The C'lever Project: Building an espresso machine from Cremina parts

[TUS172]

For the past year and a half I have been collecting parts from various sources (some from the members here on HB) for a project to build a lever espresso machine. The core components are from Olympia Cremina machines. I will cut and form the body parts for the machine. The boiler is from a '68 Cremina. This particular style of boiler has a brass bar that traverses the front of the machine and supplies a port to the pressurestat side and also to the other side of the machine that feeds the steam tap assembly. I currently have all the parts I need to build the machine except for the steam tap assembly and wand that will fit this particular boiler. If I would have been smart a few months ago one was offered but I did not act soon enough. So I am sending out a request for a steam tap assembly for this style boiler...

All the other 'support' components that I am using are new... fittings, tubing, electrical, pressure relief, monitoring and safety components... (thank God for McMaster Carr and Grainger).

Anyone have such an animal?

[mogogear]

Bob - have you had a conversation with Will at Home Espreso repair yet? He might have a tap and a wand...

I have an extra boiler with a HX in it from an Astra Gourmet- it may be about 5Liters.... and a frame for an Astra---

[TUS172]

Thanks for the offer Greg,

I have already sourced everything and purchased most the components to get this particular project under way.

Yes, I have already emailed Will and he did not have what I needed. He suggested Rudy's in NYC... I have not yet attempted to contact them.

At first I was going to build strictly with Olympia components but after a suggestion from Richard and some DD I have found that I can customize this machine with high quality components offerred from various manufacterers in the here and now. It also gives me the opportunity to modify the fittings and incorporate Stainless NPT Fittings and US standard size tubing.

I gave some thought to taking the steam tap from my original '67... 67 Cremina (Grand Ma) but that would simply be sacrilege! She works as if she were new and I have never had to replace anything on her. No this is a project from scratch. I had purchased the boiler and frame that Doug offered earlier this year but did not intend at that point to try this project so I opted to hold off on the steam tap... Now that I have determined to attempt a 'build' I might not use the original frame but instead weld a stainless frame to fit the proportions needed. We shall see...

[srobinson]

I have one from a 67, but has some worn parts on the internals. thus why I replaced. Exterior is perfect and has been rechromed. Drop me a PM and we can talk about it.

Thanks

[starry]

Bob, can you tell us what your goal is? Will this be to obtain a larger boiler or maybe an artful package? I'd love to hear the thought process behind this.

[TUS172]

I remember that the 1st time I tore into one of these units thinking that with the quality workmanship of the operating parts (boiler, grouphead, heating element and steam tap assemblies) it would be interesting to create a high quality encasement and support environment that would compliment it appropriately. We shall see how things progress... But understand that this will take some time to complete... I want to enjoy this little project. So stuff like the frame and body panels will be of my making... (I have access to a metal fabrication shop). I will be taking my time, I hate wasting materials.

[starry]

I can't wait. Projects like this are too much fun to watch. Vicarious thrills.

[espressme]

Good On Ya Bob!
First and foremost ..Ya gotta have fun! If you aren't having fun you are not doing something right!
richard / espressme
Mainly this week I are .. avoiding all work!

[TUS172]

Thanks Richard,
Hopefully I will do this project right... I may have questions along the way to ask of many of you... I have no idea at this point what to expect... Nothing is drawn on paper yet... Don't know much about CAD... Don't know that it would help. Its all a part of the adventure.

Heard from Doug!

Also had a response from SR himself...

[TUS172]

Well... I have finished welding and sand blasting a new frame. The welds and the finish on the holes need to be polished up but its fitted. The height and length dimensions are a bit different from the standard Cremina frame. All the steel in it is a bit heavier than the standard Cremina frame... I used angled steel for the uprights instead of the flat steel that is used in the original frames. And "Hey...The boiler fits!" I did cut out areas where it was not practical to have the full angled steel. I opted to go with steel instead of stainless because I will be sending it off to be Chromed in the near future.


The pic below shows the sheet metals I have bought for the body, face plate, drip tray, cover and a drawered base for the Cremina to stand on. Want to talk about the price of high grade sheet metals?! One 1X2 sheet of 14 gauge Naval Mirrored brass and one 2X2 sheet of satin finished 16 gauge stainless.


As you can probably see from the pics... I have not polished the boiler yet. I figured I will have plenty of time for that when things (Frame, Grouphead, lever, forks, etc...) are out in various parts of the country getting "upgraded".

[starry]

Glad to see your progress! Sounds like your sheet metal choices are a tad bit heavier than the standard Cremina. I can't wait for more updates.

[TUS172]

Ya I know... I know... The sheet metal is heavy especially for a tiny Cremina but I figured "What-the-Hey". There won't be anything under done on this project.

[starry]

Oh no.....don't misunderstand! I think I would have done the same thing. It will take the Cremina from a really good home unit to the level of a commercial machine. Now get back to work!

[mogogear]

I know you breathed a sigh of refief just getting the boiler to like the frame you made for it. Thats huge !

I know when I had a couple of sheet metal places look at the tight bends required to remake a body piece for me- exclaimed- "Oh- from switzerland!"! subtle things humbled some of the hard working metal guys I approached!

Good Luck and great start- I know you must feel good getting it into "3 dimensions"

[TUS172]

Thanks Greg... Ralph,

The sheet metal work is one thing I am concerned about. Back in the early '70s I worked for a place called Illinois Range near Chicago. They fabricated all the metal work for McDonald's kitchens in the mid west ...everything from service counters to the hoods, enclosures and cabinets of the food preparation equipment. Back then I ran a break and sheer for 1st stage production. But those were large machines the sheer had a 12 foot bed and could sheer up to 10 gauge mild steel and I don't even know the tonage capacity of the break. Also its been 35 years since I've played... so I'll be taking great care in measuring and deciding where and what to bend which way 1st... Make any sense?

Well I know the guys that do play and they will be right there holding my hand so I am not too worried... I don't think they would have it any other way, "Me playing with their baby's..."

I also need to try a couple of practice welds on a spot welder for the inside supports for the body to the frame... I don't want to be leaving any noticeable heat distortions on the finish of the body that can't be polished out.

I am having fun and I am just getting started.

[starry]

Working in a fabrication environment I too know some of the subtle difficulties that one can encounter by "mere details". My Cremina came with no drip tray. To fabricate it the way the factory did is a challenge even for an experienced pro....same with the powder coated case. I'd love to do the case in stainless, but a reality check made me think just a high quality powder coat would have to do. I know the kinds of choices you'll be making but that's what makes this stuff so fun and challenging at the same time.

[TUS172]

I had planned on doing some play time with the C project this weekend but yesterday realized that the switch and heating element lamp that I have is for a '60s or early 70's Cremina. I am opting to go with a new switch at the very least. New switches can be flush mount switches (snap in) and the older one for the Cremina is not. Besides if I ever have to replace the switch or heating element lamp in the '67 I have... well then I am golden.

The original OEM switch that I have is new and I bought it as a part of a package deal about a year ago from a person who had ended up with 3 complete sets of seals, 2 site glasses, a switch, a heating element lamp and various other parts (portafilter and baskets too) for the older style Cremina (I never asked how he acquired them).

Anyway I ordered the new stuff last night and when I get it in I will be able to draw up how the face plate needs to be cut and formed. I have also ordered some bar stock rounds of 2.5" stainless and I have 1.75" brass and plan on fabricating my own boiler cap and set nut that holds the cover in place. Brass works alot easier but I thought I would give stainless a whirl. I have located the 25MX1.5 bottom taps for the project but am still looking at finding a taper tap to get things started.

So this weekend may be for the more mundane chore of polishing that boiler...Maybe...

[mogogear]

Bob are you going to use a OEM Pressurestat or go with something like a CEME?

[TUS172]

You nailed it Greg... I have a C.E.M.E. 1/4" fitting.

I also have the La Pavoni pressure gauge and Reset fuse for the heating element. And I purchased a Le'Lit 1000w heating element and some .3125" plate stainless... I am going to give a shot at making my own heating element. I have a spare Cremina heating element that I bought from Doug a while back... but just for "Haws" I figured it was a novelty worth pursuing. I will be relying on the Pavoni reset fuse placed in a .25" hole to accurately be able to monitor the heating element for any irregularity.

[mogogear]

I happen to have a "modified " Cremina " element - I.e one that was drilled out and the bottom plate was then fitted with a 1000w bolt in element. That element has now burned out and I have all of this disassembled.

I would allow me to trace the plate out and then you could drill the holes where you need. I could even ship it to you for an exact template to use if you want ( It was in my Maximatic). I too had a spare Stainless Olympia element - so I swapped it out and will rebuild the old plateit with a new element later when I need to.

As you know since you have one, the new style Oly element just has the resettable thermostat screwed to a flush mount 1"x1.5" plate ( for the mounting screws to screw into) . So no need to develop a recess for the Thermostat to reside in...

That little CEME is hard to beat for the price- small dead band and quiet operation!

I do have a Steam wand knob if you don't have knobs and handles made for your creation

Cheers