PowerCube6 Hydraulic Reservoir: Difference between revisions

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Procedure for fabricating the hydraulic reservoir. Note that the preparation of the edges for welding is critical, as the welded seams must prevent fuel leaks.
Procedure for fabricating the hydraulic reservoir.
Note that the preparation of the edges for welding is critical, as the welded seams must prevent fluid leaks.


Part List:
Part List:


Rectangular tube: 1/4" x 6" x 12" - 26" long [2] Flat Steel: 1/4" x 6" x 12" Weld-in Fuel Filler Neck and Cap Small sheet plastic Fuel Pickup Adapter 1/4" rubber hose Soapy water
* 1/4" x 6" x 12" - 26" Rectangular tube
* [2] 1/4" x 6" x 12" Flat Steel
* [2] 3/4" NPTF weld-in flange
* 3/4" NPTM plastic tank breather
* 1 1/2" NPTF x 3" union
* Hydraulic tank thermometer and sight gauge
* [2] 1/4" NPTM plug - Galvanized
* [2] 3/4" NPTM plug - PVC
* 1 1/2" NPTM plug - PVC
* Schrader air valve
* Soapy water


    Grind the 1/4" x 6" x 12" plates, rounding the corners to 1/2" radius and beveling the edges for welding.
 
    Grind the 1/2" x 6" x 12" Tube, beveling the edges for welding.
Procedure:
    Cut the 7/16" and 2" holes in the tube as shown. The larger hole may be cut with an Oxy/Acetylene torch, then smoothed with a grinder. Note that the inside of the hole should be 2" in diameter.
 
    Weld the plates to the ends of the tube
# Grind the 1/4" x 6" x 12" plates, rounding the corners to 1/2" radius and beveling the edges for welding.
    Tap the 7/16" hole for 1/4" NPTF threads, smooth the welds with the grinder.
# Grind the 1/2" x 6" x 12" Tube, beveling the edges for welding.
    Pressure test the tank by covering the filler neck with a plastic sheet, then securing the cap. Secure the smaller hole with a the fuel pickup and some 1/4" hose on the hose barb. Apply compressed air to the end of the rubber hose to pressurize the tank, then apply soapy water to all welds and check for bubbles.
# Cut the 7/16", 1 7/16" and 2" holes in the tube as shown. The larger holes may be cut with an Oxy/Acetylene torch, then smoothed with a grinder.
    Mark any bubbling spots with a felt-tip marker and re-weld
# Tap threads in the two smaller holes with a 1/4" NPTF tap
    Re-test the tank and re-weld as necessary to stop all leaks
# Weld the three flanges to the tank
# Weld the "front" plate (ie: the one near the oil filter) to the end of the tube
# Drill the two 1/2" holes for site gauge and securely install the site gauge
# Tap the 7/16" hole for 1/4" NPTF threads, smooth the welds with the grinder.
# Pressure test the tank by covering the filler neck with a plastic sheet, then securing the cap. Secure the smaller hole with a the fuel pickup and some 1/4" hose on the hose barb. Apply compressed air to the end of the rubber hose to pressurize the tank, then apply soapy water to all welds and check for bubbles.
# Mark any bubbling spots with a felt-tip marker and re-weld
# Re-test the tank and re-weld as necessary to stop all leaks
 
[[image:HydraulicReservoirFab.png|600px Hydraulic Reservoir]]

Latest revision as of 12:56, 22 August 2012

Procedure for fabricating the hydraulic reservoir. Note that the preparation of the edges for welding is critical, as the welded seams must prevent fluid leaks.

Part List:

  • 1/4" x 6" x 12" - 26" Rectangular tube
  • [2] 1/4" x 6" x 12" Flat Steel
  • [2] 3/4" NPTF weld-in flange
  • 3/4" NPTM plastic tank breather
  • 1 1/2" NPTF x 3" union
  • Hydraulic tank thermometer and sight gauge
  • [2] 1/4" NPTM plug - Galvanized
  • [2] 3/4" NPTM plug - PVC
  • 1 1/2" NPTM plug - PVC
  • Schrader air valve
  • Soapy water


Procedure:

  1. Grind the 1/4" x 6" x 12" plates, rounding the corners to 1/2" radius and beveling the edges for welding.
  2. Grind the 1/2" x 6" x 12" Tube, beveling the edges for welding.
  3. Cut the 7/16", 1 7/16" and 2" holes in the tube as shown. The larger holes may be cut with an Oxy/Acetylene torch, then smoothed with a grinder.
  4. Tap threads in the two smaller holes with a 1/4" NPTF tap
  5. Weld the three flanges to the tank
  6. Weld the "front" plate (ie: the one near the oil filter) to the end of the tube
  7. Drill the two 1/2" holes for site gauge and securely install the site gauge
  8. Tap the 7/16" hole for 1/4" NPTF threads, smooth the welds with the grinder.
  9. Pressure test the tank by covering the filler neck with a plastic sheet, then securing the cap. Secure the smaller hole with a the fuel pickup and some 1/4" hose on the hose barb. Apply compressed air to the end of the rubber hose to pressurize the tank, then apply soapy water to all welds and check for bubbles.
  10. Mark any bubbling spots with a felt-tip marker and re-weld
  11. Re-test the tank and re-weld as necessary to stop all leaks

600px Hydraulic Reservoir

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