Matthew Gregory

That was my plan! Seemed to me that letting the hammer do the work would be a nice change, too... Guess I gotta get rolling on the helve. I think tomorrow I'll put a couple of the husk screws back in place and tighten them down, then loosen them up - see if the husk assembly moves the way its supposed to.

So after killing a couple hours letting fish no larger than the lures I was using stare blankly at me, I decided that I just wasn't going to wait any longer to either wreck this old girl, or continue forward. I can't justify getting a custom tap cut (especially if there's a chance that all that will happen is that the blunted, smeared threads that are left in the lower cushion cup are just going to fall out!). Seeing the damage on the original adjusting bolt (not sure what caused it to begin with), I filed the first two thread's worth off, and blended the existed threads smooth to use as a thread chaser. Here's a shot of some of the 'bulge' that caused the problem... unfortunately, I had already started to file when I remembered to take pictures, so you don't get to see that the bulging occurred all the way around: Here's what it looks like now, after removing the ruined threads: Although there was lots of resistance, bit by bit it re-aligned the smeared threads in the lower cushion cup. A quarter turn at a time, un-thread it, clean the threads out with a toothbrush, thread the bolt back in, rinse, repeat. All that's left are the final 1/4" where the greatest amount of distortion occurred. I just didn't have enough umph! to get it done today, and I was starting to get sloppy, so I quit. My bride caught this super action shot of me during the aforementioned task. Told ya I was skinny! One more day of working at it, and this shouldn't be an issue. Then on to getting the eccentric free so the ram throw can be adjusted!

Sammy, bring one of these to Ashokan, if you will - I'd like to see what it's like. Too cool!

One 40lb cushioned helve work-in-progress... 40lb Bradley rebuild

Unfortunately, I've had to put this project on the back burner for the last few weeks - too much work - at work! Also, I've encountered a bit of a stumbling block on this project and I'm not sure how to proceed... the threads in the lower cushion seat adjuster are pretty ugly, and I can't seem to locate a tap to clean the threads up. Anyone know where I might be able to score a 1-5/16" x 7tpi tap? I hate the idea of having to get one made, as it'll likely cost a fortune.

I wondered about that, Phil... unfortunately, it's the only example of one of these hammers I've seen. Maybe I should get rid of the link, as I'd prefer NOT to cause any spread on the wrong information...

Here's a youtube video of a similar hammer in action, although I think one of the comments is correct under it... isn't the drive belt supposed to go in front of the idler pulley?

Hey gang! I finished scanning the manual that Phil sent me, and I'll be hosting it here, for all to download: Bradley Cushioned Helve Hammer Manual Phil - again - I really can't say "thank you" enough, this is a tremendous boon for me. I hope it will help others, too! It's supposed to be hella hot today, so I might start work on a dedicated website for the hammer. We'll see...

Phil (aka peacock) was kind enough to take the time and effort to photocopy his instruction manual for this style of hammer, and send me a copy. I intend to scan it and post the .pdf files I create here, as well as on the website I'm planning for this hammer. Hopefully, I'll get to it this weekend. Phil, I can't thank you enough! :)

Here's what the cushion seats look like when they've been cleaned up and given a good coat of oil to prevent them from corroding any further: Compare this to the picture BEFORE I got it out, and you'll get an idea why this was so nasty! Here's a shot of the anvil and hammer separated: I've had to start a pretty nifty collection of wrenches for this project, too! Here's the striking wrench I needed to break the jamb nuts free... not too often you get a chance to use a 10lb with a 10lb hammer! Not sure why these went out of vogue, as they made short work of every single big jamb nut on this ol' girl. Finally, I spoke with a friend that has lots of hard rock maple... I need to take some measurements, then I start the helve!

So here's some updates... so far, the only real issues have just required some serious force and lots of sweat equity. The lower cushions sit in the seats shown above... however, they've got a threaded rod with a jamb nut under them, and as you can see from the picture, it really doesn't look like anything is supposed to move. Except it does, of course! I had to remove the bolts entirely (the back one was lots of work, but not too bad) then insert a 7/8" bar in the hole and break it free from underneath with a 10lb. sledge. Now, many of you have never met me, so before any of the folks gunning for me get a chance, I'll describe myself: I'm 39, 6'2", 168lbs, and have all the muscle mass and tone that a cushy job selling stereos gives you, which is next to none. So imagine a few pipecleaners with a couple wads of chewed bubblegum and you get the idea... Anyways, it was a lot of work, but the rear cushion adjustment seat finally broke free. It was entirely caked with who knows what, and it sure didn't want to come out. Here's the pocket it sat in: The front one was MUCH worse. When removing the adjusting rod, I ended up using a combination of big-ass pipe wrench and sledgehammer and spud wrench with 7' of black iron pipe as a breaker bar. Alas! The incredible resistance was a result of a completely destroyed section of thread just under the cushion adjustment seat. The threads for this seat will need to be re-cut, I hope... if not, then I'll have to drill it out and likely do a big heli-coil or something. Regardless, it took a ton of work to get the rod out. On to hammering the cushion seat free. It took three different days of slugging, and finally the only way it came loose was by removing the anvil from the hammer (heavy!) to clear a path so could 'baseball bat' swing the sledge. Using this technique and resorting to burning the surrounding area where the nasty cakey stuff was and scraping with a chisel, it broke free.

Sorry I don't have any updates, gang... I've been busy at work, and I needed to order another wrench to get some of the stuff on this pig moving! I'm not sure what kind of time I'll have, but I'll try and get some more pics of the little progress I've made, as well as some better shots of the bearings with the caps off.

Awesome story, Don - congrats on the new hammer!

Thanks, Phil! Unless you can think of any reason I shouldn't, it's my intention to generate a website with as many photos, links, and documents as I can for this project. I think if all of this was readily available it would be a greater incentive to consider these as viable projects, and maybe save a few more from the scrap pile!

I was saying meccaleccahigh, meccahigneyho back when you were naught by a spry lad! :D

Thanks, Stuart - will do. Worked a bit more on this pig today... Phil, I found what you're talking about with the "upside down cup" under the lower cushions - mine were so frozen I had to remove the adjusting screw and drive it out with a rod and 10lb sledge. The threads on the front adjusting screw are killing me. As they come out, they're as clean as a whistle, but I'm getting them out by slugging them free with the sledge and a 24" pipe wrench, as they won't budge otherwise. Got most of it out, but started getting tired and doing more missing with the hammer than hitting, and called it a day.

Hey Phil, just checking to make sure you got my email! Thanks for all the input guys - I'll try and post updates as I progress. Where should I start looking for a belt for this thing? I have someone that can staple it for me, I just can't seem to find a good source for the belting...

I understand completely! It's rather unfortunate that these documents have become as scarce as they are - I think the lack of good information on these deters many folks from considering them as good projects. Sending PM shortly!

Is there any chance I might be able to have a gander at the "books/parts list/setup & use manuals"? I'd be more than welcome to provide you with any form of collateral you might wish to hold, in order to gain access to these documents! Personal references. mortgage papers, rights to any firstborn I might have, you name it! I suspect that these washers you speak of are not missing, but in fact rusted into the bottom of the cups. We'll see...

Thanks, Stuart! I've not seen any documentation on my hammer... when I called Cortland, they seemed less than interested in dealing with the Bradley side of things. When did you last deal with them? One issue I'm having with the machine concerns the lower cushion seats. There are what I would assume are adjusting bolts on the bottoms, and the screws turn (albeit with lots of resistance) but nothing appears to move. Are the bottoms of the cushion cups supposed to be free? Also, I'm missing the nut for the slip sleeve lock... I'm pretty sure it's left-hand thread. Wasn't there a handle for some of these models, as well? Again, guys - thanks for all the input!

I need all the help I can get! I'd love to have any dimensions or info you can provide, as I've never even seen one of this type run.

Thanks, guys! Kroil is a penetrating oil from a company named Kano Labs. Their claim is that the stuff will creep into a millionth of an inch. I've used a variety of penetrating oils before, but none have worked as well as this stuff.

Getting the lower die free of the anvil was nasty. The wedge had rusted in place and basically become one with the anvil. LOTS of kroil, sledging, weeping, and cursing later: The placard on the front of the anvil: I just heard from a friend of mine that works for an industrial rubber company that the replacement lower cushions he's making for me have been poured and cured, and are now awaiting final machining to shape. Next step is to get some rock maple for the helve! ...stay tuned...

Showing the eccentric arm in place, the slip sleeve and pitman arm were fused with rust, and took a lot of work to free. Once it released, however, it was a walk in the park to get them slipping together perfectly. A shot of the bearings after cleanup, with the eccentric in place:

A cushion seat: Upper cushion threads getting cleaned: Starting in on the bearings: