CEB Press/Manufacturing Instructions/Hopper sheet metal: Difference between revisions

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== Tools Required ==
=Tools=


*torch
*Torch
*welder
*hole punch


*Welder


== Materials Required ==
*Hole punch with 3/4" dies


*sheet metal 1/2”x12” - 7'2” ?  11 gauge, 5'x10' ?
=Materials=
*hinges
*3/4" bolts
*1/2" bolts


== Diagrams ==
*[12] Door Hinges


[http://openpario.mime.oregonstate.edu/attachments/463/hopper_sheet_metal.dxf DXF File]
*[12] 1/2" x 1 1/2" bolts


[[Image:hopperfab.png|400px]]
*[12] 1/2" washers (12)


== Fabrication Steps ==
*[12] 1/2" lockwashers (12)


*Plasma cut sheet metal
*[12] 1/2" nuts (12)


*Punch 3/4" holes in all 28 hinges, in center of rounded part
*Steel plate 5' x 10' x 1/8" OR [2] Steel plate 4' x 8' x 1/8"


*Punch holes in hopper sheet metal (all the blue holes, 3/4")
*Steel bar 3" x 1/8" x 24'


*Bolt all hinges to sheet metal at the red locations marked "1" with 3/4" bolts
=Steps=


*Weld bottom hinges of ''hopper sheet 1'' to hopper mount plate
*Torch the hopper shapes as shown. Grind away any excess slag. Punch all of the holes shown.


*Weld top hinges of hopper sheet 1 to grate
[[Image:hopperfab.png|1000px]]


*Install hopper supports to hold hopper sheet 1, and bolt with the 2 bolts (1/2")
[[Image:hopper_jpg.jpg|1000px]]


*Weld hinges to hopper supports for sheet 2
[[Image:hopper_layout.jpg|1000px]]


*Weld hinges at base of sheets 2, 3, 4
*Insert then weld the 1/2" bolts to the side hopper plates such that the bolt heads would be inside if the hopper were to be assembled.


*Weld hinges between sheets 3&1, 4&1, and between 2&3, and 2&4
[[Image:boltshingeplates.jpg|500px|The bolts ready to weld]]


*At this point, the entire hopper is erected. It remains to weld the remaining hinges to the grate.
*Cut the 24' bar into 8 sections of 3' length


*Upon completing these steps, the 3/4" bolts can be replaced with 1/2" bolts for successive deconstruction and reconstruction of the hopper.
*Punch 3/4" holes in 4 of the hinge plates as shown.
 
[[Image:hingeplates.jpg|500px|Hole locations for the hinge plates]]
 
*Weld a holey hinge plate, a non-holey hinge plate and 3 hinges together as shown. Repeat for a total of 4 holeplate-3hinge-noholeplate welded assemblies. Note to make sure the side of the assembly that sticks out most is on the top; this way it won't interfere with the hopper metal below when installing the hopper.
 
[[Image:weldinghingeplates.jpg|500px|Welding the hinge plates]]
 
*Weld the no-hole plates of the 4 plate-hinge-plate assemblies to the sides of the front and rear hopper plates.

Latest revision as of 04:50, 23 December 2011

Tools

  • Torch
  • Welder
  • Hole punch with 3/4" dies

Materials

  • [12] Door Hinges
  • [12] 1/2" x 1 1/2" bolts
  • [12] 1/2" washers (12)
  • [12] 1/2" lockwashers (12)
  • [12] 1/2" nuts (12)
  • Steel plate 5' x 10' x 1/8" OR [2] Steel plate 4' x 8' x 1/8"
  • Steel bar 3" x 1/8" x 24'

Steps

  • Torch the hopper shapes as shown. Grind away any excess slag. Punch all of the holes shown.

Hopperfab.png

Hopper jpg.jpg

Hopper layout.jpg

  • Insert then weld the 1/2" bolts to the side hopper plates such that the bolt heads would be inside if the hopper were to be assembled.

The bolts ready to weld

  • Cut the 24' bar into 8 sections of 3' length
  • Punch 3/4" holes in 4 of the hinge plates as shown.

Hole locations for the hinge plates

  • Weld a holey hinge plate, a non-holey hinge plate and 3 hinges together as shown. Repeat for a total of 4 holeplate-3hinge-noholeplate welded assemblies. Note to make sure the side of the assembly that sticks out most is on the top; this way it won't interfere with the hopper metal below when installing the hopper.

Welding the hinge plates

  • Weld the no-hole plates of the 4 plate-hinge-plate assemblies to the sides of the front and rear hopper plates.
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