Lead Contributors:

Graham Coffman

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Source File:

OSE CEB Press 6 Development Board

Fabrication Drawings

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Graphic Design:

Jean-Baptiste Vervaeck

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Version:

Date:

CEB Press 6 Hopper Module

Assembly Instructions

Open Source Ecology Developer’s Manual

CEB 6 Press

Hopper Module Assembly Instructions

Graham Coffman | Open Source Ecology

Table of Contents

• Equipment
• Tools
• Welding procedure
• Materials
• Hopper assembly instructions
• Assembly Time and Difficulty
• Steps 1-9
• Hopper Seat Assembly
• Survey

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Equipment

• Some of the materials handled in this assembly are extremely heavy. Use caution.
• Safe clothing
• Steel toe boots
• Pants
• Long-sleeved shirt
• Protective gloves
• Safety equipment
• Protective eyewear
• Welding mask
• Welding gloves
• Ear protection
• Hard helmet
• First aid kit
• Fire extinguisher
• Emergency shower
• Eyewash station

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Tools

• MIG Welder x 1
• Impact Driver x 1
• Grinder x 1
• Measuring tape x 1
• Sharpie marker x 1
• Ironworker machine x 1
• Framing square x 1
• Metal punch x 1
• For more info, refer to Tutorial on Tools and Their Uses

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Welding Procedure

• MORE INFO ON WELDING AND GRINDING
• Make sure the table is clear of bumps and scrap metal
• Grind spatter and bumps from your weld table; the table down for easier assembly
• Welding heats the metal to high temperatures so the metal will warp if not careful
• To minimize warping, tack weld all parts first in different places first
• Then spread the weld apart into many different places, not closing any gaps until the very end
• Order the welding so each wield are far apart from the previous weld, welding about 2%, then 5%... 10%... 20%... 50%... 100% at each spot.
• Millermatic 200 welders - use High Voltage, 2 power setting, 60 wire speed.
• See procedure for replacing liner

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Materials

• Metal front panel (H1) x 1
• Metal back panel (H2) x 1
• Metal side panel (H3, H4) x 2

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H1

H2

H3, H4

x 1

x 1

x 2

Materials

• [2] Metal stock sections
• Cut into 30” metal hinges (H5, H6, H7, H8) x 4
• [16] ¾” nut
• [16] ¾” x 1.5” bolts

H5, H6, H7, H8

x 4

x 16

x 16

Materials: Hopper Seat

H9

H10

H11

H12

H13

Hopper Assembly Instructions

Step-by-step

Assembly Time and Difficulty

• Assembly time:

4 hrs., 30 min.

• Difficulty: 6/10
• Assembly requires some heavy lifting and novice welding skills
• Three people required for lifting at specific points when moving, rotating and clamping the hopper for welding

Step 2 (5 minutes)

• Using the Sharpie marker, label all panels and hinges on the side shown - H1, H2, H3, H4, H5, H6, H7, H8
• Note: H1 and H2 are not symmetrical

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H1

H2

H3

H4

Step 4 (20 minutes)

• Grind down sharp edges and corners.

H1

H2

Mark hinge holes with H1&H2 as templates.

Determine distance of hinge from bottom by looking at the other machine

Step 5 (40 minutes)

• On the labeled side of H3 and H4, half weld (weld 3 of 6 sides of hexagonal nut) one ¾” nut over each of the eight holes
• Note: The labeled side of H3 and H4 face towards the inner side of the hopper
• Caution: Do not make 2 identical parts - they should be mirror images

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H3

H4

Do this for H1 & H2, not H3 and H4

Step 5 cont.

• To ensure alignment of the nuts, loosely screw in the ¾” bolts through the holes while welding
• Cover the threads (with tape) to avoid welding spatter on threads

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INNER SIDE OF THE HOPPER

This is correct

Step 6 (25 minutes)

• Attach H5 and H7 to H3 by screwing one ¾” bolt through each of the eight holes and nuts
• Do the same to attach H6 and H8 to H4
• Leave the bolts fairly loose

H5

H3

H5

H7

H6

H8

H4

Hinges were not drilled yet. Lay down H1& H2, and mark the holes.

Mag drill holes.

Then

Step 7 (40 minutes)

• To secure Hopper components for welding, clamp to a table or position in the Hopper seat
• Simultaneously tack weld (1) H2 to the inside flap of H7 and H8 and (2) H1 to the inside flap of H5 and H6
• Note: Make sure the hinge ridges are facing out so that the panels come flush to one another

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Step 8 (40 minutes)

• At 2” intervals, (1) half weld H2 to H7 and H8 and (2) H1 to H5 and H6

H4

H1

H3

H5

H7

H2

H8

H6

Step 9 (20 minutes)

• Place the loosely assembled hopper into the hopper seat
• Using the impact driver, tighten the ¾” bolts to best fit the hopper to the hopper seat

H1

H2

Hopper Seat

Hopper Seat Assembly

Hopper Seat Assembly

H9

H10

H11

H12

H13

need pictures!

Hopper Seat Assembly

H9

H9

H12

H12

Hopper Seat Assembly

H9

H9

H10

H10

H12

H12

Hopper Seat Assembly

H9

H9

H10

H10

H12

H12

H13

H13

Hopper Seat Assembly

H9

H9

H10

H10

H11

H11

H12

H12

H13

H13

Survey

• Please rate the effectiveness of these instructions on a scale from 1 to 10, with 10 indicating they were most effective.

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• Which parts were most helpful? Why?

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• Are there any parts could be improved? If so, how?