CEB Press/Manufacturing Instructions/Frame with main cylinder

Tools Required

• Torch
• Hole Punch
• Mag Drill
• 1/2” Allen Wrench

Materials Required

Steel

• 6” Heavy (7/16”) U-Channel- 274 1/2”
  • A- 54” (2); Vertical Members
  • B- 20 3/4” (4); Horizontal Members
  • C- 28 3/4” (2); Drawer Members
  • D- 13” (2); Spacers
• 6" Light (1/4") U-Channel-41.5"; Cylinder support: 20 3/4" (2)
• 2"x2"x1/4" Angle: 12"; Dirt Blockers: 6” (2)
• 1 1/2” DOM Roundstock: 12”; Cylinder Pin: 8 1/2”, Press Foot Filler: 3 1/2”
• 1 1/2” Inter Diameter DOM Tubing: 2 1/2"; Pin Receptors:1 1/4” (2)
• 1”x4” Plate: Lower Press Foot: 10” (1)
• 1”x6” Plate: Upper Press Foot: 12” (1)
• 2” U-Channel: 1.5” (2); Cylinder Spacers
• 1” Pipe: 1.5” (2); Cylinder Spacers
• 1/4”x1” Flatbar: 13” (1); Magnet holder
• 3/8” Rebar: 3.5” (2); Sensor Holder
  • For Optional “Jig”: 6”x12” Tubing: 52”

Nuts and Bolts

• 3/4”x1.5” Bolts (28)
• 3/4” x 2.5” Bolts (6)
• 3/4” Steel Nuts (9)
• 3/4” Galvanized Nuts (40)
• 3/4” Threaded Rod: 16”

Hydraulics

• 5”x12” 3000 PSI Hydraulic cylinder Buy (1)
• 3/4” to 3/4” Hydraulic Coupler (2)
• 3/4” Female Quick Coupler (1)
• 3/4” Male Quick Coupler (1)

Fabrication Instructions:

Pre Assembly

The following can be done in any order, prior to assembly.

Punch the holes in the horizontal members (B) and in the drawer members (C)

Step 1

• In the horizontal members, the holes should be 7/8” in from the long side, and as close as you can get them to the wall of the U-channel. There are 4 holes in each piece.
• In the drawer members, the holes should be 4 7/8” in from the long side, and as close as you can get them to the wall of the U-Channel. There are 4 holes in each piece.

Prepare the wide cylinder supports

1. Punch 3/4" holes in the thin U-Channel in the same manner as with the horizontal members.
2. Weld the 2"x2" angle (5.5") centered and squared on one side of the U-Channel.
3. Torch a hole 3/4" away from the end of the 2"x2" for a 3/4" bolt and grind it clean.
4. Place a steel nut over the hole and ensure it is clear for a bolt and flush.
5. Weld the nut in place.

Prepare the thin cylinder supports

• Weld some 3/4" ID pipe (3/4" to 1") to the 3" U-channel. 4-8 good tacks is sufficient.
• Make some 6" long 3/4" bolts. See Making Bolts

Prepare the magnet holder

1. Shield the threaded rod from spatter by putting 2 nuts on it.
2. Prop up the 1/2"x1" flatbar so it's level with the center of the threaded rod, ensuring they are parallel.
3. Weld the two together and remove the nuts.

Prepare the sensor holders

• You will need one later which attaches to the arms, so it's suggested you make two.
• Weld 3.5" of rebar to 3.5" of threaded rod at a right angle, taking care to protect the threads from spatter.

Assembly

Step 1: Mag Drill Holes in Verticals.

1. Gather materials for the “Jig”; this means 6”x12” tubing (52”) and any extra heavy U Channel. If you don't have any laying around, you can use one drawer member, and one spacer on each side.
2. Clamp the vertical pieces to the "Jig" on each end, with extra U channel in between the tubing and the vertical pieces. See the diagram on the right:
   C-Clamp the vertical pieces to the jig as shown.
3. Clamp one horizontal member at each end of the jig.

• Ensure they are square with the jig by using a large square
• Clamp using 1 or 2 vise grips on either side.

1. Transfer Punch thru the holes on B.

Hint: It really helps to label each piece before taking it apart, so that if you end up unbolting the piece later, you'll know exactly where it goes and in what orientation.

1. Mark where the edge of the horizontal member is in relation to the vertical members on the vertical member. Use a square to mark the same location on the opposite side. Do this on all four locations.
2. Remove the horizontal members.
3. Use a Mag-Drill to drill 3/4" holes in each spot you transfer punched.
4. Flip the jig over so you have access to drill the other holes.
5. Align the other horizontal members with the marks you previously made, and insure once more that they are square.

• If it is on the mark on each side, but not square, just get it as close as you can to the marks while insuring it is square.

1. Clamp the members in place.
2. Transfer punch them.
3. Remove them.
4. Mag Drill them.
5. Unclamp the verticals from the jig.

Step 2: Assemble top/bottom

1. Loosely bolt the crossmembers on one side in place.
2. Square them up with the verticals using a large square.

• If they're not lining up properly square it up on the top of the cylinder first and tighten those bolts. Then square out the other side and torch out any spots prohibiting the bolts from going thru.

1. Tighten all of those bolts.
2. Flip over the frame.
3. Loosely bolt the crossmembers on this side and square them. Insure the members on the other side are level with this one.
4. Tighten these bolts.

Step 3: Mag-Drill the holes for the wide cylinder supports and drawer members

1. Clamp the drawer member centered, 5" from the upper cross member.
2. Clamp the wide cylinder support directly below it.
3. Transfer punch thru those holes.
4. Mag-Drill 1" holes at these centers.
5. Flip the frame over and do the same thing on the other side.

Step 4: Torch the roller slots

• The center of them is located 9 5/16" away from the top of the machine, 2 inches in from one side of the U-Channel.
• They are to be 1.5" tall, and 5/8" wide.

Step 5: Weld the spacers

1. With the frame laid down, and one of the drawer members in place, place the spacers on each side. The end of them is to be 5 1/8" away from the upper cross member.
2. Insure they are parallel with the U-channel and C-clamp in two places for each.
3. Tack the top in 3 spots.
4. On the bottom edge, weld the interior inwards as far as you can. This should be an inch or more.
5. Weld the top 100%.
6. Grind the top weld flush with the U=channel.
7. Flip over the frame.
8. Remove the other drawer member, and repeat steps 3-6.

To be continued, during the month of August, 2011...

Step 1. Torch or cold-cut channel to size

Step 3

Diagrams

Step 1: Gather the Form Pieces

Step 2: Put the Form Pieces Together

Step 3: Line the Vertical Beams along the Form and C-Clamp them in Place

Step 4: Place One Each of the Upper and Lower Cross Beams

Step 5: Flip the Frame

Step 6: Place the Remaining Cross Beams

This diagram shows the pieces needed for the frame. Click to enlarge: