Power Cube/Intro Video Script
Construction of the power cube is a multiple step process including fabrication of parts and assembly. Work in a well-ventilated shop equipped with space for storage of materials, an area for using a cutting torch, and a welding table suitable for use with an arc welder. Always wear appropriate safety gear. A list of necessary materials and tools is available on the Open Source Ecology wiki page for Power Cube/Manufacturing Instructions.
The first step in construction of the power cube is to fabricate several parts prior to assembly. This will require cutting and drilling steel up to 3/8" in thickness.
Start with drilling and cutting of the engine and hydraulic pump mounts. A torch is carefully used to cut the steel.
Two quick attach mounts are created to attach to the top of the cube. These mounts will support the full weight of the cube and make it possible to move the cube and attach it to other machinery.
Next is the fuel tank, constructed from a steel tube with two end plates. The welds on the tank must be quality to prevent leaking. Be careful not to over weld the mount to the tank and make sure to thoroughly clean the inside of the tank. Any debris mixing with the gasoline could potentially clog the engine when started.
Drill out the holes in the fan mount and connect end plates. Drill out holes in the key switch and choke mounts.
Electrical cables should be cut and connectors applied to the ends by stripping 1.5" of insulation from the cables, then slip on connectors, hammer them closed, and drill holes for connection.
Cut down steel on a bandsaw or metal cutoff saw to create battery mounts. tack and weld together.
The Hydraulic Reservoir must be carefully made with quality welds so it will not leak. Thoroughly clean the edges of the tube, the inside, and clean grind tank bungs. Tack and weld plates to either end of the tube. Tack and weld the strainer extension tube to the tank, centered around the strainer hole. Insert the strainer into the flange and insert it into the strainer extension tube – verify that it slides without binding or bottoming and that the flange is flush with the end of the tube. Remove the strainer from the flange, then tack and weld the flange to the tank. Keep the strainer away from the welding and flames, as its thin wires burn easily.
Fabrication is completed and now it's on to assembly. Assembly requires a welder (electric or torch) capable of welding metal 3/8” thick.
If you are planning on constructing multiple power cubes it saves times to first create a jig to use in assembling the power cube frame.
The frame is constructed out of twelve angled iron pieces tacked and welded together. Position two ¼” x 2” x 2” x 29” pieces angle iron on top of two 27” angle pieces as shown below. Check that all joints are square, then tack and weld joints. With one welded rectangle on the bottom, position two 24” pieces outside corner joints as shown below. Check that the angles are square, then tack and weld. Repeat the prior procedure and this one for another half of the frame assembly. Position the two half cubes together, then tack and weld. Inspect all corners to verify secure welds.
Now you can begin to assemble the elements of the power cube inside the frame. Screw the 1/4" hose barb into the 1/4 NPT flange welded into the gas tank. Perform a “soap bubble” test on the tank to check for holes before attaching to the frame.Tack and weld the gas tank mount to the frame. Position it so the gas tank is 1" from the nearest vertical angle iron support. Tack and weld the gas tank to the gas tank mount.