8" plates

[30xs]

If you were close my uncle has a machine shop that I’m free to make use of one of the lathes with plenty of swing to get a ferrule into.

Those pancake welding helmets once fitted to your face block all the light from finding its way in from the backside. It’s another expense, but may help you be able to see a little better since the only light coming in is through the lens.

[shadylane]

Another problem when wearing glasses is fogging.
I've used a CPAP machine to blow air into the welding helmet to partially remedy this problem.

[Yummyrum]

Shady sounds like you and me got same problems . Eyes can’t see as well in the dark and mask fogs up . That I put down to nerves I get knowing it’s time to weld and knowing I’ll likely stuff it uo because I can’t see .

Finally at nearly 60 got me a nice MIG TIG stick welder and realising I can’t use it cuase I can’t see .

Apparently these new Auto dark masks just go darker than they used to for safety reasons but it doesn’t help us older fellas .
I’m planning in getting some really bright spot lights in my shed to help light up what I’m doing in a hope it will help .

Just googled those pancake helmets 30xs mentioned .
Never heard of them . Maybe the balsa box around the eyes might help keep the breath from fogging the glass .

[30xs]

The box saves from fogging and cutting glare from reaching the lens from the backside, once sanded to fit your face profile. Really light weigh also.

If only Shady was hiding in the boiler room at the Trans Allegheny lunatic asylum….

[shadylane]

Shady sounds like you and me got same problems . Eyes can’t see as well in the dark and mask fogs up . That I put down to nerves I get knowing it’s time to weld and knowing I’ll likely stuff it uo because I can’t see .

Finally at nearly 60 got me a nice MIG TIG stick welder and realising I can’t use it cuase I can’t see .

Sounds familiar, now that I can afford the toys, I can't use them properly. There's a narrow window during the day that I can weld.
Definitely not in the norming just after coffee, nor until the sun is up and bright enough to see, by afternoon there's a narrow window between first drink to stabilize my hands and getting too buzzed to safely do the job.

[shadylane]

I haven't forgot about the build, but it's been too friggen cold and icy to get out to the shed.
30xs had a good idea for mounting the plates by modifying the ferule. Unfortunately, the chuck in my lathe is too small.
Sounds like a good excuse for having ordered the 8" four jaw chuck I've been wanting.

[Bolverk]

I had a similar issue with 18 ga plates i made for my 4", you can trim the inside flat portion off the gasket and it still seals just fine.

[shadylane]

I thought about doing it that way but the 8" seal is thicker than the plate, so if I trim the inside of the seal the ferules won't clamp down on the plate and the plate would weep.

[30xs]

I thought about doing it that way but the 8" seal is thicker than the plate, so if I trim the inside of the seal the ferules won't clamp down on the plate and the plate would weep.

You could wrap some Teflon tape around the perimeter of the plate, but takes a lot to build thickness. Especially on an 8” circle.

[Bolverk]

What's the plate thickness or gauge?

[shadylane]

What's the plate thickness or gauge?

18 gauge = 1.245mm = .049" = 36oz/square foot.
The 8" tri-clamp seal is 0.100" thick at the edges before being compressed by the clamp.

[Bolverk]

18 gauge = 1.245mm = .049" = 36oz/square foot.
The 8" tri-clamp seal is 0.100" thick at the edges before being compressed by the clamp.

Yup should be able to clamp with no leaks or weeping

[Bolverk]

Shady, SD sells gaskets specifically for plates. You should message them.

[shadylane]

Shady, SD sells gaskets specifically for plates. You should message them.

They don't have what's needed. Instead of using a modified gasket, I'll mod the ferule so readily available tri-clamp gaskets will work.
One thing I'm sure of on this build, is being able to easily replace the plates for future design changes.
In a couple days the new lathe chuck needed to getter done and better weather will be here.

[Copperhead road]

Shady do you have a metal rolling machine in your workshop to get perfectly round cylinders with your copper sheet?

[Saltbush Bill]

Shady I probably havnt been paying attention to this thread as much as I could have been. Maybe it's already been answered, but why cant you just solder the plates in like I did on my 6 incher.

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[shadylane]

Shady I probably havnt been paying attention to this thread as much as I could have been. Maybe it's already been answered, but why cant you just solder the plates in like I did on my 6 incher.
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Nice build Salty.
I want the plates to be easily replaceable, because I like to experiment.

[30xs]

Shady I probably havnt been paying attention to this thread as much as I could have been. Maybe it's already been answered, but why cant you just solder the plates in like I did on my 6 incher.
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Nice build Salty.
I want the plates to be easily replaceable, because I like to experiment.

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That was my reasoning for designing the way I did, flexibility. Above is a mandrel I made for the lathe so I could bolt on copper plate and machine a solid blank with no holes. If you go this route make a few extras while it’s setup to save material trying to get the diameter right next time.

[shadylane]

I was thinking an 8" chuck should fit on a 9" lathe. But didn't take in account when the jaws stick out, they would hit the lathe rails.
Anyhow, I figured a work around and got the ferules modified. Ya can't see it in the pics but the inside lip on the ferules have been cut down.

[Copperhead road]

Shady did you lathe the channel groove into the ferrules that you can see in the pictures?
Looks very clean and professional…

[shadylane]

I didn't cut the groove, only the inside lip and did it free hand with a grinder while the ferule was spinning at low speed.

[Yummyrum]

Nice workaround Shady

[Yummyrum]

Nice workaround Shady

[30xs]

I thought that looked more like grinder marks than it did machine marks. Looks pretty clean. Nice job.

[shadylane]

Next on the list is to cut copper into disks for the plates.
The game plan is to use a ferule and felt tip pen to mark the copper sheet. Then cut outside the mark with a plasma cutter.
Drill a hole in the middle of the disk and use a bolt to chuck it in the lathe and spin it while grinding the outer diameter with a flap wheel.
Two plates are needed so both will be ground at the same time.

[shadylane]

Shady I probably havnt been paying attention to this thread as much as I could have been. Maybe it's already been answered, but why cant you just solder the plates in like I did on my 6 incher.

Where did you get the copper ferules? That's downright copper porn.
Every since I saw it I've been brain storming on how to make a die and roller to turn $1 of scrap copper into a big ferule like that.

[Copperhead road]

Shady, @Enptyglass used to sell them online through the “Copper Custom Still Component” forum. The online shop shut and they are no longer available.
The CCSC forum now is called Australian home distiller.

[Saltbush Bill]

As above, I do know that it wasn't simple to make the dies to press them out.
There was a lot of trial and error in thier development, he was making them in 6in , 4 inch and maybe 2inch.
I was lucky enough to get some of the prototypes to test.
Unfortunately he has now shut shop and is moving on to other things.

[shadylane]

I had to cut the plates with shears instead of a plasma cutter because the air compressor sprang a leak. I turned on the compressor and heard a whistling sound and shut it off. Upon inspection there was a rust hole in the bottom of the tank.

[Saltbush Bill]

A small jigsaw with metal cutting blade works well for roughing out the plates Shady, that is provided the plate material is thick enough.