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  • Home made air cylinder

    Ok guys, those of you who are familiar with me, know how I like to make stuff. I have always been fascinated with hydraulics. Here is a cylinder I made from scrap material. A lot of you have lathes and making a piston or a rod or an end cap is not much of a chore. But...trying to make the cylinder with a smooth bore that is accurate is difficult if not impossible for the home shop.
    My neighbor had a new deck put on the front of his house and for ballisters they used 3/4 inch round black aluminum tubes. There was scrap left over and being who I am, I saw visions of what I could make. The tubes are 3/4 inch OD... .654 ID with a very smooth bore. On the box it said this was 6061 extruded aluminum.
    With this size bore and at air pressure of 100 psi you can expect about 33 lbs of push from this little cylinder, which is more than enough power to open large tool box lids, robotics, etc (your imagination is your only limitation).
    The first pictures show the end caps I made from aluminum and the rear end cap and piston have been grooved to accept O rings to seal better. This is a single acting cylinder and no seal at the rod end. The rod is 1/4 inch.
    The threaded hole in the rear cap is 1/8 inch pipe thread which is very common. The fitting is 1/8 inch pipe thread on one side and 1/4 inch compression fitting on the other which makes it very handy to use 1/4 inch aluminum, copper, or flexible plastic line for your air supply. The last picture shows the cylinder assembled. There is no rod end because I have not yet decided how I will apply this.
    At first, I had thought I might TIG the caps on but I was afraid that I may slightly distort the cylinder from the heat. If you will notice, on the end caps, enough of the cap is inserted into the cylinder that I could pin it in place with 1/8 inch roll pins. That is why I put an O ring on the rear end cap and the pin is between the O ring and the brass inlet fitting.
    One good thing about finding this resource (as far as the cylinder) is you can custom make any length you need to fit your exact need. I am going to check into a larger ballister tubes for more power.

    I hope some of you will find this useful.
    Nick
    PS I suggest you use a restrictor orifice at the air inlet so the piston/rod will slam out too quickly.
    Attached Files
    Last edited by monte55; 11-25-2007, 11:31 AM.
    Nick
    Miller 252 Mig
    Miller Cricket XL
    Millermatic 150 Mig
    Miller Syncrowave 200 Tig
    2-O/A outfits
    Jet Lathe and Mill
    Jet 7x12 horz/vert band saw
    DeWalt Multi Cutter metal saw
    Century 50 Amp Plasma Cutter
    20 ton electric/hydraulic vertical press
    Propane Forge
    60" X 60" router/plasma table

    www.youtube.com/watch?v=jTu7wicVCmQ
    Vist my site: www.nixstuff.com
    and check out some of my ironwork and other stuff

  • #2
    COOL PROJECT.
    it looks like the cap's are long enough you could TIG the lip at the end without distorting into the slide portion of the tube. it would no longer need the seal if it was tiged closed, so you would not need to try to keep from melting it, just keep the slide clear of the heated end as you were TIGing it. although that would make it impossible to service if it was TIGed closed. so maybe its better the way you left it.

    so what do you think it will end up on ????
    thanks for the help
    ......or..........
    hope i helped
    sigpic
    feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
    summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
    JAMES

    Comment


    • #3
      Hey Fun............If you remember some months back I put a post and a link to a youtube video of my r/c 4 wheel skid steer bot as I call it. The entire top
      swings forward like a cab on a 18 wheeler. Whenever I need to get to the inside I prop it up with a stick of wood. Rather redneck.....huh? Since it already has an air tank on it for the front forks, it could also lift the cab. How cool would that be. Kind of like a lowrider bra! If you need to refresh your mind go to youtube and put GOT BOT? in the search bar.
      Nick
      Nick
      Miller 252 Mig
      Miller Cricket XL
      Millermatic 150 Mig
      Miller Syncrowave 200 Tig
      2-O/A outfits
      Jet Lathe and Mill
      Jet 7x12 horz/vert band saw
      DeWalt Multi Cutter metal saw
      Century 50 Amp Plasma Cutter
      20 ton electric/hydraulic vertical press
      Propane Forge
      60" X 60" router/plasma table

      www.youtube.com/watch?v=jTu7wicVCmQ
      Vist my site: www.nixstuff.com
      and check out some of my ironwork and other stuff

      Comment


      • #4
        Nice job Monte. Be interesting to see it in action.

        Hopefully I have the time someday to play around a little more and experiment like that.
        Ken

        What else is there besides welding and riding. Besides that

        Miller Thunderbolt XL 300/200 AC/DC
        Hobart Handler 187
        Dewalt Chop Saw
        4" Air Grinder
        Die Grinder
        Rigid Drill Press
        Kellogg 10hp Air Compressor


        2009 FXDC

        Comment


        • #5
          Originally posted by KBar View Post
          Nice job Monte. Be interesting to see it in action.

          Hopefully I have the time someday to play around a little more and experiment like that.
          Are you talking about the cylinder or the BOT on youtube?
          Nick
          Miller 252 Mig
          Miller Cricket XL
          Millermatic 150 Mig
          Miller Syncrowave 200 Tig
          2-O/A outfits
          Jet Lathe and Mill
          Jet 7x12 horz/vert band saw
          DeWalt Multi Cutter metal saw
          Century 50 Amp Plasma Cutter
          20 ton electric/hydraulic vertical press
          Propane Forge
          60" X 60" router/plasma table

          www.youtube.com/watch?v=jTu7wicVCmQ
          Vist my site: www.nixstuff.com
          and check out some of my ironwork and other stuff

          Comment


          • #6
            STUCK IN DIAL UP HE--. no you tubeing for me.
            got a still shot of it ??
            sounds like a good plan to lift but will the home made tubes hold without sustained air flow ?? how good are the seals ??
            thanks for the help
            ......or..........
            hope i helped
            sigpic
            feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
            summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
            JAMES

            Comment


            • #7
              Originally posted by monte55 View Post
              Are you talking about the cylinder or the BOT on youtube?
              The cylinder and the BOT. I have an old golf cart I want to rip apart. Plans were to make a little dump truck with dual axles. That fell by the way side for now.
              Last edited by KBar; 11-26-2007, 08:15 AM.
              Ken

              What else is there besides welding and riding. Besides that

              Miller Thunderbolt XL 300/200 AC/DC
              Hobart Handler 187
              Dewalt Chop Saw
              4" Air Grinder
              Die Grinder
              Rigid Drill Press
              Kellogg 10hp Air Compressor


              2009 FXDC

              Comment


              • #8
                Still photos of bot







                Pictures inserted by Mrs Nick, so he may come back and edit this.
                Last edited by monte55; 11-27-2007, 10:41 AM.
                Nick
                Miller 252 Mig
                Miller Cricket XL
                Millermatic 150 Mig
                Miller Syncrowave 200 Tig
                2-O/A outfits
                Jet Lathe and Mill
                Jet 7x12 horz/vert band saw
                DeWalt Multi Cutter metal saw
                Century 50 Amp Plasma Cutter
                20 ton electric/hydraulic vertical press
                Propane Forge
                60" X 60" router/plasma table

                www.youtube.com/watch?v=jTu7wicVCmQ
                Vist my site: www.nixstuff.com
                and check out some of my ironwork and other stuff

                Comment


                • #9
                  Still phots of bot, two more





                  Notice the "High Tech" board I held up the bot cab with. I hope to replace this with the air cylinder I just made.
                  Nick

                  Photos inserted by "the Mrs."
                  Last edited by monte55; 11-27-2007, 10:42 AM.
                  Nick
                  Miller 252 Mig
                  Miller Cricket XL
                  Millermatic 150 Mig
                  Miller Syncrowave 200 Tig
                  2-O/A outfits
                  Jet Lathe and Mill
                  Jet 7x12 horz/vert band saw
                  DeWalt Multi Cutter metal saw
                  Century 50 Amp Plasma Cutter
                  20 ton electric/hydraulic vertical press
                  Propane Forge
                  60" X 60" router/plasma table

                  www.youtube.com/watch?v=jTu7wicVCmQ
                  Vist my site: www.nixstuff.com
                  and check out some of my ironwork and other stuff

                  Comment


                  • #10
                    nice to be able to see under the cover. Looks like alot of fun and challenge.
                    What are the two servo's on the front right corner running? how many channels do you need for this app? 4 or 5?
                    whats just to the left of the reciever and at about the same hieght?

                    are those grey cables to feed the motor(s) ?

                    if I may offer a suggestion, reroute the inter battery connecting ground wire and pass it under the diehard's + post. the ground looks as if it is sitting on top of the diehard + post. That could spell disaster.

                    All in all a nice rig Nick. Do you think you'll ever enter a robowar competition?

                    one day i'm going to make one too. I could have picked up a mobile electric seniors chair the other day. I didnt and now im kinda kickin myself. It was a battle of space and time. I have neither the space or the time right now..
                    too many planes and cars and boats and work and homework and life and and and
                    Last edited by SignWave; 11-27-2007, 08:27 PM.
                    Will it weld? I loooove electricity!

                    Miller 251/30A spool
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                    O/A
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                    Comment


                    • #11
                      hey nick,that is one kick *** little bot you made there,cool i fly r c helis and planes myself,question? where are the servos? how do you control turning and reverse ? electric speed controller?

                      Comment


                      • #12
                        Originally posted by SignWave View Post
                        nice to be able to see under the cover. Looks like alot of fun and challenge.
                        What are the two servo's on the front right corner running? how many channels do you need for this app? 4 or 5?
                        whats just to the left of the reciever and at about the same hieght?

                        are those grey cables to feed the motor(s) ?

                        if I may offer a suggestion, reroute the inter battery connecting ground wire and pass it under the diehard's + post. the ground looks as if it is sitting on top of the diehard + post. That could spell disaster.

                        All in all a nice rig Nick. Do you think you'll ever enter a robowar competition?

                        one day i'm going to make one too. I could have picked up a mobile electric seniors chair the other day. I didnt and now im kinda kickin myself. It was a battle of space and time. I have neither the space or the time right now..
                        too many planes and cars and boats and work and homework and life and and and
                        The grey cables are to the two motors
                        I'm using 5 channels now....left stick controls left side, forward stick forward and back is reverse....Right stick controls right the same way.
                        Left stick...left and right controls a relay thats switches power from 12 to 24
                        VDC to provide 2 speeds. A variable speed control for r/c and these size motors would be be very expensive....$5-$600 when I checked about six years ago when I built this.
                        Right stick.....to the right opens an air solenoid to raise the front forks.
                        to the left opens a different solenoid to let the forks down and also a loss of some air per cycle. The air tank is a 50 lb freon drum.
                        The forks will lift about 150 lbs.
                        The 5th channel(retracts switch) turn the headlights and taillight on and off.
                        The receiver gets its power from a Radio Shack 12 v power thing w/different outputs for cd players etc.
                        To answer another persons question....the bot is a skid steer like a Bobcat.
                        It has a lot of torque plus it's just fun to mess with. Sometimes I put a wireless camera on it and control it from inside my shop with the door closed
                        watching a tv. That's harder than one would think because of a single straight ahead view.
                        But it also does work around here. It pulls my 3 seater Jet Ski on trailer around and sometimes with the small lawn trailer I have in the idea gallery, it hauls yard stuff etc. Originally I made this to go get my morning paper on slick icy days but I just got carried away. Maybe just a bit of overkill. The contactors, micro switches all come from air conditioner parts and icemaker stuff. The contactors are 24VAC but work fine on 12VDC.
                        The only thing bought new for this were the sprockets and chains and headlights. Even the cab is modified a/c metal housings welded together. If you haven't seen it go to youtube and enter GOT BOT? and see the video.
                        Later
                        Nick
                        Miller 252 Mig
                        Miller Cricket XL
                        Millermatic 150 Mig
                        Miller Syncrowave 200 Tig
                        2-O/A outfits
                        Jet Lathe and Mill
                        Jet 7x12 horz/vert band saw
                        DeWalt Multi Cutter metal saw
                        Century 50 Amp Plasma Cutter
                        20 ton electric/hydraulic vertical press
                        Propane Forge
                        60" X 60" router/plasma table

                        www.youtube.com/watch?v=jTu7wicVCmQ
                        Vist my site: www.nixstuff.com
                        and check out some of my ironwork and other stuff

                        Comment


                        • #13
                          cool toy.
                          good way to get the morning papper if ya ask me, not over kill at all.
                          thanks for the pic's.
                          thanks for the help
                          ......or..........
                          hope i helped
                          sigpic
                          feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
                          summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
                          JAMES

                          Comment


                          • #14
                            Very, very interesting!

                            The Bot kind of speaks for itself, real nice! I was more interested in your hydraulics's (knowledge). Now please PLEASE bare in mind I know little if nothing about them but am interested in learning because I have a project (personal) that I'm going to undertake some day that will require custom hydraulics. I have studied schematics on their structure and operation and could probably fake one if I had to. But my problem is that I have never been able to understand how to develop a rating i.e 5 ton, 10 ton etc. Or perhaps to better put it, how would one go about building a 5, 10 or 15 ton jack? Is there a formula such as: cylindar lenght, width, piston design etc. Or is it based mainly on psi?

                            Been wondering, any thoughts?

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                            • #15
                              Cool

                              Thats pretty darn neat! Now if you could only adapt a mower deck and GPS to automatically mow the lawn

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