19 / 02 / 2017 | Videos

Make it extreme's plasma cutter notcher


A very essential tool for every manufacturer who uses tubes to his constructions is the notchers. The notchers are very useful as they are used to remove a piece of the tube in order to fit precisely on another tube without leaving any gap between them and so that their welding to be accurate. Generally, notchers are essential tools and particularly, in constructions like a buggy, exhaust, fields of a mini football and in anything that requires the use of tubes and the procedure of welding. 

There are various kinds of notcher at the market and each and every one has its own advantages and disadvantages. In particular, our construction uses the plasma cutter as a cutting tool. To start with, we first made a frame made of a square tube of 30 x 30 x 2mm on which we placed a tube with slots to pass a bearing through the two edges. Then, through the bearing we passed a perforated shaft, which at its back side a pulley was placed and it was connected on the motor with a strap.

Initially, we used a motor taken by car wipers but then we preferred an AC motor having the potential of moving both on the right and on the left. The motor was connected with a potentiometer to regulate the speed of its rotation and with a switch that chooses the rotational direction as well as the activation of the motor. Therefore, by activating the motor the perforated shaft rotates on the direction that we want and at the speed that we wish. After we had achieved our goal and this function, we put an aluminum flange lined with linear bearing at the front side of the perforated shaft. The linear bearing is used for ensuring a forward and backward move in our machine. 

Moreover, using these bearings, we managed to make a basis for the plasma cutter. At the back side of the basis, there is a bearing that follows a guiding ring to achieve a particular move according to the guiding ring. In specific, our system is known as a ‘pantograph’. At the front side of our machine, it was made a basis that a clamp was placed for the tubes. In this way, the plasma cutter is spinning around the tube following the orders of the pantograph and removing the material that should be removed. 

It should be noted that without the pantograph, our machine cuts in a straight line and if it is needed to cut in an angle, the inclination for cutting is chosen according to the direction of clamp’s rotation. 

In conclusion, our construction’s advantages are multiple. For example, it is mobile and light, it can cut tubes of a large diameter compared to other kinds of machines that are not capable of that. Also, it can cut straight angles and various shapes according to the guiding ring of the pantograph. More importantly, its major advantage is its cost as it is much less comparing to other machines like CNC that are also capable for the same thing.  Additionally, its potentials are not just restricted to these as it is also capable to cut round flanges and many other things using different clamps and different basis for the plasma cutter. Closing, it is hard to describe this construction in words so there are precise designs at the make it extreme patreon for any of you who is interested to make it by himself.




























Get the Plan: http://bit.ly/MIEplans


 
...
Read More
05 / 02 / 2017 | Videos

Screw log splitter


This week’s structure is a useful machine for every house that has fireplaces or wooden heaters as it is used for slitting the wood. For instance, when we cut the pieces of wood using a chainsaw, we get too big pieces of wood that they cannot fit in our fireplaces and wooden heaters so we divide these large pieces into smaller ones. Despite the fact, that there are many tools and machines for this purpose, we chose to make a ‘screw log splitter’ for the particular video. The way it works is generally simple and it is not too demanding making it besides some parts that were essential for its good performance as well as making it safe to be used.  

In the beginning, we made the frame of our structure using square tubes of 60mm x 60mm x 2mm. Regarding the frame’s dimensions are 80cm width, 106cm length and 62cm height. Then, we put wheels under the frame in order to manage to move our machine easily and save it in a good place. The wheels are 18cm height so the final height of our machine is 80cm, tall enough to keep the user to the most ergonomic position as much as possible. This is the suitable height to keep the user relaxed and high enough to keep him safe from any injury during its use.

Afterwards, we placed the electric motor of the machine that is equally powerful as 3hp power and it is the strongest single-phased motor that rotates in 3000rpm speed. Using pulleys, we decreased the spins of our last axis that rotates with 300rpm speed. The reason of doing that was to increase the torque of this axis in order to be powerful enough to split the pieces of wood that we need. We used 4 pulleys in total, one in the motor, two in an axis in the middle which is for the motion transmission and one at the last axis. 

Furthermore, we made some systems at the motor and at the axis in the middle which is used for the motion transmission, to displace them in order to be able to reach their ideal spot and achieve the best possible stretching of the belts of the pulleys as a result to have their best possible function. At the last axis, we put a screw in a conical shape that while screwing the wood, it separates it in two pieces. It should be mentioned that we bought this screw as we have not been capable of making our own, yet. It is 8mm at its thinnest part and 80mm thick at its thickest part. Therefore, while the screw is screwing the wood the particular piece of wood is being pulled towards the thickest part of the screw and the wood is divided into two pieces. Also, we put a piece of iron plate of 6mm thick under the screw and the wood has been placed on the iron plate and directed towards the screw. 

Apart of the basis where the wood is placed, the particular piece of iron plate obstructs the rotation of the wood. Additionally, the wood’s rotation is also obstructed by a vertical bar that is located under the screw and it is in the shape of an ax. Thus, the rotation of the wood has to be decreased when the machine works as there is a risk to hurt your hands. The frontal part of the screw is 10cm away from the iron plate and this distance between them encourages splitting the wood more easily. 

To sum up, after a lot of spinning and welding, we can see that our machine works great. The particular machine could be also worked using a machine of internal combustion, which would make it moveable and much more powerful. However, our form of machine makes it more useable and better for domestic use as the motor used is less noisy and it does not need any fuels from a gas station. Finally, the motor gets activated by pressing a button and there is an overload system in case the motor gets overloaded. Even if we haven’t placed any security button, yet; it is essential to place one somewhere on the machine in case of an emergency, so that the machine will be immediately, deactivated when there is a danger. Another project of the make it extreme team has been finally completed and undoubtedly it will make our life easier!










































Get the Plan: http://bit.ly/MIEplans

...
Read More
25 / 01 / 2017 | Videos

Homemade Roller Bender


The main problem that people, who are occupied with doing various metallic projects and generally constructions, face is the bending of metallic pieces. The reason that this problem is arisen during these projects is because the metallic pieces need a lot of pressure, strength as well as accuracy to be bent. There are many machines to be used to achieve this but the cost is high. Although, the metal roller bender has been already made once by the ‘make it extreme’ team, the particular construction was not affordable by anyone as more specialized machines were needed to be made than the ones that can be found in any home. Therefore, this our 56th construction is more user-friendly to everyone, is relatively affordable, is extremely useful and it will fill with feelings of joy and satisfaction the people who want to spend their time productively. 

To start with, we used a piece of home girder with total length 144cm, 18cm width and 9cm height. Then, we cut it in four pieces, 3 pieces of 28cm and another one of 60cm.  We made  the basis of our machine by putting the long piece on the basis and then we welded one of the pieces of 28cm vertically, on it. On the last piece, we connected another one piece of 28cm horizontally. In this way, we completed the basis of our machine.

Regarding the remaining piece, we connected it with a hinge of 20mm thickness and 18cm length on the horizontal, stable piece of 28cm. In this way, we created the moveable piece of the metal bender that regulates the inclination that we want to have on the bending  pieces. On the two pieces of 28cm both the moveable one and the immoveable one, we placed 4(Y)bearing of 20mm, 2 in each piece. While between the two pieces, we placed a bearing with a flange of 25mm. The height of these bearings is regulated with some holes that we created at the sides of the metal bender in order to regulate the height of the central axis according to the thickness of the material that we want to bend and they have the potential to alter positions according to the height of these bended materials. In this way, placing three metallic axis, 2 of 20mm thickness and one of 25mm thickness, we created the rollers, on which the irons roll during the bending. The inclination on the moveable piece is made with a bottle jack that it can lift up to 2 tonnes. Moreover, placing a screw at the central point of the axis, we can put the drill to revolve the axis and bend metals as well as revolve using also the hand supported by a wheel that is located on the same point. 

One detail that increases the potentials of the particular construction is that all the required adjustments have been made so that the axes from the one side can be exerted in order to make some space to place the rollers for bending tubes or circular iron materials. Also, another crucial detail that increases the functionality of our machine is the regulation through the holes, with which we can move the bearings of 20mm away from the center or vice versa. This is very important as while bending thick metals, the bearings decrease the power when they are away from the center while for the creation of narrower bending, the bearings are placed as closer to the center as possible. 

Finally, the particular idea and its original form came up five years ago and we should say that we are completely satisfied with its performance. To sum up, this time we decided to make this construction to give to our viewers the opportunity to also, try to make their own metal bender at their own home through electric welding, using an angle grinder and a drill. Our last piece of advice is to be patient while making it as even this construction is simple, it also needs a lot of patience and accuracy!










































PLEASE SHARE

...
Read More
17 / 01 / 2017 | Videos

Angle Grinder Hack 5



Not only it was an enjoyable experience but also a very amusing one creating this angle grinder 5. In the particular episode, our aim was to make a vehicle that would be able to move through an angle grinder. Having this in mind, we started making a velocipede (a three-wheeled bicycle) that is driven by the rider having a standing position. 

First of all, taking aluminum bars of 50mm width and 6mm thickness, we managed to make the framework of our bicycle. The reason that we used aluminum in our construction is to make it as lighter as possible. Then, we bended these bars to give the shape that we wanted according to the curves of the shape that we had chosen. 

At the frontal part of our velocipede, we used the frontal part of an old bicycle. While at the back side of it, we made a base that would support the angle grinder. However, the main problem in our construction was the transmission of movement from the angle grinder to the wheels. The reason of the particular problem is that the angle grinders spin a lot (11000 rpm) but to make the wheels move, it needs more strength and less spinning. 

To solve the particular problem, we took the mechanism used at the lawnmower. This mechanism is urged to spin through the lawnmower’s mechanism and this move is transmitted to the wheels by lifting a lever. This lever is connected with a handle by a wire rope. Therefore, pressing the handle on the wheel, the move is transmitted from the angle grinder to the rear wheels. The particular move from the angle grinder to the lawnmower’s mechanism was achieved by using a belt and pulleys. 

The pulleys used, were made by aluminum on the lathe. The pulley that was used to be placed on the angle grinder is 4cm diameter while the pulley placed on the mechanism taken by the lawnmower is 9cm diameter. In this way and using the mechanism of a lawnmower we managed to decrease the spins of the wheels and increase its strength as a result our bike to be able to transport our weight. 

Moreover, the wheels that we bought and placed at the back side of the bike are 20cm diameter and they are used on scooters. Even if our little bike is not powerful enough, it works incredibly fine and it can provide you a very enjoyable riding and a lot of fun.

Finally, the message that we wanted to pass across making the particular construction was that recycling and maintaining various old objects and accessories from old machines as well as keeping other old materials, we manage not only to keep our environment clean but also we can make impressive constructions.


































PLEASE SHARE

...
Read More
11 / 01 / 2017 | Videos

ELECTROMAGNET from microwave transformers



At the 0054 video, we experimented using transformers from broken microwaves making a very strong electromagnet. This electromagnet is intended to be placed on the crane that we have already made in our workshop in order to be able to lift heavy, metallic objects. 

To start the particular project, we removed the transformers from three destroyed microwaves. Then, we cut the upper surface of the transformer and we removed the secondary coil replacing it with the primary one. In this way, we turned the transformer into an electromagnet. The same procedure has been followed in all the three transformers.

As soon as we measured the dimensions of the three transformers, we took a circular flange of 10mm thickness and 25cm long that was punctured in the middle in order to place a metallic noose and this is the point that we are going to use to hang our electromagnet on the crane. Around the flange, we conglutinated a metallic wrath made out of a bar of 5cm width and 5mm thickness. The internal sum of the height of the wrath is 4cm as it is the width of the bar minus the width of the flange. 

Afterwards, we placed the transformers in the construction, that has been already mentioned above and they have been conglutinated softly in order to avoid changing place at the following stage of the procedure. Next, we connected our electromagnets in a row and we estimated their electrical resistance in order to be aware of the right transformer for electrical supply. As long as the connections have been applied, we put supports on the sides at the internal part of the metallic wrath. Also, we checked if our electromagnets function well and then we proceeded with our project by filling up our metallic frame with resin. 

At first, we put resin that is used at the fiberglass and then we used epoxy resin combined with black colour. The reason that we used common resin, initially, was because the epoxy resin is much more expensive. Doing this, we filled the gaps creating a very concrete construction increasing the electric performance and protecting the coil as well as our connections from any damages during its use. Due to the fact that the surface was now hard, we removed any unnecessary material from the resin and we used the milling machine to make the surface smoother. 

Also, removing the unnecessary material from the fame, we managed to decrease the metallic height of the transformer, too. In this way, we achieved to increase the power of the electromagnets. 

Moreover, the particular construction is able to be moved anywhere out of the shop and be placed in various lifting machines as it can be electrically supplied by batteries and the crane stored in our shop is electrically supplied by a transformer 24v 15A as well as by batteries. The reason of doing that is for safety purposes as in case the electricity supplied by the transformer is interrupted for any reason, the electromagnet will automatically be electrically supplied by the batteries and not stop working. Therefore, the object that is held at the particular moment will not be dropped preventing any possible accidents. Additionally, an alarm has been applied to warn before the blackout occurs in order to fix the problem immediately and so that the object takes its time to be put down. 

Every time the electromagnet works properly, a red light lights on the crane indicating that everything works fine. The strength of the particular electromagnet is impressive as in every experiment we carried out lifting more than 200kg, its performance was excellent without occurring any problems. The electromagnet should be normally electrically supplied by a transformer 48v 12A but because that was impossible to happen due to its high cost we used a transformer that we already had instead.

Finally, we believe that our electromagnet has the power to lift more than 600kg under ideal circumstances (thickness of a metal, efficient electrical supply, kind of material). Although, the particular construction is ideal to meet our needs, in the future, we might make a much bigger electromagnet using more transformers just for experimental purposes and to satisfy our personal desire!






































PLEASE SHARE

...
Read More