1. P.R.P.F Pimp Russ’ Portable Foundry Project Advisor: Russ Rosmait Chase Butcher Cody Haddock Mike Verren 5/27/07

2. Reason for Build Increase awareness Education Portability Sure beats building a moonbuggy

3. Design Concepts

4. Old Concept

5. Furnace Lifting Arms

9. Lifting Arms

10. Lifting arms (cont.)

11. Lifting Arm Analysis

12. Design Concept (lifting arms)

16. Jack Levelers CB

17. Storage Box Assembly 2 boxes-72” X 13” X 15” 3-13” X 20” doors Commercial Welded Hinges Welded construction Sealed joints (rain, snow… etc.) Total volume of each Box 16,200in^3

18. Assembly

22. Testing Hydraulic System –Hydraulic Cylinder –Pump (110vac) Calculations-Statics, Fluids CB

23. Testing Muller –Mounting, Run Test CB

24. Testing Propane/Furnace –Fuel requirement for two melts –Safety CB

25. Fuel Consumption 18 lb bottle 20 lbs of propane 2 lbs for every 15 minutes Can run furnace for 2.5 hours There will be a back-up bottle

26. Process Plan Clean up workspace –Organize garage Axle/ Fenders –Disassemble fenders and axle from frame –Torch fenders –Unbolt axle assembly –Block up frame Framework –Add support where needed

27. Process Plan Deck –Cut out correct dimension using water jet –Bolt to frame Boxes –Cut out correct dimension using water jet –Weld and assemble –Seal

28. Process Plan Hydraulics –mount –plumbing –position and install Furnace arms assembly –Cut out correct dimension using water jet –Machine shaft –Assemble and install Muller rebuild –Refurbish inner and outer plows –Purchase and install pressure spring for wheels

29. Process Plan Furnace rebuild –Purchase a new fire eye Paint –Paint and detail works Lighting/Electrical(110 vac) –Run wire and tail lights –Power switches for devices

30. QC issues Furnace arm mechanism Load distributions Overall functionability

31. Trailer Weight Calculations Trailer frame460lbs Furnace500lbs Muller175lbs Propane Fuel38lbs Hydraulics120lbs Fire Extinguisher30lbs Green Sand100lbs Water42lbs Dry Sand50lbs Aluminum pigs50lbs Safety equipment & tools100lbs

32. Trailer Weight Calculations Aluminum Decking/Boxes 4 sides 72" * 15" * 0.188"80lbs 2 ends 13" * 15" * 0.188"7lbs 1 top 72" * 13" * 0.188"17lbs 2 tops 36" * 13" * 0.188"18lbs 1 bottom 72" * 57" * 0.188"76lbs 1 cover 36" * 31" * 0.188"21lbs Total weight1884lbs

33. Budget DescriptionQuantityQuoted price (per unit)Actual cost Hydraulic System 36” Ram1$104.99$ 6” Ram2$76.99$ Pump and reservoir1$499.99$ Hydraulic lines6$20.00$ Hydraulic Valve1$99.99$ Electrical System Generator Head1$435.00$ Trailer light kit1$29.99$ Trailer wiring harness 1$5.99$ 5 strand trailer wire1$6.99$

34. Budget DescriptionQuantityQuoted price (per unit)Actual cost Jacks Tongue Jack1$30.00$ Stabilizer jacks4$85.00$ Fuel System 20 lb Propane tank2$150.00$ Fuel line1$41.94 Fuel fittings1$1.44 Running gear Tires 2$125.00$ Wheels2$125.00$ Axle kit (includes)↓$ Leaf springs↓$ Axle↓$ Hubs↓$ Bearings (inner & outer) ↓$ Spring hangers↓$ Spring shackles1$240.00$

35. Budget DescriptionQuantityQuoted price (per unit)Actual cost Sand reclamation System Vacuum motor1$$ Hose1$$ New muller lid1$$ Screen / filter1$$ Material C Channel12 ft$$ Bar Stock8 ft$$ Mounting bracket material 6 ft$$ Boltsx Hingesx Pinsx$$ Safety Fire extinguisher1$20.00$ Safety Stickersxx$39.99$ Total$2,138.30

36. The Build

37. Axle Installation/Framework

38. Framework

39. Jack Stabilizers

41. Deck

42. Deck (cont)

43. Boxes

44. Box Doors

45. Hydraulics

46. Hydraulics (cont)

48. Furnace Lifting Mechanism

49. Furnace Lifting Arm Video

50. Muller/Vac System

51. Muller Vac System (cont)

53. Vac System

54. Lighting

56. Electrical

57. Electrical (cont)

58. Safety Issues Furnace Molten metal Sand in the eye

59. Actual Budget DescriptionQuantityQuoted price (per unit)Actual cost Hydraulic System 18” Ram1$164.99$ $ Pump and reservoir1$429.99$ Hydraulic lines6$20.00$ Hydraulic Valve1$69.99$ Electrical System $ Trailer light kit1$24.99$ Trailer wiring harness 1$5.99$ 5 strand trailer wire1$6.99$

60. Actual Budget DescriptionQuantityQuoted price (per unit)Actual cost Jacks Tongue Jack1$52.00$ Stabilizer jacks4$85.00$ Fuel System 20 lb Propane tank2$150.00$ Fuel line1$41.94 Fuel fittings1$1.44 Running gear Tires $ $ Axle kit (includes)↓$ Leaf springs↓$ Axle↓$ Hubs↓$ Bearings (inner & outer) ↓$ Spring hangers↓$ Spring shackles1$150.00$

61. Actual Budget DescriptionQuantityQuoted price (per unit)Actual cost Sand reclamation System Vacuum motor1$$ Hose1$$ 1$$ Screen / filter1$$ Material Locks5$18.15$ electricalx131.87$ Welding Machining 200.00 480.00 $ miscx57.80 Hinges1499.96 $ Safety Fire extinguisher1$14.99$ Total$2206.09

62. Funding Russ’s checkbook $3000.00 PSU$100 Student Contribution $300 Donations Total$3400.00

63. Week 1Week 2Week 3Week 4 Tasks October Muller test Furnace test / Melt test Hydraulics review November Pricing Design review December Order materialsBreak

64. Week 1Week 2Week 3Week 4 Tasks January Install axle Install base plate Break Start of Build Build Storage Boxes February Furnace lifting arms Hydraulic system Shakeout grating March Start Trial Testing Trial testing April May

65. Build Time Jan. 20 th - April 25 th –Customer Requirements CB

66. Fragen?