[File:formwork bracing sketch.jpg|750px]]

=Thurs, Sept 12, 2013=

And, let's trench some water lines - see [[Trencher Prototype 1 Video]]

<html><iframe src="//player.vimeo.com/video/53787538" width="500" height="281" frameborder="0" webkitallowfullscreen mozallowfullscreen allowfullscreen></iframe> <p><a href="http://vimeo.com/53787538">Open Source Trencher.</a> from <a href="http://vimeo.com/opensourceecology">Open Source Ecology</a> on <a href="https://vimeo.com">Vimeo</a>.</p></html>

Foundation formwork with pipe and chase diagram
[[File:Pipe_and_chase_diagram.jpg|750px]]

Instructions for foundation build...

[[File:Microhouse_foundation_p1.jpg|750px]]

For allthread, do 2 at corners and 2 in middel - 4 per side. For blowout, do 2 of them per side - 1/3 way each. Rebar ends up at bottom 1/3 of boundation. Allthread about 5 inches down from top.
[[File:Microhouse_foundation_p2.jpg|750px]]

Stub out 8-12" of rebar.

[[File:Microhouse_foundation_p3.jpg|750px]]

Do 4 pieces of allthred per side -
[[File:Microhouse_foundation_p4.jpg|750px]]

Foundation BOM
https://docs.google.com/spreadsheet/ccc?key=0ArpE5Y9PpJCXdC1KNG80OWRmdk85TlBQTVA3YWhRbEE#gid=5

=Wed Sep 11, 2013=
Planning spreadsheet -

<html><iframe width=100% height=500 frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0ArpE5Y9PpJCXdC1KNG80OWRmdk85TlBQTVA3YWhRbEE&output=html&widget=true'></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0ArpE5Y9PpJCXdC1KNG80OWRmdk85TlBQTVA3YWhRbEE#gid=0 edit]

=Saturday, September 7, 2013=
==Specific Parts Sourced Plumbing and Electrical Modules==

I spent 90 minutes today at the hardware store sourcing the components that we will use for the plumbing and electrical module. Here is a schematic drawing of the partition-wall-utilities-module:

[[File:elec_plumb_module.jpg|750px]]

[[File:half_inch_ball_valve.jpg|200px]][[File:half_inch_cts.jpg|200px]][[File:half_inch_cts_fpt.jpg|200px]][[File:half_inch_cts_mpt.jpg|200px]]
Plumbing fittings for incoming water supply and for shower connection.

[[File:quarter_turn_sink_valve.jpg|200px]][[File:pex_roll.jpg|200px]][[File:pex_blue_red.jpg|200px]]
Pex pipe and shut-offs for sink connection and flush toilet connection.

[[File:propane_tube.jpg|200px]][[File:gas_ball_valve.jpg|200px]][[File:gas_termination_plate.jpg|200px]][[File:gas_male_adapter.jpg|200px]][[File:gas_stove_connection_tube.jpg|200px]]
Propane tube and connecting fittings.

=Thursday, September 5, 2013=
==Flyer Created and Distributed in BSU CAP==
[[File:Microhouse2013_build_flyer.jpg|750px]]

This flyer is being placed in the hands of key professors and students in order to recruit talent for our first Microhouse build. I have no doubt that we will be able to fill a van with bright young designers to help us execute this project.

==Speaking Engagement Booked==
I have been given a time slot during Ball State College of Architecture and Planning's Alumni Symposium to present the Microhouse project. During my last presentation at the CAP student symposium, I spoke to a standing-room-only crowd of over 200 students and faculty. I expect this time will be no different. The timing is perfect, too, as it comes just a month after we will finish the build of Microhouse 1.

==Profile in Book on Post-Petroleum Design==
I have arranged a profile to be included in Dr. George Elvin's upcoming book on post-petroleum design that will feature the Microhouse. George and I became friends during my time as a student at Ball State, and he had been planning to include a profile of my other natural building work in his book. When we crossed paths this morning at a Muncie coffee shop, he was working on the book and reminded me that we need to schedule an interview. I suggested we focus the profile on the Microhouse and do the interview after I return from the build week. I'm very excited about the exposure this can bring to the project!

=Tuesday, September 3, 2013=
==Current Microhouse Design and Overview of Build Week==

[[File:exterior.jpg|400px]][[File:overhead.jpg|400px]][[File:Interior_shot_of_kitchen_and_loft.jpg|400px]]

During the last few days of September and the first week of October we will be constructing a prototype house, using prototype machines, and using a prototype process: swarming construction. Numerous volunteers, with various skill levels, will be refining a method of parallel processing to construct modular components of a house that can be quickly assembled to create a beautiful, durable, and sustainable dwelling for a couple: the Microhouse.

The build processes will proceed from an instruction manual, currently being designed, that will open the doors of creating one’s own shelter to almost anyone.

Every step of the process will be rigorously documented. As components are built, the instruction manual will be marked up with times for each step and notes for how both the process and the manual can be improved. At the end of each work day, debriefing sessions will capture lessons learned to refine the process. As the next day’s work proceeds, while some volunteers are building in the field, others will be revising the manual to reflect the lessons learned the day before. In this way, the learning will be captured as it happens. At the end of the build week, the product we will deliver is far more than a house, it is a process that makes building more accessible to everyone.

=Sunday, September 1, 2013=
==Update on Prep Weekend for Microhouse Build==

Over the past two days, Marcin and myself have refined numerous details of the Microhouse design. We have settled in on a roof panel module that we believe will be quick to assemble in the field by removing the tight tolerances necessary if panels mate tightly with one another. In this system, panels will be spaced apart roughly 14" or 15", eliminating the need for precision. 2' wide sheets of plywood will be screwed into place from the bottom to contain insulation, and once insulated, 2' wide sheets of OSB will be screwed onto the top.

[[File:roof_panel_sketch.JPG|300px]][[File:roof_panel_sketchup.JPG|300px]]

The idea of the modular components for the mechanical and electrical system has evolved into the module being one of the partition walls in the building itself. This wall will contain the electrical and plumbing connections of the sink, shower, toilet, stove, and electrical receptacles. The partition wall will also support the loft panels. Loft panels will be pre-wired for electrical connections, and will plug in to receptacles on the electrical module-wall.

Layout for the interior of the Microhouse was determined.

[[File:layout_microhouse.JPG|300px]]

An intern at OSE, Lucas, and I built the rough door frame from the instructions I had created. We timed each step of the process, and also marked up the instruction sheet for the second iteration. All pictures can be found on trovebox under the tag "microhouse."

[[File:microhouse_doorframe_measure.jpg|300px]]
[[File:attaching_osb_microhouse_doorframe.JPG|300px]]

[[File:door_instruction_markup_1.JPG|400px]][[File:door_instruction_markup_2.JPG|400px]][[File:door_instruction_markup_3.JPG|400px]]

=Thurs Aug 22, 2013=
==Bill of Materials==
<html><iframe width=100% height='300' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0AlCf1fl002zpdHIycDFkWkt4a1FQV3JYazlGajc2QUE&output=html&widget=true'></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0AlCf1fl002zpdHIycDFkWkt4a1FQV3JYazlGajc2QUE#gid=0 edit]

==Sample Construction==
[[File:Detailed_model_first_pass.skp]]

[[File:Measure_and_Mark_Door_p1.jpg|800px]]

[[File:Measure_and_Mark_Door_p2.jpg|800px]]

<span style="color:red">Discussion: Materials necssary for build of microhouse windows and roof panels. Saturday & Sunday - 4 people total needed. 3 teams of 2 - the best amount of people. Goal: how fast can inexperienced people build the house?
*Constructed Wetland - alternative to septic. Peter Bane, Brian Art Ludwig ($150/hr) - all the greywater books.

<span style="color:red">Next steps: BOM for sample framing and roof sections: Monday; build procedure - by wednesday.

Make sure all blades are in good shape:
*Table saw -
*Circular saw
*chop saw
*sawhorses
*screw guns - Chris has 1
:*1 gun per team
:*Star head drive -
*2 groups work
*Ask John for Recommendations -

Spoke with both Walter Grondzik ($50/hr for up to 10 hours) and Ryan Zaricki ($40/hr - 4-5 hours for hydronics) ... both are interested in contributing to the design of the project from an engineering perspective. Ryan had several ideas for moving heat with hydronics from one module to another. He has worked on several such projects. Walter is willing to consult on any MEP issues and to review the passive heating/cooling strategies used in the design.

[[File:perspective.jpg|800px]]

Perspective shows earthen walls, door and window frames, bond beam, and roof panels.
My feeling is that with the loft, there is too much wood framing... the design no longer celebrates the earth blocks like it should... too much carpentry involved.

[[File:overhead with loft.jpg|800px]]

Overhead of sleeping loft

[[File:overhead 1st floor.jpg|800px]]

Loft removed to see first floor. Kitchen counter could wrap wall. Stove can be placed in back corner by ladder or on opposite side. Window frame on west side of building could be converted to a door to access future addition.

=Fri Aug 16, 2013=
<html><img src="https://docs.google.com/drawings/d/1-VzhZmZiX4sLR3oaqGidn9dpG7P8O0kowjoc5ke_DWw/pub?w=700&h=500"></html>

[https://docs.google.com/a/opensourceecology.org/drawings/d/1-VzhZmZiX4sLR3oaqGidn9dpG7P8O0kowjoc5ke_DWw/edit edit]

==Foundation and Frames Set Up Before Build Day==

This image begins to show the detail of what the foundation and framing set up will look like at the start of build day.

[[File:foundation with frames.jpg|900px]]

==First Steps at Construction Diagrams==

More detail is needed, but this sheet shows the steps in construction for a window frame.
A cut sheet needs to be added. Also, more detail on the nailing is necessary, even though all nails are shown.

[[File:Window Frame.jpg|900px]]

==Wood Components==

Shows detail of window and door frame, as well as a gringo block for attaching frames and a block for service entrance of data and electricity.

[[File:Components Aug 15.jpg|900px]]

=Wed Aug 14, 2013=

==Foundation Details==

[[File:Foundation Detail 1.jpg|900px]]

Drawing of foundation details without dimensions - final dimensions to be determined.

=Wed Aug 7, 2013=

==Concept drawing thoughts==
[[File:Concept.pdf]]

[[Image:mhconcept.jpg|900px]]

reverse shed roof to allow for easier mounting of solar panels

look at option of upper windows for ventilation

add landscaping
rain barrell
viney plants

Mechanical and plumbing modules - Mechanical and Electrical Equipment for Buildings -
[[File:Direct Solar Gain.pdf]]

[[Image:MHsolar.jpg|900px]]

Passive Solar - Direct Gain

Chosen as the best passive heating strategy because of the building size. Future designs should explore indirect gain systems, as well. The page of calculations is a starting point for determining apertures.

Notes, in addition to what is on drawings pages (should be added to drawing pages)
-Aperatures must be within 15 degrees of true south (north, in southern hemisphere) for the building to receive 90% of optimal winter heat gains (Green Studio Handbook 107)

also note that the Green Studio Handbook states…
“The first, and most important step in the design of a passive solar heating system is to minimize the rate of heat loss through non-south-facing envelope components (including infiltration losses).” (109)

The single-wythe version of the CEB building will have the potential for large heat losses. Although thermal mass can help, uninsulated earth walls, when they get cold, they take some time to warm up. My experience in the earthen section of my home is that if I am at home throughout the day or at least in the mornings and the evenings, the home will stay cosy. If gone for a couple days in the winter, it takes a half a day or better to make the home feel good again.

The double-whythe section offers greater potential to use the solar gain by being better insulated.

==Roof Panels==

[[File:Roof Module.pdf]]

[[Image:mhroofmodule.jpg|900px]]

[[Image:mhroofmodule2.jpg|900px]]

Despite an enormous amount of information on prefabrication on the internet and at the library, it is clear that we are not working in the mainstream here. Every prefabbed roof panel I could find was a single, lifted-into-place-with-a-crane-type. We want something that four people can comfortably lift to a height of 8+ ft. Ideally, we want this technology replicable on two-story and greater buildings.

My explorations were based on the idea that four people could move a panel with a weight of about 200 pounds. The weight for the first iteration of the roof module is about 180 pounds without straw infill. (add weight calculations to drawings – also, final documents should include both English and metric units).

I think that the roof panel design can be improved as the details are explored. I think encasing the open side of the panel so that the straw cannot impede the panels coupling together would be slick. Something like luan plywood or masonite. Ideally, this thin piece is caulked into place, and the panels are caulked together when assembled.

The roof will have more linear feet of potential crack than any other component (assuming that the stucco is impermeable to moving air).

I would like to add to the schedule of events for the Labor Day visit that we build a full-scale test of a roof panel and track the process closely. It also makes sense to prebuild a jig for assembling the roof panels.

==Construction Process==

Numbers listed in contract add up to 28.

I think the mechanical unit might be best conceived as two units – one for plumbing, one for electrical – the idea of having critical connections of water and electricity and gas all next to each other is uncomfortable, indeed. This would break the team for the mechanical unit into two teams of 2.

What type of stucco is being used? Depending on the answer to that question, I think the stucco team of 4 could be smaller earlier in the day. We could go with 10 for bricks – 3 sliding and 5 laying. This could be one way of re-arranging if we are trying or needing to stay at exactly two dozen volunteers. If not, I think your numbers for adding up to 28 are comfortable.

==House Layout==

The two modules, separated by a courtyard, will create a wonderful outdoor space to be used for eating (cooking even, if desired), for relaxing, and for entertaining. However, two buildings separated require two separate MEP systems. Is it possible to arrange the building program so that functions are separated that have similar MEP needs? Could one space function without plumbing and gas?

One module with electricity, data, plumbing and gas:
*Kitchen
*Shower
*Toilet
*Dining

One module with electricity and data only:
*Bedroom (sleeping loft?)
*Living space
*Work Space

==Brick Stacking Patterns==
[[Image:brickstacking.jpg|600px]]
This makes the most sense to me as a couple trying to build a microhouse. Why plumb, and water a space that I just want to sleep in? Separate functional spaces. Esp in hot climates an outdoor kitchen is great, but that provides shade.

=Time Log=

<html><iframe width='500' height='300' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0ArpE5Y9PpJCXdGlpV2xJWE5FQWtlamJFU0c3ODkxaXc&output=html&widget=true'></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0ArpE5Y9PpJCXdGlpV2xJWE5FQWtlamJFU0c3ODkxaXc#gid=0 edit]

= Thu Aug 1, 2013 =
*See [[Microhouse Build Planning]] and [[Chris Reinhart Contract]]
*Initial conversation on design with Marcin
*Planning first cut of design on Wed, Aug 7
*Water Glass for stone sealing or - [http://velacreations.com/shelter/building-components/flooring/item/56-ceb-floors.html]
*Stove - [[http://opensourceecology.org/wiki/Modular_Longwood_Stove]]
*Factor e Farm site plan - [[Factor e Farm Site Plan]]
*Beginning of brick courses - [[Brick Stacking Patterns]]
*Soil map - [http://opensourceecology.org/wiki/File:Soilmaponline2.jpg]

Sketchup File - [[File:Microhousev1.skp]]

Image of above: [[Image:mhv1.jpg]]

Foundry

2013-09-20T09:07:02Z

Justin Kurtz: /* Plans */

{{Template:Category=Induction furnace}}

== Overview ==

A foundry is useful for converting otherwise unusable scrap metal into useful metal parts by melting the metal and casting it into desired shapes.

==Research==

*Steel melts at around {{convert|2500|°F|°C|sigfig=3}} or slightly below pure iron
*Iron melting point - {{convert|2800|°F|°C|sigfig=3}}, 1811K
*Cast iron melting point - {{convert|1150|°C|°F|sigfig=3}} to {{convert|1200|°C|°F|sigfig=3}}, about 300 °C lower than pure iron
*From [http://answers.yahoo.com/question/index?qid=20070329141828AAaJfps]:
**Steel is iron and up to 2.0% carbon without any other alloying elements
**Above 2.0% C we are dealing with cast iron. Cast iron tends to be brittle, unless it is ductile cast iron.
**The steel melting point varies between {{convert|1540|°C|°F|sigfig=3}} and {{convert|1400|°C|°F|sigfig=3}}, gradually declining with increasing carbon content.

There are a variety of heating techniques used to get steel hot enough to melt, including:
* fuel burning
* electric induction heating
* electric microwave heating
* electric arc heating
* concentrated solar

===Alloying===
In a small induction foundry it may be practical to economically produce alloy steels for lathe cutting tools, ironworker punch tools and dies, etc.

Need to find suppliers for small quantities of alloying elements. Try [http://www.mroresources.net/index_files/products.htm],[http://www.specfoundry.com/products.htm] (more research needed). For high performance steel, contaminants in the scrap must be watched for and their influence controlled (often they can be removed through slag treatment in the furnace). Some elements are particularly hard to remove (e.g. copper, tin, nickel, chromium) and it would be good to be able to test for these in incoming scrap.

== heating techniques ==

=== Heat Requirement Calculations ===

*Based on the specific heat of iron and its melting temperature, the energy requirements for meling iron are calculated:

*Converting this to fuel requirements based on the energy content of fuels for a give weight of fuel, we can calculate the amount of fuel required for melting. Heat losses such as total inefficiencies of heat transfer to the metal need to be included:

One source claims a production capacity of 700 lb/hour in a 175kW furnace.<ref name="LFYP"></ref>
**Based on this explicit value, basic extrapolation can be done to figure out the amount of fuel required to provide this heat via simple burning. If [[LifeTrac]] burns under 1 gallon of fuel per hour, and it has a total energy use (including thermal waste) of about 100 kW, this indicates that about 2 gallons per hours should suffice to produce 700 of steel per hour. Given inefficiencies - say 50% heat transfer - we should produce 350 lb of steel per hour if we burned fuel for direct heat. The basic figure that arises is about 1 pound of fuel to 20 pounds of melted iron.

=== fuel burning foundry ===

*Flame temperatures from Wikipedia:
[[Image:Flametemp.jpg]]
*Flame temperatures from [http://www.derose.net/steve/resources/engtables/flametemp.html]:
[[Image:flametemps2.jpg]]

[http://www.backyardmetalcasting.com/bestfurnace01.html "Oil fired furnace Vs. Small cupola"]
by Lionel Oliver II says that
"melting iron in a crucible with a waste oil burner and melting iron in a cupola with coal or coke ... Overall these two methods are the most practical and economical ways for a hobbyist to melt iron."

Is the [http://blog.makezine.com/archive/2010/04/weekend_project_30_micro_forge.html "$30 Micro Forge"] big enough to be useful?

====Plans====

Using coke as fuel: "Iron Melting Cupola Furnaces for the Small Foundry" by Steve Chastain[http://www.lindsaybks.com/bks3/chcup/index.html]

Building a Cupola Furnace from loose scrap parts: [http://mervandsheila.net/merv/iron/cupola.html "Building a Cupola"]

*Plans for a 330 lb/hour iron melting foundry - [http://images.google.com/imgres?imgurl=http://www.bay-com.com/images/Chastain%2520Cupola.jpg&imgrefurl=http://www.bay-com.com/index.php%3Fmain_page%3Dproduct_info%26cPath%3D1%26products_id%3D89&usg=__OxK6pdgJw6GCr2yVrr_mqhtiw7Y=&h=400&w=500&sz=61&hl=en&start=12&sig2=VEfN1z8fber8HiCqypupIQ&um=1&tbnid=pkon85dqVixB_M:&tbnh=104&tbnw=130&ei=SP1xSYrlC5LgM67HsRw&prev=/images%3Fq%3Dfoundry%2Bplans%26um%3D1%26hl%3Den%26safe%3Doff%26client%3Dfirefox-a%26rls%3Dorg.mozilla:af:official%26sa%3DN]:

[[Image:330foundry.jpg]]

Building a cupola link takes me to a site for online dating?

====Is there a way to do an oil-fired steel-melting furnace?====

''Would a [[Babington Burner]] work?
Does this work?
http://thesteelyard.blogspot.com/2008/06/waste-oil-fired-furnace-for-bronze-iron.html

*Oil-fired foundry on Instructables - [http://www.instructables.com/id/SG29NR3FD80X4DN/]

=== induction heating foundry ===
''See the [[Open Source Induction Furnace Project]]''.

The ''Induction Furnace'', aka induction heating foundry.

*College foundry, 100 lb steel or iron, 100 kW induction furnace - [http://www.svsu.edu/set/departments/mechanical-engineering/instructional-facilities/foundry.html]
*Induction Furnace - 40 kW - http://www.ufes.com/index.php?n=Foundry.InductothermInductionFurnaceModel40-96
*Induction furnace - 75 kW, 112kg/hr steel, 25/50/100kg crucible, 1-3kHz, 775kWh/ton steel [http://www.inductionfurnaceindia.com/supermelt-li-power-system.html Agni Electrical, India]
*Induction 4000 lb for 100kW, or 1000 lb for 25 kW? - [http://www.ufes.com/index.php?n=Foundry.InductothermAutoPour4000LBS100KW]

*Induction furnaces are well- established for the melting and holding of iron, steel, aluminum, zinc, brass, and copper. High efficiency and the ability to precisely control the rate of heat input make this electric-based technology fully competitive with alternative direct-fired processes in many applications. New developments in variable-fre- quency power supplies, improved refractory linings, high-power inductor designs, furnace heat recovery, and computer control of furnace operations offer the potential for further significant improvements in furnace effi- ciency, productivity, and in the range of materials to which - excellent overview in [http://openfarmtech.org/EPRI_induction.pdf EPRI Center for Materials Production.]
*Another overview by Fairchild Semiconductor Power Division - [www.fairchildsemi.com/an/AN/AN-9012.pdf]
*Efficiencies of induction melters is 55-75% - [http://tristate.apogee.net/et/eetdifa.asp]

=== microwave heating foundry ===

*'''Microwave melting - even iron ''' - [http://home.c2i.net/metaphor/mvpage.html]
* Other technology: With the right techniques, a microwave oven can apparently heat glass to its melting point of 1,500 °C. ( [http://www.popsci.com/diy/article/2003-09/smelting-microwave PopSci], [http://www.wired.com/gadgetlab/2008/02/video-micowave/ Wired], [http://www.wonderhowto.com/topic/fusing-glass-with-microwave-oven/ Howto]). That is slightly more than melting point of steel (more or less 1,400 °C). Is it possible to use similar techniques to form small steel parts in a off-the-shelf microwave?[http://home.c2i.net/metaphor/mvpage.html] Would a thin layer of glass floating on the molten steel help block oxidation?
* I read this article. [[http://www.theodoregray.com/PeriodicTable/PopularScience/2003/09/1/index.html Smelting in a Microwave]]

=== concentrated solar foundry ===

"The maximum temperature the absorber can reach depends on how concentrated the sunlight is.
A very high quality dish reflector could concentrate sunlight up to 10,000 times.
If ordinary sunlight can heat things up to say 60 C (330 K) and the radiated energy rises as a power of 4, such as reflector could produce temperatures 10 times this, 3300 K or 3000 C.
At the maximum temperature the absorber is radiating as much energy as it receives, leaving no energy available to be converted into anything useful like electricity!
To actually get anything out of the concentrator we need the temperature of the absorber to be lower."[http://solavox.com/solconc.html]

For this reason, [[Solar Concentrators]] designed to produce electricity operate at much lower temperatures, and in fact typically have large radiators in order to keep them from getting "too hot" -- a very different design approach than a solar furnace.
''Is it possible to adapt the [[Solar Turbine Prototype at Factor e Farm]] to switch back and forth from directly melting metal in a crucible to generating electricity? Or is a solar turbine so very different from a solar furnace that it would be better to build a completely separate solar furnace?''

Several [[Solar Concentrators]] arrangements appear capable of reaching temperatures high enough to melt iron and steel.[http://www.appropedia.org/Understanding_Solar_Concentrators]
[http://en.allexperts.com/q/Physics-1358/Black-body-radiation.htm]

In theory, the maximum possible temperature of a solar foundry is the same as the temperature of the "surface" of the sun, 5,777 K.
[http://www.halfbakery.com/idea/Portable_20solar_20concentrator_20with_20high_20concentration]

"The largest solar furnace in the world is at Odeillo in the Pyrenees-Orientales in France, opened in 1970. ... an area the size of a cooking pot ... can reach 3,500 °C (6,330 °F)" -- [http://en.wikipedia.org/wiki/solar_furnace Wikipedia: solar furnace]

"Why go to the trouble of building a solar array ... just for melting metal, when you can install a steam turbine and generate and sell electricity?" -- Tim Williams[http://webpages.charter.net/dawill/tmoranwms/Solar_Power.html].
Some advantages of melting metal directly in a solar furnace, rather than indirectly converting solar power to electricity with a [[Solar Turbine]] and then using electric-powered foundry:
* Because a crucible is inherently simpler than a steam engine, it is simpler to build and maintain and lasts longer.
* Because a crucible has very easy tolerances, its capital cost is far less than a steam engine and any kind of electric-powered foundry. (Although it may require more expensive reflectors...)
* a solar furnace is easier to understand, replicate, and scale up or down.

=== electric arc furnace ===

*Arc furnace, 175kW, 700 lb/hour <ref name="LFYP">[http://www.ufes.com/index.php?n=Foundry.DetroitRockingARCFurnaceModelLFYP Detroit Rocking ARC Furnace Model LFYP]: capacity: 700 LBS serie, 175 KW, 440V, 60 HZ</ref>

*ARC, 53kW, 560 lb - [http://www.ufes.com/index.php?n=Foundry.GASMACElectricResistanceFurnace560LBS]

=== electroslag furnace ===

Electroslag remelting is complementary to the induction furnace because it specifically supports ''refining reactions'' which occur in the slag (for example removing sulfur, non-metallic oxides, and free oxygen). Example commercial scale equipment from [http://www.consarc.com/brochures/esr.pdf Consarc]. A very interesting family of mini-foundry products is offered by [http://centroteh.com.ua/unit-en Centroteh] (Ukraine). Conventionally, a previously melted and cast ingot rod from another type of furnace is fed into the top of an electroslag remelter. However Centroteh suggests that, alternatively, a fixed carbon electrode can feed the heating current and chopped scrap can be fed directly into the slag pool. Very interesting!! Could this replace the primary function of the induction furnace in turning scrap into new steel?

Electrical energy consumption is listed by Centroteh as ~320 watt-hr/lb, which is comparable to an induction furnace. The electroslag furnace does not seem to require refractory, as the process is performed directly in a water-cooled copper mold.

=Reversion=

Reversion refers to substituting know how, raw materials, and labor for off-shelf products. Using this technique, we can make steel-melting crucibles, to reduce costs. Crucibles for 300 pound shots are several hundred dollars. The materials cost about 10x less.

==Crucibles==

See also [[Induction_Furnace_Overview#Crucible |Induction Furnace Crucible]]

Getting the scrap metal into a cold crucible is the easy part.
How do you get the molten metal out of the hot crucible?

*200 lb dip out furnace for sale - [http://www.ufes.com/index.php?n=Foundry.200LBDipoutFurnace]
*3000F rocker furnace for sale, 750 lb per hour after first heat - electric with 2 electrodes - [http://www.ufes.com/index.php?n=Foundry.Detroit750LYPRockerFurnace]

Crucibles are made from special clays.
*What is the composition?
** Portland cement, silica sand, perlite and fireclay.[http://www.backyardmetalcasting.com/bucketfurnace1.html]
*Where do we procure the materials?
*How do we make the crucible?
*What is the total cost?

=Collaboration Discussions=

'''Letter sent to Paul'''

Could you do a little research on foundries? I put initial info up at:

http://openfarmtech.org/index.php?title=Foundry

We want to melt metal - to cast tractor, steam engine, and CEB press parts. We would like to do that this year. Are you by any chance interested in getting involved in this? The workshop will house the furnace.

If so, please research this and propose the best furnace to use. We want to work with steel - so any iron melting furnace will do. We are looking for a simple, low-cost design that can handle at least 200 pounds per hour, to be effective in casting - say the 2000 lb of a tractor frame - in one day.

The economics involved are producing $1000+ worth of structural steel for parts. This would make it economically feasible to produce tractors, etc - starting from scrap steel.

This would be quite a treat, to show fabrication starting at the cost of scrap metal. It's a possibility, but so far I have not seen an integrated operation that designs, casts, and builds under one roof. There is great potential for efficiency through this process, especially if we have global design sharing, and 3D printing of mold via open source printers such as RepRap. -Marcin

'''Input From Yahoo [http://groups.yahoo.com/group/hobbicast/ Home Foundry Group]:'''

''From Mikey''

The method you need to employ isn't a matter of getting the furnace hot enough at all. Take a minute and absorb that basic fact, for steel melts between twenty-six and twenty-eight hundred degrees. Now consider the fact that the even higher furnace temperatures needed to bring a charge up to that range will destroy all but the most expensive furnace refractories, while weakening crucibles to the point where they become rubbery..Iron, on the other hand, melts nicely between nineteen-fifty and twenty-two hundred degrees; a much more comfortable heat range for your equipment.

So, how did industry turn iron into steel about a hundred years back? An oxygen lance was used to burn out excess carbon while simultaneously raising the molten iron to steel liquefying temperatures from the center of the charge, instead of trying to transfer overwhelming temperatures through crucible walls.

Most steel making still uses one form or another of heating steel charges from the center out.

I believe oxygen lances are still the best method for home hobbyists today.

As to Babington burners; I mostly dislike commenting on the competition.

''From Venkat''

Marcin, it is very difficult to melt steel ic oil :gas fired furnace because its melting temp is high as 1500 DEG CENTIGRADE, so pl try with induction of arc furnace only , steel needs some alloying elements like carbon , silicon, etc depending on its usage , you can try to build home made inaction melter, as some ref may be available in intranet, that is the way as for i concerned, Best regards, V;Ganesan;

=Books=

*'''Metallurgy of Iron and Steel''' - [http://books.google.com/books?id=Rh5KAAAAMAAJ&pg=PA52&lpg=PA52&dq=%2380+iron+crucible&source=web&ots=rnakcKqZw3&sig=0jrzqDfUfvsxpZQDjL85xWmaSdc&hl=en&sa=X&oi=book_result&resnum=2&ct=result]
*Google Book, '''Maximum Production in Machine-shop and Foundry''' - 150 lb shots in 1911 foundry took 3.5 hours - with noted low production - [http://books.google.com/books?id=4uUNAAAAYAAJ&pg=PA282&lpg=PA282&dq=100+lb+foundry&source=bl&ots=S00WtZMGp_&sig=mxtsCMcC5FZVAzF6KeXKIjhRMUs&hl=en&sa=X&oi=book_result&resnum=1&ct=result#PPA281,M1]

*Google Book, The Foundry, early 1900s, has economics - [http://books.google.com/books?id=FI9NAAAAMAAJ&pg=RA2-PA44&lpg=RA2-PA44&dq=productive+value+of+a+foundry&source=web&ots=wR_z29twwO&sig=nPBg7UxB7yj11sXmUydtN-xFjMA&hl=en&sa=X&oi=book_result&resnum=2&ct=result#PRA2-PA45,M1]

*'''Principles of Foundry Technology''', Google Book - [http://books.google.com/books?id=k1slD5MmhUMC&pg=PA215&lpg=PA215&dq=thermal+efficiency+of+a+foundry&source=bl&ots=U1v2nNJcd0&sig=iQrFmmxyPiLNvAMbvhGwFZvpejA&hl=en&sa=X&oi=book_result&resnum=5&ct=result#PPA204,M1]

==See Also==
*[[Induction Furnace]]
*[[Sintering]]
*[http://www.bakerfurnace.com/crucible-furnaces.html *Crucibles, furnaces, specs]

[[Category:Induction Furnace]][[Category:Metalworks]]

Dedicated Project Visits

2013-09-20T09:04:33Z

Justin Kurtz: /* Application and Participation Steps */

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The Founder's Ted Talk]]

last updated Aug 7, 2013

=Introduction=

Collaborators who are interested in coming to Factor e Farm in Maysville, Missouri to assist with designing, building and testing the [[Global Village Construction Set|50 GVCS Machines]] can apply for a '''Dedicated Project Visit'''. Dedicated Project Visits are typically at least one month in duration, but shorter and longer time frames are acceptable. During the Dedicated Project Visit, Dedicated Project Visitors (DPVs) assist with the current development and testing initiatives, which are found in ''OSE's Master Schedule.'' However, on occasion, a DPV may request a Specialized Dedicated Project Visit where the DPV works on a GVCS product or OSE initiative that is not part of the [[Product Development Schedule]].

=Application and Participation Steps=
These are the overall steps for a Dedicated Project Visit:

#'''Initial Contact''' - Please contact OSE's Technical Community Manager: TechCommunity@opensourceecology.org . See [[Initial DPV Request]] for pertinent information to include in your inquiry, and any questions you may have as well.
#'''Application''' - After initial contact, we request that applicants fill out the Application format from the next section. Once completed, please inform the Technical Community Manager so OSE staff can review your application.
#'''DPV Interview''' - After reviewing the Application, OSE staff will conduct a short interview to discuss work experience/skills, problem solving skills/abilities/techniques, availability, project interests, and "behavioral" questions typical of a job interview. The interview should take 15-30 minutes.
#'''Evaluation''' - DPV applications are evaluated based upon the following criteria: 1) Applicant's skills, expertise, and interests meet the needs of current OSE objectives; 2) Applicant's "fit" into a communal living environment, and 3) Applicant's ability to work both independently or on a team to meet specific goals/objectives.
#'''On-Boarding''' - Once an offer for a DPV is accepted, a welcome email will be sent to the applicant to include being matched with a DPV sponsor who can answer questions about the DPV experience prior to your arrival. Additional information included in the welcome email can be found at [http://opensourceecology.org/wiki/Factor_e_Farm_Community_Standards Community Standards] and [http://opensourceecology.org/wiki/Workshop_Guidelines Workshop Guidelines]
#'''Documentation''' - all DPV participants are required to follow the same guidelines for documentation as our staff. See [[Work Log Guidelines]].

For remote collaboration, we have [[Remote Collaboration Standards]].

==DPV Application==

Note that the goal of a Dedicated Project Visit is to produce tangible, significant results that contribute to the creation of the [[GVCS]]. We are looking for those who can work both independently and on teams; and who possess initiative and a strong work ethic.

Please post the DPV Application materials on our wiki by starting a wiki page - titled 'Your Name Dedicated Project Visit Application'. See the wiki editing [[Instructions]] if you have any questions. If you are not comfortable posting your contact information, just include your email. '''Please tag your page with the Category:Dedicated Project Visit Applications - see [[Instructions]] regarding Categories.'''

''NOTE: If you are not familiar with wiki usage, please contact the Technical Community Manager (TechCommunity@opensourceecology.org) for support. Wiki usage is an important component of OSE collaboration--with a few short tutorials, you will be a whiz at wiki documentation, and the Technical Community Manager is here to help!''

#Name, location, contact info (phone, email, Skype).
#Are you over the age of 18? (affirm yes or no)
#When would you be available for a Dedicated Project Visit and for what duration?
#Please attach a resume or provide a list of work / volunteer experience and education.
#Please include a photo of yourself.
#Please submit a 1-2 minute video introduction regarding your interest in applying. This is a video-of-interest (VOI) and it must include: (1) Name and country where you are located, (2) why you are interested in applying; (3) what you would like to contribute to our effort and relevant skill set that will help you do that; (4) what are you hoping to get out of your visit? Please upload this video to a public video sharing site such as YouTube or [[OpenPhoto]].
#Are you willing to publish all the results of your work openly according to the [[OSE Open IP Guidelines]]?
#Do you have resources to support yourself while volunteering with us?
#Do you have sample work that you could upload and/or share via email? (ie. projects, designs, technical writing, graphic designs, videos, etc).
#Are there skills/expertise you hope to gain while a DPV at FeF?
#Please provide three (3) references (professional or educational). Contact information for references can be uploaded with the application, resume, or emailed directly to the Technical Community Manager: TechCommunity@opensourceecology.org.
#How did you hear about OSE and the DPV opportunity?
#Do you have any other concerns or considerations? (May be emailed separately)

==Specialized DPV Application==
#Please complete the steps for a DPV Application (above).
#Please write a one-page proposal brief summarizing what you would like to do, how you would accomplish it, and what resources you would need to do so. Include a budget as necessary.
#Develop a project plan to include: GVCS product or other OSE-related product/objective (ex: wind turbine prototype development, wiki development or permaculture study). List your goals and deliverables for your Dedicated Project Visit, to include weekly objectives and deliverables. Include the metrics by which you could assess the success of your work.
#What would you like to get out of your Dedicated Project Visit?
#Please include sample work of similar projects or scope of responsibility, if available.

Any way to create an option for farms to apply for training teams to come in and expand the network of developers using First robotics style coop ertition???? I've got a community but none of us have IT Skills. No internet at the sight, and most people are over 50. Needs some young energy to get it rolling.

I can come up and help but that doesn't get multiplication of efforts going.

=Documentation=
Documentation is the key to successful open source projects. All visitors to Factor e Farm are asked to bring a digital camera or smart phone with them to document their work. They may also be asked to [http://blog.opensourceecology.org/ blog] about their progress at the beginning and end of their DPV.

=Living and Working Environment=
Factor e Farm is a developmental facility. Basic accommodations include shelter, twin beds, showers, flush toilets, kitchen, and washer/dryer. Participants are expected to follow [[Factor e Farm Guidelines]] and [[Factor e Farm Community Standards]], and to cover their own food expenses. Pets are not allowed unless specifically negotiated.

=Sample Dedicated Project Visit Applications=
[[Scott Eisele Dedicated Project Visit]]

=See Also=
*[[Visit Factor e Farm]]

[[Category:Collaboration]]
[[Category:Dedicated Project Visits]]
[[Category:Recruiting]]

How to Build the 4 Machines in a Basic Workshop

2013-09-20T08:05:31Z

Justin Kurtz: /* So, you want to build a new civilization? */

=Basic Workshop=

A basic workshop incudes these tools:

#MIG Welder - 200 amps - $1000 used
#Acetylene Torch - $500
#[[Magnetic Drill]] - $385
#15 Amp and 5 Amp grinders - $80
#Abrasive 14" metal cutoff saw - $150

and other hand tools such as C clamps, vise clamps, a vise, hammers, wrenches, allen wrenches, pipe wrenches, holding magnets, speed square, L angle, mesuring tape, soapstone marker, and others.

'''For about a $2,100 investment in the above tools - one has sufficient tooling to build the entire tractor, CEB press, Pulverizer, and Power Cube.''' The only part not covered is about 2-4 hours of lathe work to produce tractor wheel shaft couplers. Otherwise, all else is obtained by cutting, drilling, and welding of stock steel metal sections. Simplicity of design allows one to build serious equipment with minimal effort. Skill is required - but that skill can be picked up when one really wants to do the work.

If one has access to a CNC Torch Table, Ironworker Machine, metal band saw - then the cutting and hole-making could go much faster - but for one-off production, the 5 main tools + hand tools above are sufficient.

=Basic Advanced Workshop=

A basic advanced workshop contains these 7 tools:

#CNC Torch Table for cutting steel parts - [http://torchmate.com/products/torchmate_3/ $12k off-shelf] - [http://blog.opensourceecology.org/2010/01/reptab-open-source-torch-table-in-make-zine/ $1500 OSE]
#120 Ton Ironworker machine for rapid shearing and hole punching of 1" thick metal - [http://www.edwardsironworkers.com/120ton.html $21k off-shelf] - [http://blog.opensourceecology.org/2010/07/open-source-150-ton-hole-puncher/ $1600 OSE (hole punch only)]
#CNC Mill - [http://compare.ebay.com/like/330407948304?ltyp=AllFixedPriceItemTypes&var=sbar&rvr_id=153012188215&crlp=1_263602_304662&UA=L*F%3F&GUID=6cefd2a012a0a06c1b734cc3ffef596b&itemid=330407948304&ff4=263602_304662 $17k used off shelf] - $4k OSE
#CNC Lathe - [http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=400163124262&hlp=false&rvr_id=153032086286&crlp=1_263602_304652&UA=L*F%3F&GUID=6cefd2a012a0a06c1b734cc3ffef596b&itemid=400163124262&ff4=263602_304652 $15k used off shelf] - [http://blog.opensourceecology.org/2010/01/initial-steps-to-the-open-source-multimachine/ $4k OSE after CNC addition]
#Heavy Duty Drill Press (2" hole drilling capacity) - [http://www.toolorbit.com/Jet/Jet-354040.html $10k off shelf] - [http://blog.opensourceecology.org/2010/07/open-source-drill-press-prototype-debut/ $600 OSE]
#200 Amp MIG Welder - [http://www.google.com/products/catalog?client=ubuntu&q=millermatic+252&oe=utf-8&hl=en&cid=12110604904551249361&ei=iOu1TO3qD4bc2gTE86WrCQ&sa=title&ved=0CAcQ8wIwADgA#p $2k off shelf] - $500 OSE
#Acetylene Torch - [http://www.google.com/products/catalog?client=ubuntu&q=acetylene+torch&oe=utf-8&hl=en&show=dd&cid=14262758315025162865&ei=H-y1TMOhOouA2wSOzJ2pCQ&sa=title&ved=0CCsQ8wIwCTgU#p $400 off shelf]

*'''$77,400 off shelf''' + maintenance costs of the same about every 10 years; for a lifetime (20 yr) enterprise, the cost doubles.
*'''$14,100 OSE cost pending development of these tools''' + lifetime service, as people can maintain their own machines.

=Discussion=

This would allow one to build all the above tools (self-replication), plus things like tractors, microtractors (lawnmowers), pelletizers to have people harvest their own fuel from grass clippings; cars; engines, hydraulic motors, and other things from open plans, using CNC assist. The predicted value of labor captured is $100 per hour, or a total return of $16k/person/month with 8 hour shifts in a 1000 sq foot workshop.

Make a 4000 square foot workshop to accommodate 4 people, and you have $64k/month earning capacity with 4 people.

Such earning depends on the full product release plans for all devices, and implies transcendence of artificial material scarcity in communities worldwide.

=So, you want to build a new civilization?=

The best way to do it is to do it. There is no magic. If you see the purpose in this course of action, all you need to do is spend $2.5k, quit your job, and start building. After a few hours of practice, you will gain basic proficiency in torching and welding. If you want to become a master, it will take you a lifetime.

{{Civilization_Starter_Kit_DVD}}
[[Category:Notes]]
[[Category:RepLab]]
[[Category:Introduction]]

I have a pacemaker and can't use a welder. Now what?
It will only interfere when welder or chainsaw is in use, not permanently. But seriously is there any way to use aluminum or a lighter erector set style so I don't have to worry about killing myself???? I'm in a build situation now. Have land, a slab, and clay earth all around, but the shovel and bucket of water method is a little tough. I've got about 2,000 to invest.
Keep up all the excellent work!

How to Build the 4 Machines in a Basic Workshop

2013-09-20T07:59:01Z

Justin Kurtz: /* So, you want to build a new civilization? */

Open Source Ecology

2013-09-20T07:44:13Z

Justin Kurtz: /* Organization */

==Overview==
{{Open Source Ecology}} is developing and testing the [[Global Village Construction Set]]

[[Image:Logo.jpg|left|Open Source Ecology]]

==Details==
By weaving open source permacultural and technological cycles together, we intend to provide basic human needs while being good stewards of the land, using resources sustainably, and pursuing [[Right livelihood|right livelihood]]. With the gift of openly shared information, we can produce industrial products locally using open source design and [[:Category:Digital Fabrication|digital fabrication]]. This frees us from the need to participate in the wasteful resource flows of the larger economy by letting us produce our own materials and components for the technologies we use. We see small, independent, land-based economies as means to transform societies, address pressing world issues, and [[evolve to freedom]].

[[Factor e Farm]] is the land-based facility where we are putting this theory into practice. Here we are testing the prototypes of of [[Global Village Construction Set]], working piece by piece towards self sufficiency. Ultimately, our goal is to make this self sufficiency available to all. To this end, the [[GVCS]] is designed to be self-replicable. After the first set is complete, it will be used to fabricate copies of itself from raw materials (for the cost of scrap metal). At that point we will shift to begin developing networks of interconnected self-sufficient villages and homes.

Taken literally, [[Wikipedia:open source|open source]] means that the goods and knowledge for reproducing the complete product (the "source") is freely accessible (open), and [[wikipedia:ecology|ecology]] is the study of living interactions between organisms and their natural environment. From a human perspective, we seek to push our vision of ecology beyond ecological crisis and into ecological harmony and human productivity.

==Videos==

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==Organization==

* [[Factor e Farm]]
* [[GVCS]]
* [[Media]]
* [[Marketing]]
* [[Development]]
* [[Archive]]
* [[Places]]

You had tools? How does a homeless homesteader do this? Until I can take this to the homeless and teach one guy, who can then teach another etc. Start with NOTHING. I don't see it working to the scale you present in your vision.

You had a garage, and tools, and the torches, and hoists. I'm a cardiac patient in the woods, trying to utilize a slab I found, and recycled materials. Building a compressed earth maker from salvaged parts, teach men how to do that. Then they can truly be sustainable.

Would love to learn how you got where you are. Ask you a ton of questions. Invite you to help me build a home with my bare hands. Bucket list that before my pacemaker runs out so my son has a home he can live in when I'm gone.

When a guy like me can start with nothing and do it. Then you'll have the answer. Got to be for the guy who doesn't know where to start/turn but wants to do better. This needs to work for the recovering drug addict, the single mom. The orphan who just aged out of foster care and adds to the #1 reason for homelessness in America. This has to be for that guy to find an abandoned piece of dirt and make it his Legacy!

I'd love to help make that a reality!

==See Also==
* [[Wikipedia: Open source]]
* [[Wikipedia: Ecology]]
* [[Brochure]]

__NOTOC__

User talk:Justin Kurtz

2013-09-20T05:32:25Z

Justin Kurtz: /* Community needs help! */ new section

== Community needs help! ==

Off Grid community in North Texas is in need of this technology. Looking to build a team to bring it to them. Also looking for new prospective members.