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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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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
Jason Fry
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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
Puggy625
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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.

Last edited by Bjankowski; 04-16-2018 at 10:05 PM.
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Old 04-17-2018, 08:03 AM   #11
Jason Fry
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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
Jason Fry
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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
Jason Fry
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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:
Originally Posted by bloodstick View Post
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
Jason Fry
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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
Jason Fry
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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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