Super Kiln adjustments

The Super Kiln is getting some special attention after running into some issues. The concepts of this project are new so some adaptation is required. After a great first run we pushed the envelope a little to far and ended up breaking a couple blanks of glass. These set backs pointed out several key issues and hinted to others that may arise in the future. The design of the kiln is to allow for these changes with a minimal fuss.

Randall you cant hear him but he is calmly requesting his other glove while I take a couple pictures. At 1200 degrees and up the glass came loose from the chuck and out the kiln, fortunately no one was hurt and no damage was taken. Excessive heat on the one inch thick blank caused a increase in decent speed and took us both by surprise.
Heat distribution is a crucial element with all the heat rising to the top, going to far or to fast ends in disastrous results. The controller that we have is capable of running three zones although some fancy programming may be required. Unfortunately the controller is only able to accept one thermocouple so heat sensing only comes from one point. Additional thermocouples may be used to tell temperature in other areas of the kiln but wont provide the info to the controller only to us for calibration. Other methods are also being explored but a quick re wiring of the kiln and an additional mercury contactor give us three zones, The top two sets of heating coils are the same size in electrical load and the bottom set is the combined load. The new enclosures are far simpler and mounted closer to the coil attachment. They will double as an attachment point for a arch shield to protect users and wiring.

Wobbling on a high note has been all but eliminated by two things, one a reduced speed motor going from 64 RPM to 9 RPM and still using only half the speed and two the reinforcing bearings at the top of the kiln. The bearings that were added worked at high speed but torque and poor speed control were still issues at high speed.

The info that we collected led us to many improvements it is nice that the first one worked out but learning from failure is perhaps more productive than getting a bunch of four foot ......tube socks.

First glass dropped in the Super Kiln

The first test piece of glass has been dropped in the kiln. The results are impressive with all things working as they should. The temperature, fall control, air pressure and chucking mechanism worked perfectly with only minor adjustments required for the next test tomorrow!

With the thermocouple reading around twelve hundred degrees Fahrenheit the temperature is just about right at the top of the kiln to start the glass moving. Temperature control will need to be further studied and regulated but works just fine for now. In the image below you can just make out the glass bubble coming down I didn't want to get to close its hot in there.

The chucking mechanism worked well holding the glass securely and allowing easy removal. The first one does not look to appealing but it was only a test and the fact that it even survived after the extremes we put to it is a testament in of itself. The next test scheduled for tomorrow will turn out better.

The vessel itself is about eighteen inches in diameter and almost four feet tall. Uneven heating do to the doors and lack of rotation caused some undesirable affects but should be easily fixed, Definitely a successful first run!

The wobble in the rotating chuck proved to not be tolerable even with the additional down force of the glass, this led me to develop and build a simple solution to hold us until the Iris s built. The kilns heating elements only line two thirds of the inside circumference of the kiln creating a hot and cold side, even a slow rotation will prevent problems but slow is a relative term and at even five RPM a big piece of molten glass is scary. The new clamping bearing system works around the existing setup and should hold the chuck drive pipe securely, allowing consistent rotation and maybe some playing with the glass!

I also built a set of big tongs so Randall could try to squeeze the glass since when we tried before we found even molten glass is really hard. The iris is the real solution to this shaping stuff but is also more complicated than everything combined to this point so it may take a while. While I build it maybe this will keep Randall entertained. Holes drilled in the working end of the tongs provides attachment points for different substances to work the glass.

This is an ongoing project melding design and development, ultimately this prototype will provide the knowledge necessary for a big kiln. Yea I said BIG and fancy, we are talking about an entire setup and process to support making massive elaborate vessels. Fun stuff.

Wankel Bell in full swing

The Wankel Bell is in full swing. So far I have built the rough frame for the base, cut and hung the bells, figured out some details(I wont bore you) and made some progress tracking down materials. The Base is the most complicated single piece since all the "cool stuff" is mounted within it. With the mechanics down low they are much more visible to young people. The objective of the piece is to instill wonder and intrigue specifically geared toward children and the child within. Showing a different way to accomplish goals and demonstrating mechanical actions, while being fun and stimulating multiple senses.


Cutting the tanks took a while, a couple every day or so. The tanks or "bells" had to be rotated once in the saw in order to sever the base. Made from a SINGLE piece of chromoly the tanks are extremely heavy and unforgiving.

The Frame itself was a little tricky. Layout took a while and getting the two big rings rolled and welded broke my bender and took me down a notch for several days. They came out a little wavy but I decided that was organic and should actually cost more. The three uprights took a little math and fancy measuring especially since the rings are organic, but ended up absolutely perfect. Building Wankel Bells the way the Egyptians did.

Hanging the bells was a last minute change. Due to the amount of material that would have been used going from the bottom of the bell to the top and the need to reinforce the setup I decided to hang the bells. There are pros and cons either way. The exposed Stainless Steel cable is a concern with tampering and pinch points have shown up which will have to be filled.

To facilitate removal and reinsertion of the bell components as well as replace ability of the cable as required I settled on a pinch method. The cable is run through the outer ring to this contraption. The eye bolt permits fine adjustment of height while the slip coupling attaches at any point without damaging the cable. The slip coupling is a half inch round tube that just fits the cable doubled back. As the cable pulls it drives the wedge between expanding the cables against the sides. In order to protect the wire all steel surfaces were filed and the wedge is made of brass which is much softer than stainless.

First thing tomorrow an hour or so of cleaning. The Tasmanian Devil came to mind working today as I pushed to get all the bells hung. This was a crucial step because all measurements must be taken off the tanks for the guts to fit nicely. There is a lot to fit in this little space while needing to keep everything visible and clean.

Wind power is not consistent anywhere but here we have some extremes. The Wankel Bell should perform on low wind days while surviving strong winds. With the bells hung my focus turns to rotary dampeners, adapters and drive systems. I have a lead on a differential which is the next vital item and have been thinking in roller skate wheels!?!!

Shop Carts

While working in my shop I am always thinking about how the tools I use and the things I do might be done differently. Typically these demands change and the solutions to them must also be refined. Keeping my tools at my finger tips, easy to use and put away are vital.

The Fabrication Caddy was originally the TIG caddy but after using it for some time it became evident that it was a much more use full and accessible for all kinds of things. Gloves, TIG consumables, sorted scrap, clamps, grinders, welding mask, face shields, respirators, earmuffs, and layout materials.

The Fabrication Crash Cart fits in with my different cart designs. It is my experience that carts work well to deliver tools and flat storage space to the shop in a way that can be adjusted to accommodate any project. Currently I use three rolling carts one is 1/2 inch steel plate 3'*6' and is used primarily for welding and grinding it also works well for mounting other tools and things. Herman and Cade are helping me bend pipe for the Wankel Bell with the bender mounted to the metal cart.

The other cart needs to be re built but it currently is used for layout and tools. Eventually it would be nice to have my tools and materials rolling around and stored in an efficient manner. Its getting close.

Kettle Corn Machine

A few weeks ago Glasser Steel brought a project to me that they needed help with. One customer of their sells kettle corn at events. The method that they have used to date is no longer working for them so the opted to automate the mixing process. After deciding on the design the fabrication went smoothly.

In this image you can see the welding tanks for use in the Wankel Bell.

In this project I also used a gear reduced electric motor and possibly the same model as in the Super Kiln. I attached an electrical box on the opposite side of the bracket for placing the switch and speed controller.

I kept all the "stuff" on the lid so that setup and transport would be easy and the lid could be used on other kettles. The entire lid is made of stainless steel.

The mixing rods are suspended off the bottom of the drum and fit its contour nicely.

A flexible coupling between the motor and the mixing rods ensures that a minimum load is transferred to the bearings.
This project was quick, fun and its always nice to return the favors.

Super Kiln A+ on test

The first test firing went extremely well. Assembling the Super Kiln took a long long day but the result was well worth the extra effort. All the components bolted right on which is always nice and more importantly worked to the point they exceeded expectations. Insulation of the heat was great with the Super Kiln coming up to temperature quickly and retaining the temperature well. Randall did an excellent job assembling the special insulation, taking care at every joint that it fit perfectly and be joined by a gasket. Even the doors have special built in gaskets that can be replaced as needed.

This image displays the inside of the Super Kiln through one of the bung holes. At this point the Super Kiln is about 1600 degrees Fahrenheit with a signed copy of my rendered design which is available for viewing on the google 3D warehouse.

The chain drive assembly fit well and functioned as it should with the exception that when it was at high speed and unbalanced it began to wobble. This is potentially a problem, Typically the rotational speed should be low however stability of very hot and heavy things is important and a new design Incorporated into the Iris element will solve the problem.

The electrical took a long time to put together even with the special boxes. It does look clean though.

Randall had a spare kiln that is not currently being used which furnished us with a thermocouple and a computer interface. In order to have immediate and total control of the kiln temperature I temporarily spliced in the controller to the Super Kiln. More testing on kiln demands are needed before the control box can be effectively built.

The next element is the Iris. This piece will open and close permitting the operator to shape the glass even with the doors closed. First though I have instructed Randall to play with his new toy, this is important to the development of the next few elements and new ideas that may be helpful. I am joining him to drop our first glass tomorrow.

Chain drive assembly is ready for the Super Kiln

With all the parts in hand I spent most of the day putting the finishing touches on the chain drive assembly and preparing for an early start tomorrow. I will spend the morning loading up tools and supplies as well as meeting with Colorado Welding Supply off 8Th in regards to the welding tanks for the Wankel Bell.

The chain drive consists of a gear reduced motor and sliding bracket, Two sprockets, tapered bearing and about 3 ft of chain.

The red bolts are a simple and flexible centering technique that will accommodate different bearings and allow for fast easy removal and re installation which may be the case if the glass vessels are to be removed and loaded through the top.

A single gang switch box mounted to the back of the bracket provides a connection point for the motor wiring. Left over MC cable sheath helps protect the motors wires on there way to the box.

The gears are attached to the shafts using tapered split ring bushings which pinch the shaft when tightened. Pipe was chosen for the main shaft not only for stability but also to provide vacuum and pressure to the vessel being created.

The firing is so close I can taste it. Steady as she goes tomorrow we will put her together and hopefully drop some glass.