Bender The Bubbler Build Thread

[Linny]

About fuckin time LOL

[scythe]

Might i suggest you use some electrical wiring for filler rod, i'm sure you have some laying around.
The older stuff is better as its a thicker more often a single core wire.

[Milky]

Next is the RC. 120mm in height, the same as the modules. 4 x 3/4" tubes.

I cut out the top and bottom plates using the circle cutter and then marked out using dividers the pattern to evenly place the 5 tubes. Then again used the turrent punch to cut out the holes. Filed the holes to take off the burr and the tubes fit really snug, have to use a slight tap of a hammer to get it all in.

Cut the 3/4" in the coldsaw and cleaned all burrs off with a file as to not take too much off the ends and to keep them square.

I also filed out the RC plate holes just enough to get a really snug fit. Now it is all ready to TIG apart from drilling two water line holes and cutting two pieces of 1/2" for the water lines. I will do this before TIG welding it.

20150715_134038_resized.jpg

20150716_142628_resized.jpg

20150716_135042_resized.jpg

20150716_143339_resized.jpg

20150716_143339_resized.jpg

[Milky]

20150716_142148_resized.jpg

20150716_142156_resized.jpg

20150716_142136_resized.jpg

20150716_143329_resized.jpg

[Milky]

Might i suggest you use some electrical wiring for filler rod, i'm sure you have some laying around.
The older stuff is better as its a thicker more often a single core wire.

Thanks for the offer but there was s none of that wire just lying around here sorry. I have ordered some boc copper tig weld rods so I can get a much better pool & flow than just using sheet. Just want no for them to turn up as they weren't in stock. Cost me $48 but will be well worth it. I figure that a roll of aquasafe soft solder and flu is about $50 so I was going to need to buy that if I was going to soft solder anyway.

[Milky]

Nice tig work mate :handgestures-thumbupleft: what amps were you running at?

Sorry mate, the welders at my workshop set up & test ran the TIG for copper for me. So after they said it was all good I came in and started welding and near error thought to look! When my filler rods come arrive and I start up again I'll let you know what settings I used. The welder uses a foot pedal to control amps so it is set then maintained by the user utilising the foot pedal. Our TIG is a massive unit that uses a big argon manifold which is outside the building and is permanently plumbed through the wall to the unit with multiple lines. This allows you to purge using a spare line to back gas the part you are welding up. I back gassed the module when it was welded by sealing up the ends with alloy tape.

[scythe]

I could have sent you a few bits of mine if you wanted, but it sounds like your sorted now.

[Milky]

Then I cut the downcomers for my plates.

15mm sits above the plate with 80mm below so a total length of 95mm

20150716_143939_resized.jpg

20150716_143939_resized.jpg

[Milky]

Quickly cleaned up the first module with some 3M Fine/Ultra Fine foam sanding pads by hand

20150720_133318.jpg

[Milky]

Finished flanging and cutting out the other sight glass modules. Ready to TIG them up. Here is a mock-up of Bender.

20150723_162154_resized.jpg

[drinka]

Nice tig work mate :handgestures-thumbupleft: what amps were you running at?

Sorry mate, the welders at my workshop set up & test ran the TIG for copper for me. So after they said it was all good I came in and started welding and near error thought to look! When my filler rods come arrive and I start up again I'll let you know what settings I used. The welder uses a foot pedal to control amps so it is set then maintained by the user utilising the foot pedal. Our TIG is a massive unit that uses a big argon manifold which is outside the building and is permanently plumbed through the wall to the unit with multiple lines. This allows you to purge using a spare line to back gas the part you are welding up. I back gassed the module when it was welded by sealing up the ends with alloy tape.

Sounds good thanks mate! :handgestures-thumbupleft:

[1 2many]

Looking real good Milky, very nice work. :D

keep the the pics coming. :handgestures-thumbupleft:

[Milky]

I'm going to butt up the downcomer caps right up to the bottom of the downcomers. To allow the distilate to flow, I have cut 2-3mm slots, 5mm high in the bottom of the downcomer tube.

20150728_120216_resized.jpg

I changed my mind on the idea of making a copper reducer as the only copper I had was too thin. So I went and bought a 4" - 2" reducer, 2 x 90 degree bends and a 2" - 3/4" reducer for the end of the PC. Also bought the brass 1/2" water connectors I'll need for the PC and RC.

20150729_143616_resized.jpg

I annealed the 4" of the copper reducer so I could flange it on the Jenny Form Roller. Results below...........Worked heaps better than what I thought it would...

20150729_131558_resized.jpg

Cut the 2" bits I need to join it all together and gave it all a quick sand with 3M pads.

20150729_160830_resized.jpg

[Milky]

Here it all is ready for TIG welding. And a quick go on the buffer to see how it will all look after a polish. After a polish I plan to clear coat it with High Temp clear coat

20150729_160929_resized.jpg

20150729_160952_resized.jpg

20150730_113641_resized_1.jpg

[rumdidlydum]

Looking wicked mate :handgestures-thumbupleft:
Nice an shiny :D

[Andy]

looking gooooood!!! :handgestures-thumbupleft:

[WTDist]

Looking good. I haven't the patience for making it shiny 8-} well done.

You have some excellent patience. Long time build thread :handgestures-thumbupleft:

[Milky]

Cut and flanged by hand on our metalworking stake table my 2" PC so it is 450mm long after flanging.

20150730_161957_resized.jpg

20150730_162007_resized.jpg

[Milky]

I used some flattened pipe offcuts to cut the ends for the PC. I have decieded to cut the flanged end to be the diametre of the flange itself. I will TIG this around the end and hopefully iy'll be heaps stronger than the ones I've seen that are easy flanges and only silver soldered as I've seen these crack overtime with the weight of the PC on it.

20150730_155732_resized.jpg

20150730_155738_resized.jpg

20150730_162016_resized.jpg

20150730_162041_resized.jpg

20150730_162104_resized.jpg

[Milky]

20150730_162118_resized.jpg