Axeman-Anderson Anthratube 260m disection

PostBy: LsFarm On: Mon Jul 23, 2007 1:45 pm

The Grate rollers are simple steel turnings, with no provision to lubricate them other than just squirt some oil on [at] them. So with as difficult as it is to get access to the rollers, they naturally get no service or lubrication at all. :)

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The rollers just pivot on steel pins, and three of the four are junk, the third one I may try to reuse. I haven't measured the worn spot on it yet.

One roller is worn down to the pin. I'll just turn some new ones on the lathe. I need to check and see if I have any 2.0" round stock

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The inside of the base has some serious corrosion from the ash and the wet basement the boiler was in.

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Last edited by LsFarm on Mon Jul 23, 2007 6:06 pm, edited 1 time in total.
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

PostBy: Bob On: Mon Jul 23, 2007 3:59 pm

LsFarm wrote:The Grate rollers are simple steel turnings, with no provision to lubricate them other than just squirt some oil on [at] them. So with as difficult as it is to get access to the rollers, they naturally get no service or lubrication at all.


This highlights another difference with the AHS boiler. On the AHS boiler this is a bearing that can be greased from the exterior.
Bob
 
Stoker Coal Boiler: AHS 130
Coal Size/Type: Pea/Anthracite

PostBy: LsFarm On: Mon Jul 23, 2007 7:28 pm

If I can line up the drill correctly, I may try drilling the pins from the outside for grease zerks, that way the rollers will outlive me. :)

I'll dig out the sandblaster and give the inside a blast and a coat of epoxy primer, that should keep the rust at bay for a few years. My boiler building is pretty dry, so I don't think it will rust much if sealed with good paint.

I'm planning on hooking it up just as AA designed it, try it for a season that way and see how it does. If I need to I can modify it through the season. I'm sure that with a bit of rebuilding it will do fine. This will give me a baseline to evaluate any modifications I make.

Greg L
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

Visit Lehigh Anthracite

PostBy: LsFarm On: Mon Aug 06, 2007 9:51 pm

With a busy work schedule that has resulted in me being home only four nights in the last two weeks, I haven't accomplished much on the AA boiler.
The new rollers are made, but I don't have them in my possesion yet. Forum member and fellow coal-burner GregWhite made the rollers for me. He has a machine shop and is working in it daily.

I did remove the grate operating bellcrank assembly for rebuilding. The wear is pretty bad. I haven't evaluated yet what is going to be needed to rebuild it. GregWhite will help with this too. I'm out of town way too much to get the work done in a timely manner.

My internet is giving me problems and I'm posting using a much slower system, so I can't post photos right now.

Hopefully I can upload some more photos soon.

Greg L.

.
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

PostBy: gaw On: Tue Aug 07, 2007 9:29 pm

LsFarm wrote:The boiler surface is badly corroded and the hot water coil is now using a 1/4" thick rubber gasket to seal the water leaks.


1/4" rubber gasket sounds to me like a regular water coil gasket unless A-A used something else from new.
gaw
 
Stoker Coal Boiler: Keystoker KA-6
Coal Size/Type: Rice from Schuylkill County

PostBy: LsFarm On: Wed Aug 22, 2007 8:24 pm

I'm not sure about the thick rubber gasket being standard, I guess I'm used to machinery where a gasket over the thickness of a thick business card is unusual.

Maybe since these are made from steel plate, they need thicker gaskets that would be more forgiving to not-so-flat surfaces.

I removed the domestic water heat exchanger, and found the inside of the boiler to be in VERY good shape. There is only a very thin layer of rust, and no indication of problems.

I also repaired part of the corroded lip of the fan-mounting plate. It was in pretty bad shape, I built up the thin lip with SS welding rod, and ground it to shape, the fan mount now fits nicely.

However on the inside of the lip you can see an erroded grove from the hot flames and fly ash hitting the lip where there is no heat-sink to the water or the mounting plate, I'm guessing this part of the lip runs cherry red at times, and therfore soft and suseptable to errosion from the abrasive flame and ash. I'm going to fill this groove in with more SS weld, and it should then last a very long time.
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Almost rusted and erroded away, I'm sure the rope gasket was just barely sealing here
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The lip restored with Stainless Steel welding rod, ground to fit the mounting plate.
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sorry for the fuzzy photo, you can see the depression just under the top edge of the mounting lip. The lip is protected by the mounting plate, but there is 1/2" that can get very hot.
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Last edited by LsFarm on Sun Aug 26, 2007 10:59 am, edited 1 time in total.
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

PostBy: coaledsweat On: Wed Aug 22, 2007 9:48 pm

They are not rubber IIRC, but feel very similar. You could probably replace it with Kaowool (assortment of sizes) available at most big plumbing/boiler supply.

You could fix that lip with a nice big chunk of Tungsten. :) :twisted:
coaledsweat
 
Stoker Coal Boiler: Axeman Anderson 260M
Coal Size/Type: Pea

PostBy: LsFarm On: Sat Aug 25, 2007 10:06 pm

Here are the new rollers and the new Bellcrank assembly. Many thanks to Forum member and coal burner GregWhite for doing the machine work.

Greg took the old shaft, cut off the worn end, saving the end with the ratchet-wheel, made an entirely new bracket, new brass bushings, and a bellcrank end with sleeve to fit over the old shaft, Awsome job!! For the push-pull bar that connects the pin on the bellcrank arm to the grate-drawer under the firepot, Greg rebushed the egg-shaped holes with a brass bushing, and made new [round] pins to install.. Heck of a job..

If you look at the worn shaft in forground of the photo, you can see the notch worn in the shaft, this happened after the original brass bushing wore in two, so the contact was steel to steel. With the frozen grate rollers, this boiler must have sounded like a horror film sound-effects when it was running.. :lol:
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Last edited by LsFarm on Sun Aug 26, 2007 11:01 am, edited 2 times in total.
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

PostBy: europachris On: Sun Aug 26, 2007 8:45 am

Further proof of always trying to know a good machinist and making fast friends with them. Dang, Greg, that's nice!

Every place I've worked always has a nice little maintenance shop with the basics. Two things I've always made a point of - maintenance/machine shop guys have the BEST potlucks, and keep them happy and you'll have 'government project access' any time you need it.

Chris
europachris
 
Stove/Furnace Make: EFM 350/Iron Fireman
Stove/Furnace Model: Custom bituminous burner

PostBy: coaledsweat On: Sun Aug 26, 2007 9:47 am

We probably would have made it to the moon in late '67, early '68 if it weren't for all the G jobs. :)

Nice work, I assume you will be nominating him for the boards resident machinists position?
coaledsweat
 
Stoker Coal Boiler: Axeman Anderson 260M
Coal Size/Type: Pea

PostBy: LsFarm On: Sun Aug 26, 2007 10:48 am

Greg White is hereby nominated for the postiion of NEPA Forum Head Machinist.

coaledsweat seconds the nomination.....

Any disenting votes???

NONE, vote carried.

Greg !! You Da Man !!! :lol: :) :lol:


GL
LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

PostBy: Yanche On: Sun Aug 26, 2007 11:37 am

coaledsweat wrote:We probably would have made it to the moon in late '67, early '68 if it weren't for all the G jobs. :)

Well, I was one of the ten's of thousands that worked on the moon projects in the sixties. There were lots of G jobs too. But it made me a better engineer. In the model shop I had access to, they didn't just make me what I wanted, they make me make it. Not on company time but my own time. There was lot's of overtime, but engineers were straight salary. After normal hours I learned how to run all the machines, not well but good enough to make what I wanted. After doing that I had a much better appreciation for designing things that the shop could actually make. It was a wonderful time in my career, I worked with and learned from some of the best machinists, welders, sheet metal specialists and die makers. I fixed many of their electronic G jobs, boat sonars, Loran receivers and TV's. The mutual respect for each others skills and hard work is what got us to the moon.

For those of those that don't know the term "G job". It's some job that's not an official job. Like when the owner of the company comes to you and says "My kid just crashed his bike, fix it". What do you charge you time to? Naturally it gets charged to some big government (G) job.
Yanche
 
Stoker Coal Boiler: Alternate Heating Systems S-130
Coal Size/Type: Anthracite Pea

PostBy: coaledsweat On: Sun Aug 26, 2007 12:01 pm

Aaaahh! The good old days. Well it is time to get back to it. They just signed to build the Saturn V engines again (updated), we are going back to the moon.
Put that tech into a coal boiler, then we be cookin'.
coaledsweat
 
Stoker Coal Boiler: Axeman Anderson 260M
Coal Size/Type: Pea

PostBy: europachris On: Sun Aug 26, 2007 1:08 pm

coaledsweat wrote:Aaaahh! The good old days. Well it is time to get back to it. They just signed to build the Saturn V engines again (updated), we are going back to the moon.
Put that tech into a coal boiler, then we be cookin'.


Indeed! The new moon project is an interesting mix of old and new technology. Kind of a Saturn V combined with some Space Shuttle. Pretty impressive, too.

Chris
europachris
 
Stove/Furnace Make: EFM 350/Iron Fireman
Stove/Furnace Model: Custom bituminous burner

PostBy: LsFarm On: Sun Sep 30, 2007 8:14 pm

With the coal bin project, and several drains on my free time, I've not been progressing as fast as I would like on the AA boiler.

I decided to add a layer of 3/16" thick Stainless Steel to the heat eroded lower lip of the firepot. This piece had been replaced and welding in in the distant past. But apparently this lip is exposed to a lot of heat, eroding the steel and creating cracks.

With a layer of erosion-resistant 409 Stainless on the inside of the lip, it should last me a lot of years.

Greg L
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Heat erosion and cracks, and this is a replacement piece. The original lip on the other side is in fine shape.
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This layer of Stainless Steel should prevent more heat erosion to the firepot lip.
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LsFarm
 
Stoker Coal Boiler: Axeman Anderson 260
Hand Fed Coal Boiler: Self-built 'Big Bertha' SS Boiler
Baseburners & Antiques: Keystone 11, Art Garland

Visit Lehigh Anthracite