Headers are on Sep 17, 2018
I told you a while back that Karl, my son, was planning on installing headers on his 1966 6 cylinder Mustang that he uses as a daily driver. There were several reasons. The first was that the car was significantly underpowered, especially by today’s standards and was made worse when we added air conditioning. Second is that it had the original one barrel carburetor that always smelled of gas even though it was rebuilt twice. Third, the exhaust pipe donut gasket would only last about six months even though we had it professionally installed and checked out.
We began the installation by removing the old exhaust system and welding in a port splitter into the head. After that we spent about 15 minutes trying to install the headers and realized we did not have the time, equipment or skill to do this job. My backup plan was a local mechanic who specializes in old Fords. Like most jobs of this sort, it cost twice as much as planned and took three times as long. The radiator, AC lines, transmission lines, alternator and starter all had to be removed. Body work was done on the inner fender to clear the headers and the transmission lines and AC lines had to be rerouted.
The exhaust system was a generic V8 Mustang Kit from Summit Racing. We knew we would have to do some fabrication on the front part but even the tail pipes did not fit. Our mechanic took it to his buddy with a muffler shop and he fabricated a whole new system for $400 while using only the mufflers from the Summit Racing Kit. I swapped him the rest of the kit for the chrome tips.
The kit included a two barrel Webber carburetor with some generic linkage. The mechanic tried to fabricate a linkage but it had a real bad catch which would cause sudden acceleration. Once we had it back in our shop, we made a whole new bracket so that the motion was all down and back rather than up and back then down and back. This solved the problem.
Was it worth it? It is no speed demon but there was a 30% improvement in acceleration, even with the AC on, the smell of gas is gone. We think that the exhaust leak is permanently fixed and it sounds good. Most importantly, Karl is happy so yeah, it was worth it.
Uneven Reel Grinding Sep 8, 2018
I have been asked several times if reel grinding can cause the reel blades to be uneven. I made this video to explain what I think is happening.
Why Not Aug 30, 2018
I was at the YMCA the other day and saw this in the parking lot and thought to myself “Why would someone do this, make a BMW El Camino?” Upon closer look, they did a nice job. Fit and finish was very good and it did look pretty good. The inside of the box was finished in plywood but it may have been a work in progress. As I looked closer and admired it, I changed my mind and asked “Why not!”.
Revisions Aug 24, 2018
What is the difference between a politician and an engineer?
If it doesn’t work, an engineer will try something different.
Ya, I know, lame joke but it is funny because it is true. A while ago, I told you about our mobile work stations made from scaffolding. The first one I made was all set up to do wiring and pneumatics. It had an LED light and power for the tinning pot, a peg board with all of the tools required for that work and shelves with all of the small parts used to assemble component boards and switch boxes. The only thing it did not have was enough room. Another problem was that since the bins were open, the parts would be dusty after only a few months. We moved all of the small parts to sealed cases to be pulled out when needed. The work platform was re-tasked as our parts shipping station. The grinding wheels, which were across the aisle from shipping and located on the bottom of our machine racks were moved to mobile shelves behind the shipping station. This freed up extra rack space for more machines and allows us to easily move the shipping station when we scrub the floors. The mobile shelves and scaffolding both come from Northern Tool and run about $130 to$180 each. We bought the shelves on sale for about $80. So far the changes have worked out well.
Another design we tried that did not work was the type of glue we used to bond The Stone. It adhered well to the wood and rubber padding but did not hold once the granite slab was bonded. We changed to a different adhesive and now it works perfectly. The problem is that we made up a half dozen of the board bases with the old adhesive and it works well enough that you can’t remove the rubber padding which has been applied to both the top and bottom. Turns out they are the perfect size for many of our subassemblies and the padding both protects the subassembly as well as have just the right frictional coefficient so that it will only slide when you want.
Thomas Edison famously said “I have not failed. I've just found 10,000 ways that won't work.” At least it only took me a couple of tries to turn these failures into success.
Lies and damn lies Aug 18, 2018
I began my engineering career designing test simulators at Martin Marietta Aerospace (now Lockheed Martin). A wise old engineer told me that you need to have two different ways of testing for the same factor. If the tests gave compatible results, you could have a high confidence level in those results. If they were different, then you needed to devise a third test to break the tie.
One of the first times I used this concept at SIP concerned the speed of grinding. I had a lot of people tell me that the Peerless 2000 was much faster than my competitors. This is anecdotal evidence and not necessarily reliable. I went to a college that actually owned all of the grinders and asked them to test the grinding speed. They found that the Peerless was twice as fast as the Bernhard, three times as fast as the Neary, and four times as fast as the Foley at removing metal. That is very strong confirmation of the anecdotal evidence. But then I compared our video of a touch up grind to a competitor’s claim of “floor to floor in 5 minutes”. I have two videos that show a touch up grind taking 2-3 minutes which further bolster the claim that the Peerless is the fastest.
This brings me to the Twitter survey of a couple of weeks ago. I have always felt that SIP customers are more enthusiastic about our products based on the comments and feed back we get. While the Twitter survey would be considered unscientific for determining which grinder company is best, it does give us some useful data. I believe it confirms previous anecdotal data showing SIP customers are more enthusiastic about our products. While we came in second overall, if we divide the percentage by market share we get what I call the “enthusiasm factor”. SIP is first at about 5, Foley is second at about 1, Bernhard and Neary are tied for last at about .0.6. Beware the statistician, he can tell you whatever you want to know. Now if I could just turn that enthusiasm into more sales.
Much thanks to all who voted SIP!
Tool Tip Aug 10, 2018
I am in the process of writing the shop assembly manual for the Ideal 650 Bed Knife Grinder. One of the first steps is to assemble the pneumatic components. As I was tightening the NPT swivel elbows into the pilot valve, I was frustrated because the wrench would not easily engage the hex nut. A light bulb went off and I took the wrench over to the sanding belt. I ground two lead ins on the wrench. When I continued assembling the fittings, the wrench engaged much more easily without losing any contact area. I thought “I can’t be the first person to come up with such an obvious idea, or can I?” Let me know if you have ever seen this before so I can know if I am either a super genius or someone too dense to know what is what.
Boston Golf Club 3000 Rebuild Aug 4, 2018
I get a lot of questions about our remanufacturing program so I decided to make a little video of a Twitter thread I did last year chronicling the remanufacture of Boston Golf Club’s Peerless 3000 Reel Grinder. You can watch the video here.
Twitter Survey July 28, 2018
There is an interesting Twitter survey here that asks “What is the best reel grinder brand?” This is a pretty unscientific survey that is more about stroking egos than telling you which grinder is best, but it does indicate a couple of things. Considering that we have about one tenth the market share of Foley and Bernhard, 23% in this survey is pretty respectable. I have done another survey which may only be slightly more scientific. I asked as many people as I could who have used all three manufacturers’ grinders for at least a year each, what their preference was. In that survey, we scored well over 90%. Still not real meaningful. However, if you have a Twitter account, you can go the above link and vote. My ego could use a little stroking.
Machining a Balloon July 21, 2018
We took a radical approach when we designed our Reel Height Of Cut gauge. When everyone else was using aluminum flat bar, we decided to use thin wall, structural steel tubing. This kept the weight comparable but increased the stiffness by a factor of over 20. There is a set of holes in the center of the bar for the dial indicator to pass through with a round tube to guide the brass shield. The tube guide was located by a very shallow counterbore on the underside of the top surface and held in place by a retainer on the bottom of the main tube. Because the wall is so thin, the tolerance on both the counter bore and the length of the guide is very tight.
Any time you have to tighten tolerances, you increase the cost for two reasons. First, you have to be more careful and take more time to get it right. Second, you get it wrong more often so you get more scrap. Also, because of the thin wall, we got a lot of flexing when we machined the top surface; which had to be flat to .001 inches. The fixture is quite complicated so that it can hold the tube firmly without distorting it (the same problem you have when grinding bed knives). Our machinist likened it to “machining a balloon”.
The last batch of tubes proved especially difficult and we ended up with over half of them scrapped because the counterbore was too deep leaving virtually no lip to retain the guide. I was not happy, especially since we were backordering the RHOC gauges. I looked at several different ways to rework these tubes but did not really like any of them until I came up with the idea of tack welding the guide into the tube before we machined the top surface. This eliminated the counterbore and its tight tolerance and it eliminated the tight tolerance on the guide because any excess would be machined off when the top surface is machined. The best part is the welded guide added a lot of stiffness to the top surface right where we needed it. This makes machining the top surface easier and results in a better surface finish. Needless to say, we are able to salvage all of those scrapped bars and I have changed to this design for all future batches. The best part is that the RHOC is no longer back ordered.
Scrapped July 13, 2018
Occasionally, we will deliver machines instead of shipping them when the customer is close to the factory. We usually do this when the dealer is taking the old grinders in trade. We bring them back to the factory and store them for the dealer. Because they are not worth much, the dealer ends up giving them to us. We had one set of our competitors’ grinders in storage for several years. We looked at repairing them but the cost of the parts was more than the grinders would be worth. So even though they were only fifteen years old, we decided to scrap them. We got $67 for the reel and bed knife grinder. I was disappointed because that is my Christmas money. A quick calculation showed that we would have gotten about $105 if we had scrapped a set of our older grinders. Even though our grinders are more compact, they weigh significantly more because we use plate steel instead of sheet metal in the construction. Even better news, we will pay a minimum of $1,000 for any old Peerless 2000 or newer grinder regardless of condition. The one on the left in the photo went underwater twice in two weeks when a muddy river overflowed its banks…$1,000. The one on the right was left outside for an extended period of time…$1,000. Both of those will be completely disassembled and remanufactured to like new condition. The one in the middle is about 23 years old and was well maintained. It will be checked out and sold as used.
Brace Yourself July 7, 2018
A year and a half ago, I changed the design of the Ideal 6000 door. I added two braces to the top panel. This stiffened the door and provided better bonding of the panels to the frame. It also split the top panel into three smaller panels which means you can buy replacements at the local Lowes or Home Depot or we can easily ship them via UPS. The original 6000 door was all Lexan with no metal frame. If it became damaged or dirty, you had to replace the whole thing at a cost of over $1,000 with shipping. Now you can replace a damaged panel for about $30.
One of the main reasons that we made this change is that the top panel would come loose from the frame because it was so large. By splitting it into three pieces, the panels were much smaller with a larger taped surface. Two sided tape is used because it minimizes stress which can cause the Lexan to crack.
We now have a free upgrade kit for anybody who has an Ideal 6000 with the original steel frame door. It takes about 30 minutes to install and gives you all of the benefits of the new 6000 door. You can see video installation instructions here. Contact us or your local dealer and order Part Number 60022-10.
If you watch the video, please ignore the fact that I badly need a haircut.
Wired July 1, 2018
We do a pretty good job of providing factory direct telephone support especially with the advent of Skype and Face Time. A picture or a quick video makes it very easy to diagnose almost every problem…almost. We occasionally get a call that the spin motor on a reel grinder is not working so we tell them to first check the fuses and that almost always fixes it. If not and it is an older machine, we tell them to check the brushes and that fixes most of the rest of them. If it doesn’t then it is in the controller, the motor or the wiring. This requires that you pull out a multimeter and start checking both the input AC voltage and the output DC voltage. If you have AC going in and no DC coming out then it is the controller. If you have DC to the plug then it is the motor, fairly straight forward to trouble shoot.
Last week, we had a customer that has an older 2000 and I was told that his spin motor had stopped working. We went through the trouble shooting and from what he told us, it needed a new controller board. We sent him a new board, he replaced it and it still did not work. After a week or two of back and forth on the phone with no luck, Larry and I were stumped so he decided to drive from Phoenix to Texas and see if he could solve the problem. After a few hours of checking everything, it looked like the new replacement board had to be defective, so Larry drove to the local Grainger and bought another one. The next morning, he installed it and it STILL didn’t work. As we talked on the phone we were frustrated but decided it was not likely that we had three bad controllers from two different manufactures, bought in two different cities. I felt something had to be wrong with the wiring even though the multimeter test said it was okay. I told Larry to send me pictures of all of the wiring connections. The minute I saw the above picture, I knew the problem, the black wire to terminal 2 on one contactor and the white wire to terminal 2 on the other contactor had been reversed. After I pointed that out we tried to figure out how that could happen. Turns out that the spin motor had not just stopped working. It had not been working for at least three years. A new mechanic came in and tried to use it when he determined what was wrong. He did not know that the previous mechanic had replaced the contactors, three years ago and that is when the spin motor stopped working. Larry reversed the two wires and the machine works fine. So if you call in for support, please be patient when we ask you a bunch of questions or ask you to send us a bunch of pictures. In the long run it will save you some time and us a four day trip to Texas just to switch some crossed wires.
Happy Fourth of July.
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