TWISTEDWILLOW Posted January 12, 2022 Share Posted January 12, 2022 Alright all y’all, every so often someone makes a post about wanting to buy a replacement handle and or counter weights for a blower, Buffalo, champion, Otto ect.. and recently I asked a member why they don’t just make their own.. but then I thought to myself… i says self, why don’t I put my money were my mouth is and make some replacement handles myself? So I’ve decided to make a blower handle… actually several of them lol, this has been a top secret project I’ve had in my mind for at least a whole 2-3 weeks! I started hunting for some 2” or close to it size round stock a week ago, to use for the round thingamabob that mounts to the main crank shaft, and was able to scrounge some off someone who works in an electric motor place, at an 1-3/4 so close enough.. I hope! Lol next I started hunting across the vast expanse of the internet for 2” steel balls! I first started looking at mill balls but I couldn’t find a company that could even tell me what exactly they were made of… and they was expensive! then after a suggestion from a concerned citizen on here (Glenn), I found a place that sells hot stamped steel balls out of Texas, (I don’t know what these are made of, couldn’t get no one on the phone) but they were cheap and freight was much lower! So I took the bait and through caution to the wind and ordered 5, lol, They came in yesterday and I couldn’t help but mess with one, so I used a punch to notch a starter point, and a drilled a small hole through it with my 100 plus year old junky drill press that definitely does not drill straight… (another story) then I drilled a bigger hole with a 5/8” bit, and half a quart of 30 weight oil for lubricant it seems, well buy that time it was dark and cold outside so I didn’t feel like going out an fooling with the forge, so I grabbed a cold brew an set by the shop stove, Now it gets crazy… or lazy? Lol, anyways I got the bright idea to throw the 2” ball in the wood stove, I didn’t think it would get hot enough to mess with but what the heck? to my surprise in the measurement of time it took to drink one cold refreshing beverage it was glowing! so I grabbed an big old rusty wrench and cut off both the ends and grinded one to a point, sort of.. then I went out an grabbed the swage block, then being as how I didn’t have no ball tongs I just used the fire poker to skewer it through the pre drilled hole, and place it on a round hole, and I took my improvised drift and hammered away, then knocked the ball off when it cooled down an threw it back in the wood stove, it accurately took one Brew per heat, and slowly I was able to drift a nice looking oval shaped hole through it while setting in my shop chair next to the stove, Lol anyways it would probably have gone much faster in my coal forge but this is just the first one, and now I can say it was forged using a wood stove, I will post my progress as I make each part of a hand crank forge handle several times over, I think I’ll do the rest of the heating on the other parts in the forge though lol, One last thing… I may or may not have used the shop cats water bucket to cool down the drift and quench the ball…. Again to lazy to walk outside… lol Quote Link to comment Share on other sites More sharing options...
TWISTEDWILLOW Posted January 12, 2022 Author Share Posted January 12, 2022 I looked at the existing blower handles I had and mounts, There’s a couple different styles, one being the the handle part is one with the crank lever, the other the handle is riveted onto the the crank lever, this is the way I’m gonna go, there’s a couple different mount also, here is the 1-3/4” round stock im gonna use for the mount part since I don’t have a lathe to turn it down I’m gonna opt for the bulky style mount, Quote Link to comment Share on other sites More sharing options...
Frazer Posted January 12, 2022 Share Posted January 12, 2022 This is how I did mine. 90 deg bend, threaded the end and put a nut and washer on there. I like the riveted method too. Different mounting method at the input shaft though. Quote Link to comment Share on other sites More sharing options...
TWISTEDWILLOW Posted January 12, 2022 Author Share Posted January 12, 2022 I like it Frazer! What did you use for the mount? I see double set screws, but is that a nut? Or is that a split in the bar? Quote Link to comment Share on other sites More sharing options...
Frazer Posted January 12, 2022 Share Posted January 12, 2022 So there are 3 pieces (4 including the counterweight). 1" round, forge welded to 3/4" square, forge welded to 1/2" sq that was drawn out into the handle portion. Part of the 3/4" sq. piece was upset, slit/drifted to fit the the blower and holes were drilled and tapped for 3 cap head screws (I ended up needing 3 staggered axially) to lock it in place. There was a recess in the blower shaft for one set screw, but it was pretty wallered out when I got the blower. I probably didn't need to forge weld so many pieces together, but I wanted to practice With a better fit between the shaft and the handle I probably wouldn't have needed all 3 screws. Alas, I mismeasured my marks for the slit ---- Finally, the mystery of your search for steel balls reveals itself! Quote Link to comment Share on other sites More sharing options...
Latticino Posted January 12, 2022 Share Posted January 12, 2022 Frazer, Well I've got a perfectly acceptable handle on my crank blower. Now you have me wanting to make a custom one... Quote Link to comment Share on other sites More sharing options...
Irondragon Forge ClayWorks Posted January 12, 2022 Share Posted January 12, 2022 Same here. Quote Link to comment Share on other sites More sharing options...
Frazer Posted January 12, 2022 Share Posted January 12, 2022 I recommend it! It was a fun project. This is what it looked like when I got it (I don't have a better picture handy, this one is from the original Craigslist post for the forge). I needed the upgrade from the wooden block approach taken before. Both work... Mine looks nicer in the shop. My one regret is the handle side is longer than it really needed to be. I could always cut it off, but ehhhh... it doesn't bother me that much. Quote Link to comment Share on other sites More sharing options...
TWISTEDWILLOW Posted January 12, 2022 Author Share Posted January 12, 2022 6 hours ago, Frazer said: Finally, the mystery of your search for steel balls reveals itself! AH HA! it was the blacksmith! In the workshop! With the blower handle! I really like your custom handle! I’m gonna try and make these look as close to factory as I can, but when I get done playing with these I might have to try my hand at a custom handle also! Quote Link to comment Share on other sites More sharing options...
Frazer Posted January 13, 2022 Share Posted January 13, 2022 23 hours ago, Frazer said: Part of the 3/4" sq. piece was upset, It's not really shown in the pictures so I'll be a little more specific on how I formed the socket. I upset the bar, corrected the thickness in one direction and used the edge of the anvil, a set hammer, etc. to push either end to one side. The last step makes it a little easier to slit and I think it looks nicer to have a flat front. Quote Link to comment Share on other sites More sharing options...
anvil Posted January 13, 2022 Share Posted January 13, 2022 Nice job both of you. For what its worth, the reason for an adjustable ball and an adjustable handle are to be able to set/maximize blower rotations when at the forge, and for blacksmith heights. Quote Link to comment Share on other sites More sharing options...
TWISTEDWILLOW Posted January 13, 2022 Author Share Posted January 13, 2022 8 hours ago, Frazer said: I upset the bar, corrected the thickness in one direction and used the edge of the anvil, a set hammer, etc. to push either end to one side. The last step makes it a little easier to slit and I think it looks nicer to have a flat front. Frazer, That’s good to know! anvil, thanks I’m excited about this project! I didn’t realize that was the purpose of why these old blower handles were adjustable, keen something new every day! Thanks for the info! Quote Link to comment Share on other sites More sharing options...
KMADDOX Posted February 8, 2022 Share Posted February 8, 2022 Good work so far Twisted, look forward to seeing your finished product for a factory like option! Frazer that is a good looking handle also! Quote Link to comment Share on other sites More sharing options...
TWISTEDWILLOW Posted February 10, 2022 Author Share Posted February 10, 2022 Thanks KMADDOX! I’ve been sidetracked on other projects here lately and haven’t been working on the rest of the handle for a few weeks, I’ll try and get some more progress done soon and get some pictures on here, Quote Link to comment Share on other sites More sharing options...
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