Construction of 7' Grasshopper Treadle Hammer

Click on any thumbnail for an enlargement

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Staging the Material

270# scrap shaft for anvil post, 6" D, more or less 7' Posts and side plates Other parts cut to length

D/N 1000: Base and Frame Components

Side plate weldments, left outside, right inside Stantion posts and side plates aligned and clamped for welding Sides are aligned together by sheet metal separator pinched between posts, plates
120# base with welded eyes, on lift table (don't solo this project without one). Anvil post ready for cutting: lift table for coarse positioning, wooden wedges for fine. Finished post. Note 2# bag of saw/grind dust, from correcting saw cut gone slightly awry.
Frame leveled with wedges, squared, and clamped for welding top brace. Erect frame and anvil, just sitting on the base. Hardy holder, with painstakingly(!) hand-filed 1" square hole.

D/N 1000: Base and Frame Assembly

Some of the setup and leveling is done with a hand level ... and some with a 5-beam laser plumbline, a really slick toy. The frame uprights are now permanently welded, and the struts are tacked into the proper triangle. Departing from Bruce's plans, I'm delaying the welding of the anvil till I can physically align it to the mounted ram.

D/N 2000: Ram Assembly

Finished ram.
A bit after this point (in Spring '02) with all the pieces at least cut and drilled, things took a 3 year 1200 mile detour.

In Spring '05 things finally got back on track. I obtained the updated plans from Bruce and switched to the new kickback design. Everything fit together with surprisingly little grinding. :-)

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D/N 9000: Assembly of Hammer

The assembled hammer! The winch (from Surplus Center) is the only marked change from the plans; its conformation made it preferable that it and its control shaft be mounted on the left. And it works ... here the ram (and treadle) are up, here down (almost).
Finally, just for scale, here we are together.