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  • 2017 - ITTSB project: Assembly of a Variac Powerstat 226U 5 1
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Offline giorgos

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #20 on: May 13, 2017, 04:17:10 PM »
Very nice finish!
 I have not ever work with this kind of tool, anyway I think that most important point for this procedure,is to keep brush in stable angle, and pressure on aluminium surface.

Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #21 on: May 13, 2017, 04:49:08 PM »
Actually they are involved allot more details.

Brush alone with axle this is half kilo of weight ... Rotation RPM .... weight of power tool it self ... stable hands and control.
Actually there is dedicated power tool just for this brush, with metal handle and shield against particles.
I could not afford paying around 300E for it, I do not do mass production this justifying cost of ownership.

While I am making the case for the Variac,  Variac transformer this is all ready working in to a wooden test box.
And Variac worked at helping me at controlling power drill RPM   ;)


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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #22 on: May 13, 2017, 05:08:04 PM »
After 10 hours so far of workflow I am finally ready to start working at front panel.  ;)
When metal work this is over, next step this is a paint-job.
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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #23 on: May 16, 2017, 05:58:09 PM »
95% of machinist work this is completed and I am getting closer to finish line   8)

For now it looks as this to be a magic picture this getting assembled slowly as the project this moves ahead.

 
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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #24 on: May 17, 2017, 08:46:22 PM »
People if you have long time to see something beautiful here it is your chance.  8)

Product of Made in Greece ingenuity and also hand made !!
It is a fact that speaking of use of hand tools and power-tools, and even my own skills, everything were pushed to their limits.

Spotless execution regarding machinist work,  0% Error in Geometry.

Pictures below are from first testing assembly.

   
 
 
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Offline giorgos

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #25 on: May 18, 2017, 06:07:42 PM »
Perfect job !
It looks like have been made by cnc machine!

Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #26 on: May 18, 2017, 06:43:49 PM »
Perfect job !
It looks like have been made by cnc machine!

For every step until final assembly, I did paid the price in advance ( money and patience regarding shipping time) so all necessary tools them to be here for this project.
CNC machine has several cutting heads as tools, some of them have 50 and some others 70 or more.

If our choices are characterized by precision, the outcome this will be always successful. 

Thanks giorgos  :)

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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #27 on: May 19, 2017, 12:08:59 PM »
Today I got ready for next step,  this is new paint job for the case.  :)

I did visit most advanced shop specialized at auto paints in my area, and I requested them making for me a custom color identical to original of this box.
End result this is spay can including highest quality of paint (as material) and also this very specific color mixture.

The color specialist were supersized because original color this is beige including metal particles but even so this is matte color.

My planing this is restoring original color by a gentle fix over scratches and a fresh look.  ;)
 
 
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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #28 on: May 19, 2017, 09:05:58 PM »
This is a fact of life, that when you have real paint in your hand you do not need any more software assistance from Photoshop, about making things looks nicer in pictures which you take with your digital camera.    8)  8)  8)

Even the paint job were a huge success !!

Next step this is eight hours additional drying time, so the paint to become totally hardened.
Back plate this were prepared prior get painted speaking of required holes for parts installation.

First new parts assembled this taller high quality rubber feet.    ;) 
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Online Kiriakos GR

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Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
« Reply #29 on: May 20, 2017, 09:09:23 PM »
I am not intending to take a picture of its one wire that I am installing  ;D  but some details cannot be photographed with aluminum front plate in place.

Regarding cooling I made a choice for 12V DC fan even if I will have to add another one smaller transformer making a mini DC power supply.
Unfortunately most case fan 120mm at 220 ACV they are serious source of noise, and my goal this is gentle cooling and noiseless.

This is Variac specially designed for laboratory use, and therefore it is not following usual rules of universe.  ;)
 
 
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