Device Build In Progress

Build queue Blog January 2018.

Tuesday!  13Feb2018

Holy cow, we’re shipping….

More than half of this run are out the door, but I was quiet last week, so here’s what everyone missed.

I got sick, it was super exciting.  Actually that was Friday.  Tues,Weds,Thurs, Victoria made an appearance in the shop and she’s helping me with some documentation to train folks up to take on some of the tasks with assembly.  It slowed us down a bit, but it’s going to make it so we’re delivering a better product so I figured the time spent was well worth it.

So, where are we?  Well, I was under the weather Fri, Sat, Sun (migraine) – so not a whole lot.  But – we’re back on track.  One Device went out the day before yesterday, four left today.  Tomorrow I have to play car guy for a 1/2 day so I’ll probably only get two out the door, but everything should be ready to ship by this Friday.  I was playing catch up yesterday and today and I did a really bad job of taking pictures.  I snapped a few today tho.

Final phase assembly on a schwanky pearl blue and silver cased number.  It looks like it’s almost ready for me to take inside for Abby to do some test spinning on.

Yet another from today, waiting for Abby to do some test spinning.

 

So, what do we have left?  There are four of yours and one of mine.  Mine is last, but I’m sure you’ve all noticed that they haven’t been assembled in ‘order’.  They’re not.  They don’t get added to the list in order so for final assembly I randomly choose numbers (electronically) to try and make it as fair as possible.  Anyhoo, so now you know.  I’ll do my best to take more assembly pics tomorrow.

And tomorrow’s contestants are:

I’m not sure if I’m a car guy in the morning or the afternoon, but they’ll make the 18:00 shipping cut off tomorrow.  I have to work around Brian’s schedule tomorrow as he finishes up a couple other things.

I’m sorry everyone but at least it’s a pretty car I’ll be working on, there will be pictures of that on Instagram tomorrow also.

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Newest entries at the top, oldest at the bottom…

Monday, 05Feb2018

We finally received a partial Pelican order late Thurs, I opened it first thing Friday – all of our black cases arrived. It’s enough to start so start we did. All of the black cases in this run were drilled and had the first part of assembly done, I’ll post more pictures tomorrow when I’ve got a helper.

For now, lets look at knobs.    I made these maybe a month ago.  9 of the 10 knobs used in this batch are shown in the above picture, the 10th is out of a batch of knobs I’d made previously.  The parting tool had a chip in the cutter and chewed up the last that I cut out that day.  It was too ugly to use and I just left it in the bin with the other 1/2 dozen or so orphaned knobs.  Today was it’s day..

In machinists circles not getting a clean cut and having to hand finish the part is typically something that gets the maker of the part teased.   I hand finished that part.  Tease away.

Anyhoo, I’ve just finished assembly on the first device in this run…  A couple decals need to be applied but that all gets handled when I finish it in QA.  I have help coming in tomorrow to help with final assembly and QA to maybe get this batch out the door faster.  I’m still waiting on some flyers and some cases, but I’m hoping that they’ll be in before I’m done with the 6 black cased Devices in this batch.  Fingers crossed.  I suspect that everyone who ordered a device in a black case will get notified that we’re ready to ship by the end of the week.

There are some aesthetic choices we’d like to be able to give folks.  The ribbon that aids in the removal of the batteries is actually a funny thing.  For instance, I have yet to find ribbon that’s close to any of the purples I have, but the couple I have are at least complimentary.  I buy good ribbon as I find it.

I’d found a paint that matches the purple powder coats I have and I’ve started painting the tachometer housings to match for the purple Devices, I haven’t had as much luck with the other colors.

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Saturday, 27Jan2018

Here’s where we’re at… Fabrication and coating application is complete. Hooray! If our pelican case order was here I would be starting assembly today, sadly – it is not here yet. The pelican order is due to arrive this Thursday afternoon, assembly will begin Friday and the first of this batch of Devices will be ready to be shipped to their new homes the beginning the week of 5Feb. Hows that?

Happy Weekend everyone – I’m going to go work on my beetle. Ciao!

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Monday, 22Jan2018

Welding is done.
Welding is done.

All the welding is knocked out. Everything on the 1/2 sheet pan is ready for bead blasting and powder coat. The toolheads need a bit of cleaning up and grinding. We’re still waiting on some of the ordered parts to arrive. Assuming cases get here by the end of the week, I’ll be starting assembly by the weekend. The cases are supposed to ship tomorrow/weds – here’s hoping. (It seems silly but ordering a dozen or two pelican cases at a time takes longer than one would think.)

But for now, part of our powder coat order arrived with some new colors to try out. The larger order with the huge amount of purple powder isn’t here yet, but I think I have enough to start this run. Anyhoo, see if any of these names grab ye…

Some new power coats colors to try out.
Some new power coats colors to try out.

I’ll be shooting test panels in the AM, and I’m really interested in how the brembo orange gold turns out. It’s supposed to be very gold flake and some orange – we’ll see. The aqua orange pearl is going to just be a warmer aqua rather than an aqua-y orange I think; but again – we’ll see.

That’s it for today…. just a couple more steps and these parts get assigned to specific devices.

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19Jan2018

Lots done today. Still in parts mode. All metal parts are cut and drilled. Tomorrow I’ll start prepping the pieces for welding and we should be ready to start welding together hard parts no later than Monday (Even self-employed people have to take a day off now and again because they ran out of clean clothes.)

I’d like to say a very special thank you to Abby and Victoria. They have really streamlined the process for starting these production runs. What usually takes me a week after Abby hands me a list of names they knocked out in an afternoon. Which leaves me extra time for things like this.

Bins!
Build Queue – Jan 2018

Look at that. If you’re in the queue, I’ll wager you can find your name. For now the bins hold small parts that I dole out at the beginning of the build, it helps with our inventory. Some custom parts are in the bins. I did a run of brass scotch tension knobs, the last few runs of Devices had bronze knobs; but mostly they’re generic parts like bearings, pulleys, etc.

That’s as far as I thought I’d be this evening after getting the queue set up and getting parts orders in by the end of the day today. Nope, as I said Abby and Victoria handled all that and I’ve been in the metal shop over the past three days getting a head start.

Bins of parts!
Hard parts build process for January Device build queue.

The further something is to the right in that picture the closer it is to powder coating. In the red bins there are nuts, and metal samples (ignore those). In the yellow bins are toolheads ready for welding, motor bracket bases ready for welding, toolhead bases ready for welding, and some bolts I use for setup. The yellow bin with the black painted front has a couple fixtures I use for welding these things together. Finally the green bins on the right are parts ready to be bead blasted then powder coated. The motor brackets are ready, as are the bearing plates, and the switch plates.

I don’t know if I will be able to find time every day for updates, but there should be at the very least a few a week.

I’ve got to finish gathering up my ‘homework’ for tonight and try to find the floor of the metal shop under all of the metal chips.

Stuff I do while I'm watching TV.
Chad’s Friday night homework. Footswitches and battery holders. Oh my.

Happy Friday everyone.

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18Jan2018

Howdy and welcome. Wanna know how your Device is moving threw the production process? You’re in the right place. Welcome to the Build-a-long Blog. Once we have everyone signed up for this run – I’ll label the bins and you folks will get to track your actual Device’s progress as we move threw this production cycle.

We have 10 e-spinners in this batch, no doodads. 8 of those 10 are custom for you wonderful people who are paying to keep the heat on and feed us our supper. Two are for a small inventory I’m trying to build for festival season.

Fabricating Motor mounts.
Part progression – motor mounts.

We are currently in what I call “Hole drilling phase”.

When I build these various pieces of textile equipment I do not build each and every part every time. I build parts in batches, making extras every time to try and spread out the labor across builds and help the whole process move along as rapidly as possible. This time what I was low on was motor brackets, bearing block brackets, and bearing blocks. Currently I’m in the middle of fabricating the motor brackets, and hopefully get the bearing blocks cut up and drilled. The bearing brackets I finished drilling yesterday – they just need deburring.

The motor mount bracket is a tear-drop shape that I can’t just cut into it’s final form on the chop-saw. The added weight helps the Device run silent and not vibrate. We’ve do everything we can think of to make these e-spinners as fast and quiet as possible.

For the motor mounts, first I cut the pieces to size, drill 4 – 1/4″ holes, mark out the shape, cut it out roughly on the band saw, finish the shape on the 2×72″ belt grinder, and finally en-biggen the center hole to make space for the motor’s “protrusion”. Once I get the last of the ‘hole drilling phase” work done – we’ll move into full fabrication and I’ll be welding and grinding to make these ready for powder coating.

Follow along – it will be fun.