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> The HERMS Project, A pictoral documentation
stout_fan
post May 3 2005, 11:15 PM
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OK, I've threatened to do this and so far nobody has stopped me. (IMG:style_emoticons/brewboard/tongue.gif)
First we start cutting up metal. That's 1 1/4" x 1/8" thick angle iron from the HD.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/001_burner_cut_metal.jpg)

The burner donors were King Kookers I picked up on closeout at the BassPro shop. Here's what they look like after they meet the angle grinder w/ 4" cutoff wheel.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/002_cut_up_kooker.jpg)

The basic welding is done here:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/003_burner_base.jpg)

The smaller one for the HLT is 14 1/4" across. The larger one is for the boil kettle and is 14 3/4" across. So they nest thusly:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/004_burner_nesting.jpg)

So now we have to mount the wind shield. I thought about this for a while, and the idea of a 45 to capture the top seemed like the best idea. Here it is getting sized up:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/005_burner_layout.jpg)

And here is a rough fit-up. I then will cut it to length:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/006_burner_support1.jpg)

Ah..... fixturing. That's where all the time goes. Magnets hold the 45 in position.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/007_burner_support2.jpg)

Then it's a simple job of adding the second 45 sizing and cutting and welding (yea right) (IMG:style_emoticons/brewboard/crazy.gif) :
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/008_burner_done_welding.jpg)

That's it for this installment. Now to decide if I continue onto the next stand tomorrow night or go to the movies to see HHGTTG. So do I weld or relax?
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stout_fan
post May 4 2005, 06:42 AM
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Ya know yer lame when the only one posting to a thread is the guy who started it (IMG:style_emoticons/brewboard/tongue.gif)
So comments anybody?
.
.
.
On the stand, not my lameness...
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carluchi
post May 4 2005, 06:46 AM
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Are you working off of a plan or are you 'winging' it?
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Ironkite
post May 4 2005, 06:54 AM
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QUOTE(carluchi @ May 4 2005, 07:47 AM)
Are you working off of a plan or are you 'winging' it?
*


He had already built one out of wood. But that burned down, fell over and sank into the swamp.

I'm sure he's got plans. He has plans for everything. He don't walk down the hallway without a plan. He even plans on which way the rotation of his coffee spoon will be when mixing his coffee.
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Given2fly
post May 4 2005, 07:02 AM
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(IMG:style_emoticons/brewboard/rolf.gif) (IMG:style_emoticons/brewboard/rolf.gif)

Nice design Stout, would like to see the final plans!

G2Fly
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Bosco
post May 4 2005, 07:04 AM
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This thread is giving me the itch. More please. (IMG:style_emoticons/brewboard/smile.gif)
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stout_fan
post May 4 2005, 07:05 AM
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To quote Harrison Ford in Indiana Jones-
"I'm making this up as I go"
No plans, just been giving this one a lot of thought.
Just wish I've gotten started sooner.
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ChefLamont
post May 4 2005, 07:08 AM
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Movies? That's what Blockbuster is for. I'd be welding.
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stout_fan
post May 4 2005, 07:10 AM
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Bosco- thanks, yes, I intend to document the entire construction from beginning, to the raising of the first glass. Presuming that in the process, I don't bore everybody to tears. Or make them gnaw their foot off like when listening to Vogon poetry (Obscure HHGTTG reference).
Thanks ChefLamont- one vote for welding.
Hmmm... maybe we should start a poll:
1. weld
2. go see movie
3. go away.
4. No pants option. But that would hurt when welding (IMG:style_emoticons/brewboard/omg.gif)

This post has been edited by stout_fan: May 4 2005, 07:13 AM
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Guest_Lee_*
post May 4 2005, 07:22 AM
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Looks nice so far. After seeing a couple of them lately it is giving me the fever again.
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TexanBrewer
post May 4 2005, 07:35 AM
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StoutFan, sweet!

Please keep it coming. Please let us know all the details...

Stick or MIG? I see you've plenty of magnetic clamps and that sure does look like quite a welding table.

How do you plan on attaching the burners?
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stout_fan
post May 4 2005, 08:41 AM
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QUOTE(TexanBrewer @ May 4 2005, 07:36 AM)
StoutFan, sweet!

Please keep it coming.  Please let us know all the details...

Stick or MIG?  I see you've plenty of magnetic clamps and that sure does look like quite a welding table.

How do you plan on attaching the burners?
*
Thanks TB, MIG a Millermatic 200. Picked the table up at a scrapyard when I worked in Gathersburg. The burners attach by one bolt through the hole in the wind screen. I'll make sure I get a shot of that to answer any questions. Thanx for asking.

BLAM a question that I wanted to ask just popped into my head.

For those with similar burners, the newer versions have a aluminum plate under them as a heat shield. Can anybody post a picture of this detail and mounting of it so I can duplicate it. I don't remember seeing it on any of the dozen or so at BassPro.
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Walt
post May 4 2005, 10:33 AM
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Ya Buddy!
You weld that sucker!!
MIG's rule (IMG:style_emoticons/brewboard/smile.gif) I've gotta Campbell Hausfeld.
Looking great!

Keep the pics coming!
Walt
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Ryan P
post May 4 2005, 11:57 AM
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Looks good so far. Can't wait to see more! I've been thinking about taking the next step and making some sort of brewing cart. I've got an Extra Sanke laying around, a good source for materials and welding......hmmmm......
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stout_fan
post May 4 2005, 10:16 PM
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I came,
I saw,
I welded.
I gave up on going to the movies and decided (by popular opinion) to stay home and do something constructive! (IMG:style_emoticons/brewboard/tongue.gif)

So looking back on my last shots they were all static. "BORING" I hear you say. "Let's see something burning, blowing up or exploding!"

OK so here are some "action" shots. Hold onto your mouse! (IMG:style_emoticons/brewboard/hehe.gif)
Here's the second burner construction with the pictures taken with the adreneline junkie in mind. First we're going to cut some of that 3/4" angle iron on a 45°. Hey, I told you this was exciting---
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/009_burner_cutting.jpg)

Hey, I bet that has you on the edge of your seat. So we have to bevel off those sharp edges so we don't cut outselves while brewing:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/010_burner_beveling.jpg)

Hey, some sparks there- (IMG:style_emoticons/brewboard/omg.gif) I told you this was going to get exciting.
Well, after we grind them corners down we've got to clean them up for welding. Here's that end getting cleanned up on the other side of the grinder, where I have a 6" SS brush wheel attached-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/011_burner_cleaning.jpg)

So here's a before and after the SS brush treatment. It really cleans up that scale on the angle iron-
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/012_burner_cleaned.jpg)

And we have to also clean up the frame where it goes. Here I am with a wire brush in an electric drill cleaning up the frame:
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/013_burner_cleaning2.jpg)

I was worried about frying the CCD in the camera, but what the heck. Nothing is too good for my friends on this board.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/014_burner_welding.jpg)

I tried to get the little glowing blob on the end of the MIG wire. It looks OK in high resolution.
(IMG:http://img.photobucket.com/albums/v225/stout_fan/HERMS/015_burner_welding2.jpg)

Well....
That ought to do for a posting. More to follow.
So what do y'all think of the shots so far?
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