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Old 04-15-2018, 08:30 AM   #1
Jason Fry
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Default Rusty style DIY power hammer

A power hammer is one of those things that many Smith‘s dream of, but a few of us can afford. Retail hammers run anywhere from 3-10k if you could ever find one. Being as I have more time than money, and I have a friend with an epic scrap yard, decided to build a hammer. There are a couple of different designs out there, but I chose to go with a guided spring helve. This style of hammer is called a Rusty, or an Appalachian. It’ll probably take me three or four weeks more work to finish, but I have a few pictures from day one. Yesterday we did most of the major cutting, layout, and engineering. This kind of project is like building from a tub of Legos. You know what you want to build, find the pieces you have that will work, and you put it together. It’s not at all like building Legos from a set.

The head of the hammer will be about 40 pounds, and the anvil around 400.

Layout on the floor... we don’t need no stinking plans, LOL.


Most of the big parts laid out.


A closer shot of the spring arm and head lay out.


After that, I put it all in the truck and hauled it home. 1000 or 1200 pounds in the back of a Tacoma is quite a load. Lowrider for sure, LOL.

Lots of drilling, tapping, welding to go, but I have the next two weekends to do it.


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Old 04-15-2018, 08:46 AM   #2
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Push a pedal, lose a thumb
Those things do work though!! Following.
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Old 04-15-2018, 08:58 AM   #3
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I had to google/youtube what the hell that is. I definitely see how that would come in handy.
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Old 04-15-2018, 07:32 PM   #4
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Quote:
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I had to google/youtube what the hell that is. I definitely see how that would come in handy.
Fixin to google it myself, cause it sounds like a pretty cool contraption but i cant get an image of it in my head.
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Old 04-16-2018, 08:24 AM   #5
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I'd love to have a power hammer, money is not an object, I just don't have the room. I'm looking to rent a building somewhere in the country so don't have to deal with city codes and regulations.
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Old 04-16-2018, 12:45 PM   #6
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Going for forgiveness over permission on the codes, etc. Hopefully I can be cool with the neighbors and avoid the cops by being reasonable. Keep it to mid day and weekends. No late night Damascus, lol.


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Old 04-16-2018, 03:56 PM   #7
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awesome

Quote:
Originally Posted by Jason Fry View Post
Going for forgiveness over permission on the codes, etc. Hopefully I can be cool with the neighbors and avoid the cops by being reasonable. Keep it to mid day and weekends. No late night Damascus, lol.


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officer: sir, we have reports of loud banging noises?

JF: yea, its my power hammer in the garage, Im making a skinning knife

officer: you make your own knives?

JF: yea, all kinds actually

officer: Cool

JF: I could make you a knife?

officer: noises? what noises? have a nice day sir

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Old 04-16-2018, 04:18 PM   #8
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in for the finished product
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Old 04-16-2018, 06:15 PM   #9
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Quote:
Originally Posted by Quackerbox View Post
awesome



officer: sir, we have reports of loud banging noises?

JF: yea, its my power hammer in the garage, Im making a skinning knife

officer: you make your own knives?

JF: yea, all kinds actually

officer: Cool

JF: I could make you a knife?

officer: noises? what noises? have a nice day sir

sounds like experience...........lol
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Old 04-16-2018, 10:02 PM   #10
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Quote:
Originally Posted by Jason Fry View Post
Going for forgiveness over permission on the codes, etc. Hopefully I can be cool with the neighbors and avoid the cops by being reasonable. Keep it to mid day and weekends. No late night Damascus, lol.


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The noise is another issue, I've slowed down a lot of my anvil work for that reason. I live in a golf course community and so far my neighbors don't have a problem of course they all have knives I've made for them for presidents. We now have some new houses up the street and my hammer on anvil carries that far. I'm sure people that pay 500k for a house don't want to have my racket.

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Old 04-17-2018, 08:03 AM   #11
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Fortunately we're in a "regular" older neighborhood, with no HOA. I'll try and get some pics tonight of the progress from Sunday.
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Old 04-17-2018, 08:50 PM   #12
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I ended up breaking my tap wrench threading holes for the head guide, so I switched to laying out the flywheel. The idea is to bolt the flywheel to the car room, so that if the tire wears I can just replace the tire. I plan to put three big nuts welded to the flywheel, maybe four, so that I can adjust the stroke length. I’m thinking of setting it up for six, 6.5, 7, 7.5 inch stroke. I left 10 inches of room in my layout on the head to allow for some flex in the springs. The flywheel is 11 inch circle of 1/2 inch plate.



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Old 04-18-2018, 09:55 AM   #13
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I have no idea what this thing is, but I like it!
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Old 04-18-2018, 11:42 AM   #14
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One of these...

https://www.youtube.com/watch?v=nyaoFtARF80
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Old 04-18-2018, 04:48 PM   #15
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Quote:
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Looks like a living nightmare






.....I want one


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Old 04-19-2018, 08:47 AM   #16
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Looks like some kind of medieval sex machine.....
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Old 04-20-2018, 07:57 AM   #17
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Excellent DIY project. Keep us posted on progress.
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Old 04-20-2018, 10:13 AM   #18
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Looks awesome! I'm finishing my forge today and should have it fired up this afternoon. Maybe this will be my next project!


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Old 04-20-2018, 12:54 PM   #19
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Hope to get the whole thing minus the drive train assembled this weekend. Pics eventually, lol. Next weekend will be motor, drive linkage, and tuning.
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Old 04-20-2018, 01:30 PM   #20
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If you watched the most recent forged in fire, on elf the people had this exact power hammer in their shop
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Old 04-20-2018, 07:44 PM   #21
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Quote:
Originally Posted by TMC50 View Post
If you watched the most recent forged in fire, on elf the people had this exact power hammer in their shop
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Old 04-20-2018, 08:15 PM   #22
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Quote:
Originally Posted by TMC50 View Post
If you watched the most recent forged in fire, on elf the people had this exact power hammer in their shop


Is that the one that blew apart mid stroke or was that a different episode? One of the finalists were using his home built hammer when it went kaput.


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Old 04-20-2018, 09:42 PM   #23
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Quote:
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Is that the one that blew apart mid stroke or was that a different episode? One of the finalists were using his home built hammer when it went kaput.


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It was this weeks episode. I am pretty sure it broke at one point. The only reason I saw it was because I saw this thread and the spring.


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Old 04-21-2018, 05:35 PM   #24
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Worked on the top of the center upright, to get the pivot in place for the leaf springs. All recycled/used/scrounged materials so far.



Closer look at the pivot.



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Old 04-21-2018, 07:15 PM   #25
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Quote:
Originally Posted by savin yours View Post
Looks like a living nightmare






.....I want one


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Lol!!!


Looking good OP

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Old 04-22-2018, 02:29 PM   #26
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The hammer ram goes up and down inside a guide. That’s the “guided” part of the guided helve hammer. Inside the guide will be UHMW plastic, adjustable with screws. Lots of tapping in 1/4” thick tubing with 3/8” tap.



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Old 04-22-2018, 05:22 PM   #27
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Here’s the roller assembly that will transfer the curved path of the helve spring into a straight up and down guided hammer head.




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Old 04-22-2018, 07:51 PM   #28
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Here’s the other end of the hammer head. Made for interchangeable heads in case I want to try different die shapes.



Also built die plates for the anvil top. That way I can change the die or angle there as well.



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Old 04-25-2018, 08:23 AM   #29
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Got the base plate screwed to the RR tie base last night. I also have most of the pieces ready to assemble on the base. Got bearings in the mail yesterday, and the motor should arrive tomorrow. Went with a 1.5 HP 1750 RPM motor and 3" drive wheel, which should end up around 218 beats per minute. I'll still have to fabricate the wheel once the round stock arrives later this week. Still lack the treadle and motor mount, but the design and fab there shouldn't be much, an hour or two. It'll be a hard push this weekend. If I can get it together on Saturday and work out the kinks on Sunday, that'll be perfect. Just as likely I'll fall a little short.
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Old 04-25-2018, 03:24 PM   #30
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.......those welds! That thing is AWESOME!!!!


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Old 04-25-2018, 03:40 PM   #31
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This project multiplied my previous welding experience x10. That, and I'm just beyond the capability of my machine. I'm using flux core in a Lincoln 180. Some of this is 3/8 to 1/2. I'm beveling edges and laying it on thick and ugly, lol. I really don't know what'll hold, but I'd be surprised a little if everything sticks just right.
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Old 04-25-2018, 04:15 PM   #32
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This is great. As a new welder turned “I bet I could make that” type of person, making stuff like you said, just trying to fit available pieces and material towards a final goal, is about as fun as it gets. I’m going to show this to my 11yr son. He will have us making one next weekend!
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Old 04-25-2018, 06:00 PM   #33
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Quote:
Originally Posted by Jason Fry View Post
This project multiplied my previous welding experience x10. That, and I'm just beyond the capability of my machine. I'm using flux core in a Lincoln 180. Some of this is 3/8 to 1/2. I'm beveling edges and laying it on thick and ugly, lol. I really don't know what'll hold, but I'd be surprised a little if everything sticks just right.


Oh I’m not poking fun, we’ve ALL been there! Some of mine are still sketchy at best...


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Old 04-27-2018, 10:02 PM   #34
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More progress. Got the tire mounted where I think it needs to be on the base.

Got the bearings for the ends of the drive arm set up. Smaller one goes on the spring end, bigger one on the tire end. Threaded parts allow me to adjust the distance between the dies.


Hers a shot of the plate from further up the page. Bolts to the rim. Nuts welded on for 6.5, 7, 7.5 stroke.


Long way to go yet. More pics tomorrow and Sunday.


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Old 04-27-2018, 11:08 PM   #35
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Great build!


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Old 04-28-2018, 07:37 AM   #36
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Default Rusty style DIY power hammer

Here’s the part I was most worried about. The anvil for the hammer is. 32” piece of 5.5” round stock, at 215 pounds. That is then inserted into a mud pump sleeve that’s another 175 or so, and also 5.5” bore. Now y’all know a hole has to be bigger than the thing you plan to stick in it. I polished all the rust out of the sleeve, then worked over the post with a flap wheel to knock off all the handling gouges and high spots. With that much weight, there’s not an easy way to test fit. It is all or nothing. I welded on some lift points to the anvil so I could lift it with a come along. I set the sleeve underneath, and used the come along to slowly lower the rod into the sleeve. I’ll be darned, it slid right in there. Whew!






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Old 04-28-2018, 08:43 AM   #37
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Heck of a diy project. Good luck
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Old 04-28-2018, 08:57 AM   #38
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Quote:
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Fortunately we're in a "regular" older neighborhood, with no HOA. I'll try and get some pics tonight of the progress from Sunday.


I was working in the back on the hammer when my grumpiest neighbor came out to the alley to dump trash. Struck up a conversation and I invited him over to see the project. Turns out he has interest in knifemaking. Considering how fussy he’s been, to get him interested before I start banging away with this thing is a good step.


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Old 04-28-2018, 07:11 PM   #39
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First major error. Got the column together and figured out that the column was a foot too tall. That 4” square tube is 3/8 wall, killed a chop saw blade but got it cut down and re-welded. Back on track.






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Old 04-29-2018, 03:51 PM   #40
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Looking good. But hope it doesn't hammer it to death from the stress! Keep us posted!! I worked at, International Harvester when I was young. One of our presses, 5000# would break a 5 foot thick crank shaft in half about once a year. All it was pressing was white hot 4 cylinder crank shafts.
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Old 04-29-2018, 04:23 PM   #41
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Man, I am ready to see this thing come to life. Any more progress today ??
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Old 04-29-2018, 05:30 PM   #42
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Default Rusty style DIY power hammer



Got the guide mounted and the hammer head installed. I also added the push arm and mounted the motor. Still need to wire the motor and tune everything.

Agree, hoping the welds hold and it doesn’t catastrophically and dangerously fail.

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Old 04-29-2018, 08:32 PM   #43
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Got the motor mounted and wired and let it go a few hits for proof of concept. Still a lot of adjustment, tightening, and final welding of tacked parts. Once it is running right, I’ll do a YouTube video.
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Old 04-30-2018, 10:55 AM   #44
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Quote:
Originally Posted by savin yours View Post
.......those welds!


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U should name it, "The Widdowmaker"....
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Old 04-30-2018, 11:39 AM   #45
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I'm kind of thinking "Rattletrap" since I used to tournament fish...

Turns out my neighbor (who likes to fuss at my kids) works at a fabrication shop. If (when, lol) something breaks, we can pull it apart and get it welded by a real welder.
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Old 05-01-2018, 09:20 PM   #46
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Final pic of the anvil assembly. 400 pounds.


Linkage between the push rod and the spring pack.


Final tire assembly



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Old 05-02-2018, 08:03 AM   #47
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You gonna set off seismic sensors all over Texas with that thang
Run for your lives folks. It's the big shaker we been warned about.
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Old 05-02-2018, 08:36 AM   #48
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You gonna set off seismic sensors all over Texas with that thang
Run for your lives folks. It's the big shaker we been warned about.
Lol, possible. Whole contraption is 800 pounds minimum, I'd guess. Should be enough weight to keep the giant bounce down to a steady thump, lol.
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Old 05-07-2018, 07:41 AM   #49
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Today’s the last day of my road trip. This hammer must absolutely be running by next Monday. Expect the finishing touches this weekend.


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Old 05-07-2018, 07:48 AM   #50
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Can’t wait
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