Manual and Hydraulic Presses
One of many hobbies!
Pin Press (2011)
This press is used to push out the square pins from header strips.  The pushers are 0.020 dia piano wire pushed into a brass holder. 
Bracket Former (2010)
3/4' wide x 1/8" thick aluminum strip pressed into brackets used to hold AC power cords into a fixture plate.  Metal is heated with a torch until the flame glows orange.
Transformer Winding Slicer (2008)

I have buckets of transformers to recycle for the copper but they are really hard to pull apart, and don't even think about using a band saw to cut the windings or a plasma torch to cut the core!  Cutting the wires would seem the natural way to strip these but that's a lot of work too with a chisel and hammer.  Version 0 (0a-0c) is the first POC test of what will become a hydraulic or air operated slicer; the test power source was a sledge hammer.  Cutting both sides of the winding was a waste of energy so version 1 (1a-1b, still using a sledge hammer) only slices the top off which while only requiring half the force also yields only 2 pieces of wire per turn vs the 4 of version 0. Version 2 will have bolts to hold down the blade and a hydraulic jack to force the core through.





12 Ton wide throat stamping press (2004)


Tool to form CapPlate
6 Ton motor driven press (2004)

The shaded pole motor drives a 60RPM output gearhead reducer connected to a four position cam.  Selecting one of the four cam settings, an elevator output speed of 10.0 to 17.5 thousandths of an inch per stroke can be achieved.  Pull down rods at the side are for jack return springs, as shown the jack must be reset manually.   Built to squeeze lithium-ion cell phone batteries until they fail.

6 Ton manual press (2004)
6 Ton manual press (1990)

One of my first presses, I had to use wood and bolts because I had not yet learned to weld.  I could braze but this method of metal joining never stood up well to the stress.

1000 pound manual Can press (2005)

Engineer + Caffeine = Projects,  Supplied by coffee, soda or other.  My delivery choice has always been soda hence the six foot high pile of cans next to my house because, of course, a can isn't just a can, it's a project waiting to happen.  I've long wanted to build an automatic crusher with a magazine feed but my wifes tolerance for the pile and then the ensuing avalanche of cans (Once the bags that held them disintegrated after 3 years in the sun!) came to an end at the end of 2004...  The hydraulic crush thickness target was to be 0.100 inch (45:1) but I settled for <=0.500 inch (9:1) for a manual crusher.  The average was actually about 0.350 inch or 12:1.  The toughest part of the can to flatten is the pressure resisting curve on the bottom.  1 weekend and 3 years of saving cans = 2700 units!  My arms can do 25 units per minute / a milk crate holds 64 cans / a 33Gal glad bag holds 225 uncrushed or 1350 crushed cans (before the plastic fails). 




Any questions or comments?
 This page last updated on September 03, 2011