Soil Pulverizer: Fabrication Manual
Contents
1. Parts Assembly Hydraulics 31 Assembly Hydraulics Tools e Rags e Jar e Various Wrenches e Thread Tape Procedure Prepare the hoses Materials e SAE 10 to 1 2 NPT swivel 2 e SAE 4 to 1 4 NPT swivel 1 e 30 gpm Quick Coupler set Body Size 1 2 Thread Size 3 4 14 NPT 3 e Quick Coupler set 1 e Male quick coupler 1 e 1 4NPTM x 12 Hose 1 e 1 2 NPTM x 12 Hose 2 e To each hose attach a male quick coupler at one end and a female at the other e Use thread tape between each connection Assemble motor hydraulics 1 Removethe plugs in the motor e Have rags and a jar ready in case there is fluid in the motor 2 Install the swivels into the ports as shown in the photo e Do not use thread tape on the swivel fittings 3 Install the quick couplers as shown on the right using thread tape for each connection Parts Assembly Hydraulics 32 4 Attach the hoses to the quick couplers in preparation for attaching to a hydraulic power source2. e Insure a 75 bolt can go thru the big hole e Insure the rod can go all the way thru the tubing through the smaller holes 2 Grind away the slag 12 00 Parts Fabrication Frame Pivot Hinge 3 Fully weld the nut and Joint Plate to the Large Tube as shown When welding the nut cover the top of the nut so no spatter goes inside and insure the hole is clear and the nut level The two will be mirror images of eachother 2 00 Parts Fabrication Shaft and Motor Frame 15 Parts Fabrication Arm Rest Tools Materials e Welder e 2 x2 x1 4 Square Tubing 13 5 2 e x2 Flat 4 2 Steps You need two of these 25 e Fully weld the plate to the tubing as shown Parts Fabrication Shaft and Motor Frame 16 Parts Fabrication Shaft and Motor Frame Tools Materials e Torch e 1 2 x2 Flat 4 25 2 End e Welder Plates e Hole Puncher e x8 Flat 12 3 Bearing and Motor Plates e 2 x4 x1 4 Rectangular Tubing 56 1 Cross Tube e Angle Grinder Parts Preparation Motor Plate You need 1 of these 1 Punch the smaller holes 2 Torch the larger hole 3 Grind it smooth 2X 0 88 Bearing Plate You need 2 of these 1 Punch the smaller holes 4X D 75 2 Torch the larger hole 3 Grind it smooth 23 00 2 19 4 00 Parts Fabrication Shaft and Motor Frame 17 Cross Tube 1 Torch the holes shown e Insure 75
3. bolts will go all the way through the tube 2 Grind away the slag 56 00 THRU Parts Assembly 1 Fully weld the end plates centered to each side of the cross tube 2 Fully weld the motor and bearing plates to the cross tube e Itis crucial that these all be square in every direction Double check it and weld it slowly so it doesn t warp e Note that the motor plate is welded to the end plate Parts Fabrication Tines 18 Tines 1 Note Tines will not have bent tips until a later step Tools Materials e Torch e 375 x3 Flat 11 5 24 e Welder e 2 Sch 80 Pipe 3 5 12 e Hole Puncher e 75 Nut Steel 12 e Angle Grinder You need to make 12 of these total Procedure Prepare the tines 1 Torch a hole in the center of each flat as shown e Check that the pipe will go through it 2 Torch approximately 1 slits at each side of flat as shown 3 Grind away any slag 10 02 375 n Parts Fabrication Tines Prepare the Pipe 1 Torcha hole in the pipe as shown e Insure a 75 bolt will go through 2 Grind it smooth 3 Weld a nut over the hole insuring the hole remains clear Protect the threads while welding Weld the tines to the Pipe 1 Weld the tines onto the pipe as shown They should be perpendicular to eachother Fully weld all joints Make sure no spatter enters the nut The one closest to the end should be 25 away from the e
4. N Vis N jo Primary Part Name PIECE PARTS BUCKET BUCKET BUCKET BUCKET BUCKET BUCKET BUCKET BUCKET TINE FRONT FRAME ARM REST BUCKET BUCKET PIECE PARTS FRONT FRAME FRONT FRAME BUCKET BUCKET PIVOT COUPLER TINE COUPLER PIECE PARTS PIECE PARTS PIECE PARTS PIECE PARTS BUCKET PIVOT PIECE PARTS ARM REST FRONT FRAME Secondary Part Name TOP PLATE SIDE PLATES BOTTOM PLATE BACK PLATE BLADE TRIANGLE PLATE CROSS SUPPORT PLATE CROSS SUPPORT PLATE LOWER REAR MOUNTING PLATE TINE END PLATE CROSS TUBE PLATE ARM REST SKID PLATE BOTTOM MOUNTING PLATES PLATE MOTOR MOUNT PLATE MOTOR END PLATE BEARING HARD STOP PLATE SIDE BRACE PLATE JOINT PLATE COUPLER SHAFT SIDE TUBE TINE SLEEVE HINGE PIPE ROD HINGE ROD PIN SHAFT LARGE TUBE ANGLED LARGE TUBE SMALL TUBE SMALL TUBE ARM CROSS TUBE Parts Fabrication Bucket 8 Parts Fabrication Bucket Sketchup Model Tools Materials e Torch e Nuts Steel 4 e Welder Type Size Length Gty Part n O Z o e Angle Grinder e Hole Puncher Protractor 0 5 X 3 SKID PLATE 0 5X4 6 2 BOTTOM MOUNTING PLATES 0 75 X 2 HARD STOP PLATE 0 75X4 23 75 SIDE BRACE PLATE 0 25 X 16 SIDE PLATES 0 25 X 24 BOTTOM PLATE Square 0 1875 X Piece Parts Preparation Large Tube You need to make 2 of these 1 Torch the holes as shown Make sure they are large enough for a bolt 2 Grind away the slag 3 Weld the
5. Nuts Galvanized 2 9 16 x2 Bolts 8 9 16 Nuts 8 9 16 Washers 8 Assembled Parts e Various Wrenches o Bucket o Arm Rests o Frame Pivot Hinges o Shaft and Motor Fran e 17 8 Bearings 2 e 1 8 x 2 5 Cotter Pins O O O O O O O O O Procedure 1 Insert the Arm Rests into the Arm Rest Slots in the side of the Bucket as shown e Make sure the arm rests have the correct orientation See the illustration 2 Insert and tighten both x1 5 bolts on each side to hold them in place e The armrests should both be sticking up about 8 from the slots Parts Assembly Front Frame 25 3 Boltthe Frame Pivot Hinges to the top side of the bucket so it rests on the arm rests e Make sure they both have the right orientation by looking at the image e Usethe 1 bolts and nuts with a washer on each side e Tighten the bolt but leave a little space so the Pivot Hinges are free to rotate 4 Insert the Small Tubes into the pivot hinge as shown so that the holes are on the outside of the bucket 5 Put the hinge pin through both sets of tubing as shown on each side e Which holes you put it through are not crucial as this can be adjusted later However insure both small tubes are adjusted the same e Put the cotter pins though each side of the pin 6 Tighten a x1 25 bolt into the nut welded to each pivot hinge 7 Bolt the Shaft and Motor Frame to the Small T
6. lock collars 10 Tighten x1 25 bolts into each tine using a socket with an extension Parts Assembly Install the Top Plate Assembly Tools e Welder e Mallet Procedure 1 Lay the top plate onto the frame as shown 2 Insert the pipe onto the Hinge Rod as shown and position pipe and rod as shown e Space the pipes approximately as shown so they are in 4 sets of 2 evenly spaced 3 Position the top plate and rod pipes approximately as shown on the right 4 eld one pipe from each set to the c one to the top piece e Protect the shaft so that no welding spatter sticks to it e Weld the highlighted ones in the photo above to the top piece and all others to the cross support piece 5 Insert the cotter pins into the holes at each end of the rod 29 Install the Top Plate Materials e Assembled Parts o Bucket Front Frame o Hinge Rod e 51IDx 75 OD Round Tubing 2 8 e 1 8 Sheet 40 x48 Top Plate e 1 8 x2 Cotter Pins 2 ross support piece and Parts Assembly Paint 30 Assembly Paint Procedure 1 Check all external surfaces for sharp edges and smooth with angle grinder 2 Remove any surface rust with wire brush and or sandpaper 3 Apply a thorough coating of paint to all steel surfaces e You will need to prop up the top piece while painting so you can paint everything e Do not paint the motor 4 Allow 24 hours to dry before handling
7. nuts 100 over the holes insuring the nut is level and the hole is clear e Cover the top of the nut so no spatter goes inside while welding Parts Fabrication Bucket 9 Triangle Plates e Torch or shear the flatbar into two pieces as shown Side Brace Plates You need 2 of these which are mirror images of eachother 1 Torch or shear the flatbar into two pieces as shown 2 Punch the hole as shown 3 Torch away the corner as shown 4 Weld the Hard Stop Plate to them as shown 10 Parts Fabrication Bucket Bottom Mounting Plates You need to make 2 of these 1 Punch the hole as shown 2 Torch or shear away the corner as shown Piece Parts Assembly Side Plates You need 2 of these which are mirror images of eachother 1 Torch or shear the plate as shown right 2 Weld the Side Brace Plates and Large Tubes as shown below Back Plate e Fully weld the bottom mounting plates to the back plate as shown e Insure they are square and do not warp while welding Parts Fabrication Bucket Bottom Plate e Fully weld skid plates and blade to the bottom plate as shown o Only weld them from the bottom side NOT the top or sides yet o Insure you get the right spacing on them by looking at the lower diagram o The blade will stick out on each side and the skid plates will stick out 1 4 on each side Cross Supports e Weld the Cross Support Plate Cross Support Plate Lower and
8. shaft as shown e Be sure they are in the right orientation to lock onto the bearings e Don t lock them yet you ll do this later 2 Angle the shaft properly and hammer it though the other bearing until it s poking through the bearing mount plate about 1 Parts Assembly Install Shaft and Motor 28 3 Install the coupler onto the shaft e Insert the coupler onto the shaft e Once the coupler is on hammer the shaft through until it is fully inserted in the coupler and it is positioned as in the photo on the right e Rotate the coupler so that the holes in the coupler and the shaft line up e Insert the 3 8 bolt through the hole and tighten the nut onto it Use loctite on the bolt 4 Loosely bolt the motor mount plate to the frame using the x2 Bolts e Use a washer the side of the nut 5 Slide the motor through the mount and into the coupler e Make sure the motor is oriented so that you will be able to bolt it to the frame e You may need to rotate the motor shaft or the shaft with the tines on it to get the motor shaft to fit into the coupler e Don t insert it all the way yet just get it started 6 Loosely bolt the motor to the frame with the x2 5 bolts with a washer on the side of the nut 7 Lightly hammer the motor until it is flush with the motor mount plate 8 Tighten the bolts on the motor and the motor plate 9 Tighten the set screw on the coupler and the bearing
9. E OE AS A EE eer ree 30 Assembly HydtauliES ES ee EO Re Sania oe De DE oe AR oe ee ee EG saat adduct Ge ER GE DEE 31 Prepare the NOSES is E o A 31 Ps enible motor Nara UIC asse iii ai 31 Bill of Materials Steel Tybe Sheet Plate Beveled Flat Flat Pipe Round Tubing Round Square Tubing Stock Size Inches 0 125 X 48 0 25 X 16 0 25 X 24 0 25 x 16 0 5 X 6 0 25 X 2 0 25 X 2 5 0 25 X 5 5 0 375 X 3 0 5 X 2 0 5 X 3 0 5X4 0 5 X 6 0 5 X 8 0 75 X 2 0 75 X4 2 SCH 80 Pipe 2 SCH 40 Pipe 0 5ID X 0 750D 0 5 1 875 0 1875 X 2 5X2 5 0 25 X 2X2 0 25 X 2X4 Bill of Materials Length inches 40 29 48 48 49 5 5 43 5 43 5 324 16 5 39 12 36 35 75 44 5 16 58 52 36 75 56 Hardware Type Nut Hex Nut Hex Nut Hex Nut Hex Steel Nut Hex Galv Nut Nylon Lock Bolt Hex Bolt Hex Bolt Hex Bolt Hex Bolt Hex Bolt Hex Bolt Hex Bolt Hex Washer Wide Washer Wide Washer Wide Washer Wide Misc Misc Misc Size Inches 0 375 16 0 5 13 0 5625 11 0 75 x10 0 75 x10 1 8 0 3750 16x3x3 0 5000 13x2 5x2 5 0 5625 11x2x2 0 7500 10x1 25x1 25 0 75 10x1 5 x1 5 0 75 10x2 x2 0 75 10x5 5 x1 75 1 0 8x3 x2 25 0 5625 0 5 0 75 1 0 COUPLER 1 3 8 6T SPLINED BEARING WITH LOCK COLLAR FS210 1 7 8 COTTER PIN 1 8 X 2 QTY BON OND ND ND A Bill of Materials 6 Hydraulics Description Ouantity
10. EN iodo 8 PISCO Paris Se is le AE NE RE EE ON RE OE RA AE OE 8 Leelee 8 Triangle PIAleS ril lalla 9 SoS Brace Pi N EE EE EE A EE E EE EG 9 Bottom Mounting Plate EE Ee Ee EE 10 Piece PAGES NSS MOLY naa 10 O di RE EO AE DA EE EO A 10 Breda A N EE RO OE N ME N N ER GEE LE N EE 10 Bottom Plate siria N N RA N OE OR N OE 11 AOSS de seat AR EE ER o O ea 11 P AS lye OR e EE EE 12 li Meld BUC KOT LAL CS GENE E E ita 12 2 Veld Cros SUD DOTES seks eie RC IAT 12 3 Weld Rear MOUNTING Plate sesse ion e E r ironica iraniana Se sg Eg des 12 Parts Fabrication Frame Pivot Hinge sesse ee ee ee ee ee ee ee ee ee see ee ee ee AR Ee ee ee ee ee ee ee ee ee Re ee ee AR ee ee AAR ee ee ee RE Ee ee 13 geo ni Oe OE A e o y EE AEE 13 LEE EE IO I SOTTO 13 bebe ao ia 13 Parts Fabrication Arm RES see ee enor ee ee eee ee o EA 15 Parts Fabrication Shaft and Motor Frame i 16 nn e oo e A 16 OOF PINE r a Po OE EE AE N OE 16 al die dye SE EE N EE EE EE EE o o OE OE 16 OSS MEE ol EE OE aaa 17 PASSI 17 Table of Contents 4 Parts Fabprication C6uplers is oe Ee Ge Ge ee a 20 Parts Rabricati n Additional Piece Parts ses RE id E N N EEE Na 22 AA o ET OR A oe ee 22 Motor Mount Plate ses ala 22 INS ROG cele 22 Bere 23 ASSEMBDIV F ONT eA Sie allaccia 24 Ass emblys Bend the Ties asie EE en Ee ais 26 Assembly Install the Shaft and MOOD ee Gn Ee ee oes Ge oe aaa 27 Assembly InstalFtneTop Platecpa cai 29 ASSEMDIVS n E
11. Soil Pulverizer Complete Fabrication Instructions 2011 Open Source Ecology Introduction Introduction The purpose of this guide is to provide all information to make the 2011 version Soil Pulverizer from stock steel and parts More information and a constantly updated procedure can be found on the OSE wiki Soil Pulverizer Manufacturing Page This guide is broken into 2 main fabrication steps Parts Fabrication and Parts Assembly After these two have been completed the machine can be painted After it s painted the remaining hydraulics must be installed After that it should be ready to go See the User Manual for how to adjust the height of the tines to your soil cutting needs Parts fabrication begins with the cutting of all stock steel as listed in the cut list It focuses on cutting drilling punching bolting and welding the steel into parts pieces and then assembling the parts pieces into individual parts Each part IE Bucket Arm Rest listed in this section is independent of all others therefore the parts can be fabricated in any order Parts assembly joins all of the parts into the whole machine It mostly involves bolting but some parts must still be welded upon assembly Table of Contents 3 Table of Contents aage ELD ene A EE e o 5 OE OE e ssn o A 2 SEE VV AE STV IU EE EE ME EO DR EE EE OE 5 ds AR ET N o ER 5 LORI AM oo PA Aa 5 AP e e 6 AE AE e RE EO Ef AA A 7 Pets AO ICA CIO gt ICKL io ia SE
12. Source Hydraulic Motor 1 https www surpluscenter com item asp item 9 7368 125 amp catname hydraulic SAE 10 to 1 2 J https www surpluscenter com item asp item 9 6900 10 NPT swivel 8 amp catname hydraulic AE 4 to 1 4 NPT l i a E https www surpluscenter com item asp item 9 6900 4 48 catname hydraulic 1 2 NPTM x 12 i 2 https www surpluscenter com item asp item 905 12144 amp catname hydraulic 1 4 NPTM x 12 l i i 1 https www surpluscenter com item asp item 916 14144 amp catname hydraulic 30 gpm Quick Coupler set Body Dal H Size 1 2 Thread AOM RyALAUNES Size 3 4 14 NPT vy Coupa 1 https www surpluscenter com item asp item 9 6314 amp catname hydraulic vy oe ues 1 https www surpluscenter com item asp item 9 5924 amp catname hydraulic Coupler Cut List Type Sheet Plate Beveled Flat Flat Pipe Round Tubing Round Square Tubing Stock Size Inches 0 125 X 48 0 25 X 16 0 25 X 24 0 25 x 16 0 5 X 6 0 25 X 2 0 25 X 2 5 0 25 X 5 5 0 375 X 3 0 375 X 3 0 5 X2 0 5 X2 0 5 X3 0 5 X4 0 5 X 6 0 5 X 8 0 5 X 8 0 75 X 2 0 75 X4 0 75 X4 2 SCH 80 2 SCH 80 2 SCH 40 0 5ID X 0 750D 0 5 0 5 1 875 0 1875 X 2 5X2 5 0 1875 X 2 5X2 5 0 25 X 2X2 0 25 X 2X2 0 25 X 2X4 Cut List Length inches 40 29 48 48 49 5 5 48 5 48 5 48 11 5 4 25 19 5 12 12 23 75 2 9 os 50 52 12 24 13 3 56 QTY Py ME EP PR EER RR RR BR ie PN N
13. Triangle Plates together as shown with one Triangle Plate at each end of the supports o Fully weld all seams except the one shown 11 This end is flush Bottom Piece Fully weld skid plates bottom piece and blade ONLY weld this Skid Plates side though Don t weld the top or sides yet Blade Parts Fabrication Bucket 12 Parts Assembly 1 Weld Bucket Plates Fully weld the side pates bottom plate and back plate together at all joints as shown below Detail B Da FULLY WELD BUCKET PLATES ITEM NO 1 2 3 4 11 TOGETHER AT JOINTS Detail C ISO VIEW ITEMS REMOVED FOR CLARITY 2 Weld Cross Supports e Weld Cross Supports as shown o Fully weld all seams except the one marked not to 3 Weld Rear Mounting Plate e Weld it in place from all angles as shown at a 45 angle with the back plate Parts Fabrication Frame Pivot Hinge 13 Parts Fabrication Frame Pivot Hinge Tools Materials e Torch e 75 x4 Flat 6 2 Joint Plate e Welder e 2 5 x2 5 x3 16 Square Tubing 12 2 Large Tube e 75 Nut Steel 2 e Angle Grinder e Hole Puncher 6 00 Procedure T 4X1 00 Joint Plate SI A 07 You need 2 of these D1 00 00 i 1 Punch the hole as shown 4X 1 00 4 p 4 00 2 Torch away the corners as shown ND 2 00 _ pe 2 Sea Large Tube You need 2 of these 1 Torch the holes as shown
14. dge of the pipe LIA A 19 pos Parts Fabrication Coupler Parts Fabrication Coupler Tools Materials e Bandsaw e Coupler 1 3 8 6T Splined e Welder e 2 Sch 80 Pipe 2 5 1 Shaft e Drill Press with 3 8 bit side coupler e 2 Sch 40 Pipe 1 1 Sleeve e 1 875 Round 52 1 Shaft e 3 8 x3 bolt Procedure Note if you have access to a lathe you can simply lathe out about 1 8 long section of the splined coupler so it fits directly into the Sch 80 pipe This ensures concentricity You could do away with the sleeve and weld these two directly together 1 Cut down the splined coupler 2 00 so it is 1 25 long 2 Tack it to the sleeve as shown e lf there s any play get the coupler as centered as possible in the sleeve R 6875 L 1 25 _ 3 Tack the pipe and coupler with sleeve together as shown e Insure that the sleeve and the pipe are concentric This is a critical part e t would help to set the two on the welding table and tack from the top then twist until they re perfect Tack them in many dimensions to insure nothing warps 5 Weld it fully with at least 3 layers of weld 20 Parts Fabrication Coupler 21 6 Mark and center punch where the hole in the pipe will be 05 9 375 00 THRU ALL 7 Insert the shaft fully into the coupler Drill through the coupler and the shaft 9 Insure the 3 8 bolt goes through both t
15. he coupler and the shaft If not re drill with a slightly larger bit Parts Assembly Additional Piece Parts 22 Parts Fabrication Additional Piece Parts Tools e Torch e Angle Grinder e Welder e Hole Puncher e Drill Press Small Tube po Ed Materials i EN 3 00 V e 2 x2 x 25 Square tubing 24 2 You need to make 2 of these Steps 1 Torch all holes as shown 4X 50 07 y Y e Insure the proper size bolt or THRU ALL rod can go through each hole 1 00 2 Grind away all slag 2 00 a Motor Mount Plate Materials o x6 Flat 8 1 Steps 1 Punch the smaller holes as shown 2 Torch the center hole 3 Grind away the slag Hinge Rod Materials e 5 Round 50 1 Steps 00 2X D 13 1 Drill a hole as shown at each end of the rod THRU Parts Assembly Additional Piece Parts 23 Hinge Pin Materials 4 00 7 e 5 Round 4 2 You need 2 of these Steps 2X D 13 1 Drillthe holes as shown THRU Parts Assembly Front Frame 24 Assembly Front Frame An assembly video is also available Note that not all steps will be the same as some parts still need to be welded or bent Follow the written instructions Tools Materials e Fasteners 1 x3 x2 25 Bolts 2 1 Washers 4 1 Nuts 2 x5 5 x1 75 Bolts 2 x1 25 Bolts 2 Xx1 5 Bolts 4 34
16. ubes as shown e Use the long bolts You need washers on each side of the bolts 8 Loosely bolt the bearings to the shaft and motor frame as shown e You will tighten the bolts in a later step e Use the 9 16 bolts with a washer near the nut Parts Assembly Bend the tines 26 Assembly Bend the Tines Tools Materials e Pipe wrench e Assembled Parts e Mallet o Tines o Bucket Front Frame o Shaft Procedure 1 Hammer the shaft through one bearing as shown so the hole for the coupler is positioned as shown e Angle it to the side to allow room for the tines to slide on 2 Slide all tines on the shaft so they are all oriented in the same direction as shown 3 Usea pipe wrench to bend each of the tines as shown If it is too 135 00 difficult you can use a torch to heat them up l gt e Their shape doesn t need to be precise e Make sure you bend each piece as in the lower image un 38 Parts Assembly Install Shaft and Motor 21 Assembly Install the Shaft and Motor Tools Materials e Mallet e Assembled Parts e x2 5 Bolts 2 e oi o Bucket Front Frame e Y Nuts 2 e Ratchet socket set o Motor Mount Plate e Y Washers 2 e Socket extension e Motor e 3 8 x3 Bolt 1 e Lock Collars for Bearings e 3 8 nut 1 e Allen Wrench e x1 25 Bolts 12 e Loctite e x2 Bolts e Nuts Galvanized 2 e Y Washers 2 Procedure 1 Place the lock collars on the
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