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.

Slight delays in the Super Kiln

The project is progressing nicely however a missing part in an order forced a delayed first firing. This also allowed me some much needed rest. Below are some progress photos and descriptions, for a complete list of photos the archive is up to date.

The kiln from the front where the doors will go. This image displays the inside and coils nicely, the total electrical load is 60 amps 208v three phase.

Connections between the coils and electrical supply are made by small copper lugs. This setup allows for easy and flexible attachment as well as eventual replacement. A total of 12 coils make up the heat source of the kiln, each one is individually run back to the load distribution center. This method while more difficult also allows for isolation of any coil. I am slightly concerned about the heating rates of a vertical kiln and the potential for more control within the kiln is welcome.

The load distribution is facilitated by two 30 amp mercury relays. I attached lugs to two sheets of polycarbonate for use as load distribution. This setup should keep wiring neat and easy to change later as needed.

All the pieces to the chain drive are cut and almost ready for assembly, The assembly consists of a gear reduced 115v electric motor, speed controller, two gear sprockets (1:1 ratio for now), chain and a slip bracket for tension. Eventually changes to speed and direction may be desired. Changing the gearing on the chain drive and adding a revers rotation switch should be simple.

Monday should be our first real test fire and Tuesday dropping our first glass. While building this Super Kiln I have labored to keep things as flexible as possible. This allows for alterations, additions and need be fixes. The necking device is next on the build list and it will be fancy.

Glass holder for the super kiln ready for delivery

Worked late and got up early but the first real firing of the kiln is close at hand. With any luck sunday. Now onto the gear drive mechanism.
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The Glass Chuck "holder" for the Super Klin

Jesse is helping with the construction of the kiln element that holds the glass at the top of the kiln. All inside kiln elements are stainless steel "ss" so they can easily handle the 1700 degree F temperatures.
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My steel shelf painted red

This is a steel shelving design that I came up with and due to popular demand this one has been powder coated red with gold flake. This design focuses on an organic theme using graceful lines and open shelving. The steel frame is extremely strong and for increased stability the shelf could be attached to the wall.
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Brads Stairs

These are the images of the stair case i built for Brad. The stairs are not completed at this time however brad has assured me that he will complete the necessary construction and fabricate the finish treads in a timely fashion. I used Google Sketchup to build a 3D model of the stairs prior to construction not only to convey the concept but also to reference clearances and dimensions. It worked great, With Brads help we measured, cut and bent the 8in by 3/16in stringer elements with each stringer taking two plates. The tread bracket fits between the two plates and is welded in place level to provide a support for the tread. In this design the treads provide a significant stiffening element. The steel itself is stiff on edge providing plenty of support but horizontally the stringers can flex. The treads limit this flex by transferring the force on the circumference of the stringers and by creating a boxing effect between the stringers and the treads.

The original rendering is available on the Google 3D Warehouse and the photo archive will be updated soon Enjoy!