Need some more photos...

Here are some photos of the new way I am doing the Crown Wheel.  Unfortunately, I stopped taking photos later in the process.  When I get back to the forge, I will update with more photos.

Starting with a straight piece of metal, I mark where the spokes will connect to the Crown Wheel.

 

I then punched rectangular holes.

 

I make a quick hacksaw cut through the top.  It is intentionally slanted.  This is to make it easier to fold them back over and have them contact each other.

 

The two top pieces folded open.  This is what I am doing new.  This lets the hub and spokes to just be dropped into the Crown wheel.

 

Finally, this picture shows the wheel being bent into shape using a circle on the layout table as a guide.  Also notice that it has the spokes drawn so I can be sure its lining up.

 

I actually did get to the point where the Crown Wheel is fully formed.  The hub and spoke drop into it nicely.  In fact, the only problem is that I made the openings a little too big.  I think I am going to go ahead and connect the two to make sure the process works, then I will try making it again.  The good news is that I am getting very quick with it and the new job is settling down so I should have more time.

No pictures yet but did get some more work done.

  Due to starting the new job, didn't have as much time this weekend as I would have liked.  However, I did still manage to get some forge work in.  I decided to spend the day trying out some techniques for making a new Crown Wheel.  Basically, it is how I connect up the hub to the outer ring of the Crown Wheel.  I tried a few variations but finally found one that produces good results, is relatively easy and it appears it is a viable way that it may have been done on the original.  I'm planning on next weekend being the weekend I finally remake the Crown Wheel.  I really, really will try to get up some pictures.  Words cannot quite describe how I am doing the Crown Wheel this time.

  A good bit of news on the Crown Wheel.  I did discover a hub that I had made on a previous attempt to remake the Crown Wheel.  A quick glance at it and it looks like it would be perfectly fine to use in the new wheel.  I have to take a better look at it.  This would be good because one of the most time consuming parts is make the hub and spokes.

Very good weekend

This weekend was productive. I was able to remake the Crown Wheel arbor (axle). I am typing this on my phone so I will write more with photos when I get a chance.

Working some over the Holiday

I've worked off and on over the past few days and I've made some good progress.  Chiefly I remade the verge and foliot.  I am going to try re-making the Crown wheel and its arbor hopefully tomorrow.  Pictures and possibly videos to follow.

Hopefully some real progress coming soon.

  So I am ending my current job to go on to a better job.  My current job ends tomorrow but my new job doesn't start up until a week from Monday.  Also, no plans for Thanksgiving (not that big of a holiday to me) so wife and I are going to stay home.  What that means is that I hope to have a week to work on the clock.  My goal, and its going to push me, is to have the clock actually ticking.  It is a lot of work but doable.  If I can get the clock ticking, then it will be incredible motivation to push forward.

Tool day...

  Was going to work on the verge and foliot assembly yesterday but after a small mistake, I decided I needed to take a step back and make some tools.  So today, made a trip out to pick up some tool steel.  Made several punches and a bending fork.  Not exciting but it was related to working on the clock.

Here's the video...

[youtube http://www.youtube.com/watch?v=Uw7MCwZrIDY]

Rather than make excuses or give explanations, lets just say I'm working on the clock again.

So, seems like a broken record but I'm finally back to working on the clock.  And now we have video!  Anyway, I've been working on redoing the part that holds the oscillating verge and foliot.  Like so many parts in the past, I'm having to redo them.  I'm pretty happy with the results.  So, without further ado, some pics....

What you are looking for here is the attachement that comes off of the top of the clock and is used to hold the vaguely T shaped piece hanging by the wire.  I've made this part several times before but I think I'm finally happy with it.  The T shaped piece (the foliot) will be remade or reworked eventually but I'm pretty happy with the results.  I have some video and as soon as I upload it, you will have a better idea how it works.

Back to work and a good day

  After taking several weeks away from the forge to let my elbow rest(bad tennis elbow), I was back on the forge yesterday.  My arm held up well and I think that part of the problem was that I was using the wrong length hammer handles.  I had bought a new handle that had a better fit and found myself using a 3 pound hammer all day when in the past I've had trouble with using the 3 pounder for more than half an hour.

  Anyway, I got back to work on a post that helps support the verge and foliot.  The smithing work is now done on the post and I am doing cleanup work with files.  I didn't take any new photos but this is a photo of the old post to give you an idea of the part I am talking about.  Look for the piece that is just to the left of center of the photo..  It is coming out of the top of the clock.

 

  I remade this piece due to some issues with it not fitting quite right and partly because I could have done better with the overall appearance.

  I am switching to doing more file work for the cleanup on the pieces.  In reality, that was the mistake I frequently have made in the past.  Because file work can be slow and tedious, I tended to avoid it.  With this project I can't do that.

  I did finish the forge work on the piece and then I tried something new.  I let the piece soak in muriatic acid (basically, hydrochloric acid) for about 30 minutes.  This helps to break apart any scale on the surface of the piece and makes it easier to file.  For any other smiths reading this, muriatic acid is nasty stuff.  If you don't want to work with it, you can also use vinegar but you need to let it sit overnight.  I started in on the file work and I'm happy with the results so far.  I promise new pictures soon.

  With the time change last weekend, I will now have another hour of daylight in the evenings.  What that really allows me to do is get on the forge after work more easily.  I hope to get this moving.

Started back on the clock

  I finally got back to doing work on the clock today.  I'm working on a part I've made or started to make at least 4 times already.  However, I think I'm on the right approach this time.  Everything is looking nice and clean.  The part I am working on is a portion of the assembly that is used to hold the verge and foliot (the tic-toc part of this kind of clock.)

  Although things are looking good, I did not get as much progress as I wanted.  I started to get some pain in my elbow and from what I am reading, it is probably tennis elbow.  So I may have to put the hammer down for a bit.  Really sucks since I was looking forward to making progress.

Finished the layout table

  Finished up the layout table today.  Its actually pretty neat.  I built it so it actually pulls out from the work bench so its out of the way when I don't need it.  Since space is a bit of a premium for me, I have to do these kinds of things.  Anyway, it didn't come out perfect but it is workable.  I'm anxious to get back to the clock so I'm not going to worry about doing any shop improvements for a bit.  I want to get a few parts done because I am anxious to see some progress. 

Bad weather but still got some stuff done

  Unfortunately, bad weather kept me from doing as much this weekend as I would have liked.  Didn't get as much done on the clock but I did manage to nearly complete my new layout table.  The layout table is critical to me doing a better job with making the gears.  Its really just a table with a metal top.  I've made a custom one on my work bench that easily slides out and sets up for when I work.  Just need to trim the metal a bit more and then attach it to the table top.

Gonna try something new

  I had fun this past week.  I went to the John C. Campbell Folk School in North Carolina for a week long blacksmithing class.  Although the focus was locks, my personal goal was more to focus on precision and cleanup type activities.  I completed my lock (I may make a second to improve my work) and mostly completed a pair of dividers.  For whatever reason, the dividers were more interesting to me.  I think just because I could potentially use them to help with the clock.  I also had a chance to ask the instructor about some of the issues I've run into with making the clock.  I got some very good helpful hints that hopefully will make me move forward with this project.

  I also had to seriously look at my own work.  The clock has made no serious progress in about 3 years now.  I was struck by the fact that most of the clock parts (I took them with me to the class) had some rust on them.  They also weren't the best made.  If I am ever to complete this project (and I really want to) I need to make a complete mental shift on how I do things.

  I have to be more disciplined about this project.  To that end, I've started to put together a worksheet with time tables of when certain things should get done.  I'm not going to rush work to complete on time but I want to use it to keep myself honest and moving forward.  I hope to use some of the momentum from my class this past week to jump start working on the clock again.

  So, on the agenda for this week are two items.  The first is to complete a pull out layout table that is attached to my workbench.  This table will allow me to layout and work on the gears more easily.  The second bit to remake the verge and foliot support.  That is what I have scheduled for next weekend.

  Hopefully I can push and complete a major portion, if not all of it, by the end of this year.