4" Lazy Boy Bubbler Build

[Dmnted]

Thought I would post up the start of my 4" perf plate bubbler build.
I am being lazy for a lot of the build because I have a mate who owns a mechanical engineering business, and I'm lucky enough that they are helping me out me out!

A run down on what I'm building.
Obviously it is a 4" perf plate modular bubbler
140mm plate spacing with 5 plates
3" sight glasses
3/4" downcomers with config yet to be determined.
5" reflux condensor with 7 x 3/4" tubes.
500mm x 2.5" product condensor with 4 x 3/4" tubes

Where I am cheating compared to most home builders. :oops:
I am using expanon ferrules to slip over pipe and avoid making ezy flanges which are reduced in length by a lathe
pipes cut with and industrial drop saw and cleaned up on 110mm bore lathe
Holes in 4" for sight glass, milled with cnc machine

What was achieved first weekend.

We first used a lathe to mill down the lenght of the expandon ferrules so they dont take up so much of the overall column length.

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We then cut our 4" pipe down to 140mmm lengths using an industrial drop saw and cleaned up the ends with a 4' bore lathe.

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A job was in the cnc machine so we couldn't mill the 3" sight glass holes in the 4" but that should be completed tomorrow. :dance:

[dogbreath vodka]

Damn it would be nice to have machinery like that to use...
Paint me jealous

The build is looking good dmnted
:handgestures-thumbupleft: :handgestures-thumbupleft:


DBV

[Yummyrum]

I love that look .Virgin copper pipe with a tight little band of Stainless........gone off for a toss :laughing-rolling:

Seriously ...it looks excellent....what are these expandon ferrule you refer to

[Kimbo]

Wow! keep the pics coming dude :handgestures-thumbupleft:

[Camikaze]

:text-+1:

Very cool mate :handgestures-thumbupleft:

[Dmnted]

I forgot to mention we also dropped a 3" holesaw through the 3" sightglass pipe to ensuer we had things perfectly squared today.
We will run a 4" through shortly to complete the sightglass t-piece.

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Yummy, The expendon ferrules I got here:
http://www.geordi.com.au/Products21d.htm
They do end up pretty expensive though when you add them all up!
Basically they are made to expand over the pipe with a little bit of heat and have a water tight seal.
I have found with copper they are about spot on with imperial size pipes and slide over with gentle persuasion but I will silver solder to be sure.

They are only bumped on with my hand at the moment but will be flush with the pipe end when it's cleaned and ready for solder.

[Dmnted]

Ok so time to update this thread again.

We dropped the 4 inch holesaw though the 3 inch to make the sight glass connections.

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We also used the CNC macine to cut out the 3 inch sight glass holes.

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Then slotted them together to test the fit.

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I have a 180 degree 2 inch and 3/4 inch bend on the way from overseas and hope to get them early next week and pretty much everything needed to silver solder on the way.
I have decided to use silver solder ssf-6 from muggyweld to get everything together.
http://muggyweld.com/silver-solder/ssf-6-starter-kit
Its expensive because its 56% silver self fluxing rodand apparently 1 inch flows to 18 inches.
I have NO experience soldering and an AWESOME member of this site has offered to solder things together for me. ^:)^ :handgestures-thumbupleft:

Today we got the first plate through the CNC machine.
106mm diameter with 1.5mm holes on a 5mm grid and 3/4" hole for downcomers.
My hands go up to those who do this themselves!!!
It would drive me crazy drilling all those holes and 5 times over!

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So I now have source some stainless fittings for water feed and drain on the product and reflux condensor.
I will be using push on stainless braided lines.
What ID is everyone using ?

I know most people dont have access to CNC machines but happy to post up the CAD files if anyone wants to walk into a shop with a cnc machine and pay them to mill plates out.
I also have files for a 4" reflux and 2.5" product condensore with 3/4" holes.

[coollinz]

Got some awesome gear to get that quality. Looks amazing. My lazy build is buying a complete one from Mac. :handgestures-thumbupleft:

[Dmnted]

In hindsight, I probably should have bought from Mac.
Damn this thing is turning out expensive! :crying-blue:

[Bushy]

Yes, but, you will have built this one yrself. Lookin real good mate. Build on.

[1 2many]

Coming along nicly Dmnted , wish i had those tools to play with far out too cool :mrgreen:

[Dmnted]

Thanks All, I am lucky I have access to these kind of tools.
Like I said before, I am in awe of people who do this by hand as it's pretty full on doing it with precision machines!

So all the plates were finished today.
Perf, Product & Reflux Condensor as well as two modular plates for a packed section.

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I assume with using ball valves to restrict flow, it doesn't really matter on the ID of water lines.
I think I will use 3/4" fittings for the water feed and return.

I am just awaiting a parcel to clear customs with 2" and 3/4" 180 degree bends, then I can look to get this puppy soldered all together :D

[Dmnted]

I need some feedback from some experienced members on the DC's.
I have visited this before in another thread.

I am looking to run my DC's 20mm above the palte.
I'm not sure how far beneath the plate i Should drop them?
I'm thinking, drop them down with the bottom of the 1 inch cap sitting 20mm above the plate below.
This way they are above the bath.

Should I go higher or lower or is it a matter of.... won't make much difference at all?

[Aussiedownunder01]

I need some feedback from some experienced members on the DC's.
I have visited this before in another thread.

I am looking to run my DC's 20mm above the palte.
I'm not sure how far beneath the plate i Should drop them?
I'm thinking, drop them down with the bottom of the 1 inch cap sitting 20mm above the plate below.
This way they are above the bath.

Should I go higher or lower or is it a matter of.... won't make much difference at all?

Come on somebody answer him I am about to start soldering as well
I have gone with Macks 3/4=1/2 idea just need to know how much drop

[MacStill]

isnt there enough information out there about downcomers ?

[Dmnted]

You are right mac.
Plenty of info out here which I have read alot of.
It appears that there are many different ways that all work which leads me to believe if there is not a general consensus, I am open to do whatever( hence my "wont make any difference" comment)
I posted what i intend to do but i guess what I was really after was, someone to pipe in who has experience and tell me there was no issues or suggest something different that may be a benifit in the operation

[Sam.]

If you can't find anything yourself here ya go

If your not happy with that find it yourself

[MacStill]

if I see something wrong I will say something, I'm just way too busy to give everyone all the answers ;-)

[Dmnted]

Cheers sam / liv
I hadnt come accross that in my searches.
I was possibly going to cap build at a later date which is why I have gone modular.

Thanks and Understood mac. You have given me the piece of mind I was looking for. :handgestures-thumbupleft:

I didnt want a "WTF did you do that for" after I soldered it all together 8-}

[Dmnted]

Just a little update.
I recieved my 2" and 3/4" copper 180 degree bends from ebay user "sister1252010" in china.
They were great with communcation and their product is great!
A little sanding is needed to get the 2" to fit aussie pipe but I am happy none the less.

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This is the 4" to 2" and 2" to 2.5" adapters sitting loosely in place.

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I also found a scap metal ebay / quicksales user who sells copper plate and pipe named "offcuts.galore "
Even small sections of 8" :shock:
Quick shipping and will cut to size with same day shipping
Hope it helps future builders source materials!