I would like to show you my next project: a Wilford power shovel B.
It's not completely new, because Gordon Birrell and Marty have shown us their excellent models here in the forum before. But this will be the first model in 1:35th and brass construction.
Ray Dunakin took good photos of a prototype at the Central Nevada Museum in Tonopah, which he thankfully let me use as a basis for the build.
(Picture: Ray Dunakin)
Also very helpful was additional information and pictures from Ted Valpey, President of the Northeast Rockbusters. He has perfectly restored one of these machines and shows it in operation from time to time. For example to see in the videos
https://www.youtube.com/watch?v=vZ6Z-OfoOnA (https://www.youtube.com/watch?v=vZ6Z-OfoOnA)
or
https://www.youtube.com/watch?v=Y1EDmw_sdFo (https://www.youtube.com/watch?v=Y1EDmw_sdFo)
starting at 12:00. There you can see that the operation of such a machine is connected with a lot of physical effort.
(Picture: Ted Valpey)
The Prototype
William Ford, the younger brother of automaker Henry Ford, entered the construction equipment business in 1925 with the formation of the Wilford Shovel Co. in Detroit. The most obvious component of the tracked 1/4-yard Wilford shovel was a Fordson skid unit, used as drive. In addition, the shovel used several parts from Ford cars and trucks: the crowd device on the bucket was a Ford truck worm gear. The machine could be purchased at Ford dealerships.
In 1927, that company changed its name to Universal Power Shovel Company, with William Ford as its president. In 1928, shortly before the Great Depression, Universal Power Shovel Company was acquired by Unit Corporation of America.
The power shovel was modular in design and could be built in different versions.
For example, as a dragline excavator, ...
... as a clam shell excavator ...
... or as a crane.
A sign on the shovel at the Central Nevada Museum in Tonopah shows that the machine was built in 1927. It is the source for my model.
(Picture: Ray Dunakin)
Lot of good background information there.This will be a fun project to watch.
Do you know which version you will model?
Thanks Bill. I will model the version as in the first picture. I will use the power shovel together with the bucket chain excavator in my clay pit. It will remove the dirt above the clay layer.
Bernhard
That first picture Looks like LAWN ART to me ;D
It seems we have two or three Fordson based projects underway now (Chuck and Bernhard, of course, but I can't remember who else) and the builders are world class modelers. I'm really looking forward to seeing the finished models and enjoying the progress reports. -- Russ
Take your breath away - dribbling all ready
Barney
Awesome project! Looking forward to watching this.
Also, thanks for the video links. It's cool to see one restored and in operation.
That's going to be a great project.
Les
Thank you all for your interest!
Before we start building, here is a lesson in mechanics.
How it works
I tried to understand how this machine works exactly. After all, all functions of the excavator and the track units are driven from the Fordson tractor, which runs continuously and at a constant speed. The drive is distributed to the various functions via a complicated system of chains, reversing gears, clutches and brakes.
(Picture: Ray Dunakin)
Track units
The tracks of the shovel are driven by the rear axles of the Fordson tractor.
Ted Valpey describes the function as follows:
"In the foreground is the 4 levers to propel the machine. 2 levers are for the left and right drive chain brakes and the other two are for left and right axle engagement. To turn the machine to the left you engage the right axle, disengage the left axle, and apply the left brake as needed while driving (forward or reverse). The seat turns 180 degrees to face rearward to give access to the 4 levers as well as the clutch and gearshift lever while propelling the machine. The two brake levers can be locked on while digging."
(Picture: Ted Valpey)
This is how it looks in the model:
All other functions are driven from the PTO of the Fordson tractor.
Main drive
A chain leads from the PTO to a bevel gear located in the center under the turntable. From there, motion continues upward and is distributed.
This is how it looks in the model:
Bucket drive
The bucket is lifted by a winch. Lowering is done by gravity. The winch drum has a clutch and a band brake.
This is how it looks in the model:
Bucket arm drive
The bucket arm is driven by a rope and a rope drum that works like a capstan. The rope is attached to the bucket arm at the top and bottom. By reversing the direction of rotation of the rope drum, the bucket arm retracts or extends.
(Picture: Ray Dunakin)
This is how it looks in the model:
Rotary drive
The turntable is rotated by a reversing gear and then by a sprocket to a large internal geard ring, mounted on the frame of the shovel (see picture 011).
This is how it looks in the model:
All in all, a really impressive mechanism! Rebuilding this in 1:35 scale will be similar to building a Swiss wristwatch. The turntable is 35 mm in diameter, just about the size of one.
Bernhard
Wonderful work so far! Excellent CAD. Very interesting how they used both the rear axles and the power take off.
I couldn't possibly have figured out all that mechanical stuff ... unless my mom helped me. The CAD drawings are beautiful and must have taken weeks to create. An outstanding start. -- Russ
Incredibly complex piece of kit Bernhard, but you are well on the way to producing an outstanding model. As always, your CAD work is excellent... well done.
Its giving me a headache already ! incredible workmanship in producing the impressions and drawings - it looks like its going to be an impressive little critter
Barney
I'm glad you like what you've seen so far.
But now enough of the theory. Let's get down to business!
The model
For the construction some main dimensions are used, which Gordon Birrell published in his thread. Further reference dimensions are taken from an original brochure, as well as a good picture, from which missing dimensions can be approximately measured out.
From this I spent many hours creating the 3D model of the shovel.
...
The first assembly to be created is the frame of the shovel.
I did not take any pictures of the production of the frame itself. But it is simply soldered together from various U-channels, H-Beams and some gussets.
As you can see in Ray's pictures, the individual parts of the frame are held together by distinctive rivets.
(Image: Ray Dunakin)
These must of course be reproduced in the model. To do this, a large number of holes with a diameter of 0.8 mm must be drilled in the frame.
To display the rivets, I used the method Frithjof showed here in the forum some time ago.
A brass wire with 0.8 mm diameter is rounded on one side with a concave cutter.
The wire is glued into the hole with Loctite, cut off and the protruding remainder is also rounded.
The diagonal frame is made similarly. For soldering and subsequent drilling, I milled a simple jig on the rotary table.
...
The upper pivot bearing and supports are riveted to the diagonal frame.
Then the two parts are assembled.
The internal geared ring is a 3D printed part. It has a module of 0.3 mm and 110 teeth.
For this project, I had all 3D printed parts made by a supplier in Germany that Volker recommended to me. All parts, most of them very thin walled or extremely small, came in top quality with barely visible layer buildup. The sprocket from the rotary drive even runs correctly in the geared ring.
The frame has been completed with some more parts and is ready for now.
Bernhard
Hello Bernhard,
I like that, both your CAD and your frame.
Why are you using Loctite and not soldering the wires?
Overall, a great project that I am happy to continue to pursue!
Your work is very well done for a neat result.
An excellent start. Like Frithjof, I also wondered why you used Loctite. (It seems like a good idea.) -- Russ
Good morning Bernard.
Happy New Year to you and your family.
Yes just echoing the rest of the comments. a very complex project a very well done miniture.I particularly like the rivets a small item that is often not done well.
All the best Kim
You are building another interesting, complicated machine.
Thanks guys for your appreciation and for your interest.
There are several ways to assemble structures with many parts. One is brazing and soldering. But I have not yet dared to braze, because I fear that the small parts warp or even burn. I therefore always solder the basic structure, so that it has enough stability. The remaining small parts are then glued with 2-component glue (or Loctite).
Bernhard
Hallo Bernhard,
For such cases, a resistance solder is very helpful.
Otherwise, I secure neighboring places with toothpaste. After soldering, everything is rinsed with water and soap.
Fortunately, I also have the holy grail of soldering technology, a resistor soldering unit. But the toothpaste is a good hint, I have never tried that. Thank you.
Bernhard
As always, I am in awe of this stunning level of precision work!
Just amazing - so fine and precise - and a nice unusual model to build
Barney
Bernhard,
I'm pretty speechless. What kind of glue do you use to fix the 3D prints to the brass frame?
Cheers,
Volker
Volker, I normally use Araldite Rapid. It sticks very well, but in an emergency the parts can be removed without damage with a little care.
For very small parts, such as fake screw heads, I use CA instant glue.
Bernhard
Thank you for your interest.
The next subassembly are the track units.
This is what the original looks like, ...
(Image: Ray Dunakin)
... and this is the design for the model.
The basic bodies of the two crawler tracks are made of solid material.
The bearings for the idlers are soldered together in a simple jig, then cut to the correct length.
A few more parts will complete the crawler tracks.
Now 32 idlers need to be turned ...
...
... and drilled.
The drive rollers are 3D printed parts.
The tension rollers are also turned.
And these are the bearings for the drive and tension rollers.
The track links are also 3D printed parts.
With this, the first crawler track can be dry fitted.
Now a few more small parts have to be manufactured:
The brake pads for the band brakes.
The lever for operating the band brake is so small that I put it under the microscope to photograph it.
2 levers for operating the differential lock in the rear axle of the Fordson tractor.
All parts put together for a test.
The drive chains are etched parts, glued together from 4 layers each 0.3 mm thick.
This subassembly is now complete. The parts will be assembled after painting.
Bernhard
Hello Bernhard, very good model architecture thank you for showing.
impressive!
Great work, very impressive! And those CAD drawings too -- you could just about build the real thing from those.
Astounding. -- Russ
Your work is really accurate. I'm impressed !
Amazing work as always Bernhard... always enjoy seeing your in-progress shots.
Quote from: Bernhard on January 23, 2022, 08:42:03 AM
All parts put together for a test.
Crazy cool microengineering!
Unbelievable work!!
Jerry
Superb engineering - and in a small scale
Barney
And Bernard.
I will leave you at the top of my comment blitz.
Truly fine mechanical jewelry love it.
all the best KIM.
Thank you for stopping by again.
I don't want to bore you too much with the production of the countless individual parts. So I will show you only some of the most interesting ones.
For example the etched parts from 0,3 mm brass sheet ...
... and from 0.2 mm brass sheet. Difficult to photograph these shiny sheets.
As already mentioned, the 3D printed parts were printed by a service provider recommended to me by Volker. The quality of the printed parts is excellent, that of the first photo unfortunately less.
For the turning plate, I had to turn the outer ring and the hub.
Subsequently, the parts were soldered together.
In the plate I provided several small position holes, for the exact placement of the A-frame and the various bearing blocks.
Here are two nice turned parts: a small pulley and the capstan drum for driving the bucket arm. The turning tool in the second picture has a width of 0.5 mm and a radius at the front.
These are the shift forks for operating the clutches on the reversing gears.
The pre-assembly of the A-frame, i.e. the 3D printed parts are glued to the two U-channels.
The boom is ready, only the rivets are missing.
The bucket arm.
The bucket, soldered together from etched sheets, and his teeth.
Two different mounting brackets for attaching the bucket to the bucket arm.
I actually wanted to 3D print the cover for the pulley as well. However, the wall thicknesses were too small for functional parts. So I remade it from brass.
This was the first time the bucket could be temporarily mounted on the bucket arm.
The Fordson tractor: as always, I used the resin model from plusmodel, despite its deficiency.
I built a jig for machining the mounting surfaces of the stub axles and the PTO.
A second jig is used to bond the stub axles in exact alignment with the bottom of the tractor.
Now all parts are ready for priming and subsequent painting.
Bernhard
Outstanding.
Bernhard, I look at your new postings and try to find words to say how much your craftsmanship impresses me.
Amazing looking and even has functional parts. What can I say?!!
Bernhard,
It's always worth seeing how cleanly you conjure up these rather small parts :-)
It is not only the work that is outstanding; it is also how quick you progress...
Just perfect miniature engineering - well thought out and absolute prototype - we can only hope that one of the kit companies will make a decent Fordson tractor in plastic - perhaps one day
Barney
Where else can we find modeling to this degree of perfection? Exquisite. -- Russ
Magnificent! Such fine, precision work!
Exquisite indeed... the force is strong with this one!
Thank you for your interest and comments.
Now we continue with the assembly of the power shovel.
The first step is to attach the control levers for the track units.
Then the belt brakes are attached, and the bottom section of the Fordson tractor is inserted into the frame for the first time.
The crawler tracks are pre-assembled, ...
... and the frame put on it for a test.
A few operating elements for the tractor still need to be made ...
... and then mounted.
On the turntable, first the bearing blocks ...
... and then the entire drive mechanism for the shovel are built.
Then the turntable can be mounted on the frame. It can be rotated and the pinion correctly engages the sprocket.
The winches for lifting the bucket and boom adjustment are installed in the mast.
The main boom is completed.
Bucket and pulley are mounted on the bucket arm. The chains are used to unlock the flap at the bottom of the bucket.
Then the bucket arm is mounted on the boom.
Now the mast can be built on the turning plate, ...
... and the track units receive their tracks.
Finally, the various ropes must be fed in.
And thus the work is done.
Here once again the comparison between the prototype , ...
(Image: Ray Dunakin)
... the design ...
... and the finished model.
Some more pics
...
...
...
Next I will build a small diorama to showcase the bucket chain excavator and the Wilford power shovel in action.
Bernhard
Congratulations great model Bernhard.
Outstanding. -- Russ
Outstanding with a big Plus and an unusual subject for 1/35th
Barney
Magnificent!! Really great work -- it looks like someone could sit down, fire up the engine, and start shoveling! I like the paint and weathering too.
Stunning work as usual Bernhard!
Beautiful job Bernhard! Spectacular scratchbuilding!
Bernhard-that is just an excellent piece of machinery!!
Jerry
That is a terrific model, Bernhard!
Great Modeling ;D
Very nice job and good starting weathering !
Bernhard
You already know this kind of work belongs in my personal world to the category Science Fiction.
I havew seen every page and there is only one thing i can say:
(https://live.staticflickr.com/1646/25409164483_cc7318f041_c.jpg) (https://flic.kr/p/EHjBmP)DSC02509 (https://flic.kr/p/EHjBmP) by d.caso (https://www.flickr.com/photos/daniel_1_32_scale/), on Flickr
Daniel