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Rebuilding the Oly twins... a saga - Page 5

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Link to "Rebuilding the Oly twins... a saga"by mogogear on Tue May 15, 2007 2:23 pm

Good News-! For me anyway.

My empty headedness got a little better today -I found the bag with my circlips and piston rod washers and other goodies. So ....... No needing to detour to making new washers has been avoided! So buffing and polishing the face plates and top panels and powdercoating the bodies are the final obstacles- those darn micro scratches from imprudent cleaning -:evil: I hope they can be buffed out easily by me or someone else- :roll:

Does anyone have a Sure-fire polish to recommend for chrome?


Plus a small tease- some nice custom -DIFFERENT- handles and steam knob is becoming a reality from the elves.......... and wait till you see the powder-coat color I chose for the body- I hope the camera will do it justice!
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Link to "Rebuilding the Oly twins... a saga"by mogogear on Sat May 19, 2007 5:13 pm

Just a couple of details- The Cremina surrounds are off to the powder coater along with the body to the Bezzera- $60 gets all sand-blasted and powder coated. One Cremina will be a matching color to the Bezzera- the other Gloss black. Not bad at $20 each. Of course YMMV in your area- There was a minimum of $50 charge- So I found out what all that would handle- It never hurts to ask. Now I had some light hazing in one polished face plate and some minor bumps, not dents, into the older brushed face plate. After getting a quote form the Chrome folks of $60 to polish one with no guarantee... OUCH! So , among others, I asked Espressme if he knew any ways to achieve a unblemished look on this S/S. His suggestions worked great ! Thanks Richard!

1. I laid the face plate flat on a two adjoining surfaces that had a small gap between . The gap let the reflector area of the face plate that is recessed have some relief. I did tape off the recessed area- but found that it didn't matter since I was using a flat sanding block. The recess stayed mirror polished!!

2. I then used a good rubber sanding block and started with wet / dry 600 grit sand paper and stroked from the bottom curved lip ( that is under the drip tray area when assembled) and pulled in ONE direction -over and over. Note: I spent about 5 minutes on each grade of paper.

3. Then moved to 400 grit- repeated, and then on to 320 grit. All the scratches are gone. I have a very factory fresh satin finish on the face plates ( yes I did both and am very pleased with the look) I don not miss the polished look- This is not better but an very affordable alternative---- have I ever mentioned that I actually had a budget that I was trying to stay within?? Do ask... :oops:

Image

So new gaskets from McMaster- Thanks Bob! are installed under the elements-Now I am foodsafe ! I corrected a mistake in "open-sourcing" that I had made. All seals touching water must be foodgrade! I had forgotten that - Sorry. I will also go back and re-tighten after the initial warm up! These new ones are the 1/16 thickness- but they are very firm and I will want to double check their tightness after acclimating to a hot element in the neighborhood! A regular hole punch worked fine form me to make the bolt holes. I also had to notch the inside edge of the pre-cut gaskets to allow for a little rub with the well that holds the thermostat . I trimmed out a small finger nail gouge and all lined up fine.

One small note-You may or may not recall I used a replacement resettable thermostat made for La Pavoni 127c vs the factory 131c model that I could not get. I will keep everyone informed if it trips too easily. Any way I was going to inform you that like many Olympias that have a metal disc spacer behind your thermostat, this one needs it also. It maintains contact between the Thermostat and the element flange. I had no such spacer- so I made my own- I soldered three old copper pennies together in a stack.. installed .....

The Levers are on and pistons re-assembled in the group-heads. Note- as Steve Robinson indicated as many other have- I used a seal installing tool- basically sharp small scribe -like tool. it has a small thing pointed end about 4 " long. After pushing the pistons in up to where the piston's seals contact the leading edge of the cylinder wall. I then used the seal tool to "tuck" the edge in. All seals and piston shaft and inside of the cylinder walls were lightly lubed DOW Corning 11 o-ring and valve lube. FOODSAFE AND HIGH TEMP! Man o man what am I going to do with 5.3 OZ of this stuff ?


So it is a bout a 2 week wait for the powder coating to arrive. 8) 8) Also some nice baubles are en route! I can't wait to reveal them- nice custom made handles, steam knob and a matching tamper later on.
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Link to "Rebuilding the Oly twins... a saga"by mogogear on Sun May 20, 2007 1:12 pm

MY brain is dead and now I am doubting my own information.....

QUESTION PLEASE:

Some one please correct me before I put in my PF gasket incorrectly- Inside chamfered edge up .... or down. Seems as if I have always know UP to be the answer. Too long on this project has me doubting myself........ :oops: :oops:
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Link to "Rebuilding the Oly twins... a saga"by mogogear on Sun May 20, 2007 1:44 pm

While I was finishing up a few details under the hood- I finished one last small modification. I added a V-shaped vertical reflector behind each site glass. This is made from light weight aluminum flashing found in rolls at Home Depot. It is 6.5" tall and 2 " wide. Folder in half along the long axis. So a long V trough. I trimmed tabs in each end to grasp the Site glass fittings when installed. So no screws needed.

So hopefully you can make it out in the picture

Image

I also made a simple "splash / leak shield" for the switches located right below the Steam fittings on the 1981. This should help directly possible drips of water should the fitting leak. I don't know why critical switches are always right under the "faucet" on many machines. Sorry to be so anal on a seemingly small detail. I just go back to when i was needing to source a switch( mine was missing) and I had to make do with re-casting with epoxy resin the broken part of the only switch I could get--The newer models use a switch and opening that is fairly common- Not so on the older girls..

Image

Trussed up waiting on body panels and the handles and knobs...

Image


Ciao' for now
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Link to "Rebuilding the Oly twins... a saga"by hbuchtel on Mon May 21, 2007 3:54 am

They are looking niiiiiiice Greg... can't wait to see them finished up!

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Link to "Rebuilding the Oly twins... a saga"by Paul on Mon May 21, 2007 5:04 am

great stuff. nearly there!

pf gaskets - chamfered edge goes up. I guess the only function is to make installation easy.
cheers
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Link to "Rebuilding the Oly twins... a saga"by timo888 on Mon May 21, 2007 5:28 am

mogogear wrote:While I was finishing up a few details under the hood- I finished one last small modification. I added a V-shaped vertical reflector behind each site glass. This is made from light weight aluminum flashing found in rolls at Home Depot. It is 6.5" tall and 2 " wide. Folder in half along the long axis. So a long V trough. I trimmed tabs in each end to grasp the Site glass fittings when installed. So no screws needed.

I also made a simple "splash / leak shield" for the switches located right below the Steam fittings on the 1981. This should help directly possible drips of water should the fitting leak. I don't know why critical switches are always right under the "faucet" on many machines.


Clever ideas. You should get you a mule and a little covered wagon and travel the land: Bring out yer Creminas! Bring out yer Creminas!

Did you make the drip-guard out of the same material as the sight-glass reflector?

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Link to "Rebuilding the Oly twins... a saga"by mogogear on Mon May 21, 2007 10:57 am

Thanks Paul for the definite answer, and Tim- yes the aluminum is the same stuff. Easy to work with. I have several large guillotine paper cutters- they make short work of crisp lines and cuts. I scribed a line down the center of the 2x6.5" rectangle with a straight edge and a awl. The aluminum has a buff side and a more reflective side- I won't describe it as mirrored- but it does capture light and make it easier to see the water level.

I was happy to have found an old blue line site glass- So I kept it in the 85-- the red one went in the 81. The more I look back at the pictures of the face plates - the pictures don't do them justice- I have to say the fine grit sand paper did an awesome job- they are as close to flawless as you can get for "not new".

Baubles to be here today by 3pm! Yeehaw! Load up the wagon Jed!, we are movin' to Beverly.......
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Link to "Rebuilding the Oly twins... a saga"by timo888 on Mon May 21, 2007 12:18 pm

mogogear wrote:Baubles to be here today by 3pm! Yeehaw! Load up the wagon Jed!, we are movin' to Beverly.......


Don't fergit them purty coffee-squeezers.
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Link to "Rebuilding the Oly twins... a saga"by TUS172 on Mon May 21, 2007 2:09 pm

Very nice work Greg... considering the rebuild costs... about how much will the first 100 espressos cost per machine? :) :P
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Wear plating

Link to "Rebuilding the Oly twins... a saga"by espressme on Mon May 21, 2007 7:11 pm

timo888 wrote:http://en.wikipedia.org/wiki/Delrin

EDIT: I don't know Delrin's hardness relative to brass. It could be harder. But if it is softer than brass, a sacrificial bushing might be used to prevent or reduce deformation of the slot. If it is harder, perhaps a thin slot liner could be made from it?

EDIT: Delrin's hardness.

Hi Tim,
I would not suggest a soft thin material for a shim. Any small contaminants may get lodged into it and become abrasive in the extreme. A very hard material or at any rate a bit harder than the sliding part is good. It should be firm and properly shaped so as not to cause undue wear into one portion of the machine's anatomy.There are exceptions to this rule but the materials are unobtainium in cost and are made for machine tool rebuilding. Think $100 up!^^^
The piston rod itself might be plated with Magnaplate® or the group head wear area also. Even the inside of the cylinder / group.Only one wear surface. It is a Teflon® impregnated wear material that is plated onto/into the substrate and there are food safe versions I have used for specialized medical equipment. It is similar to the hardcoat plating inside the real high buck professional French cookware. It protects aluminum or other surfaces from darn near anything.
sincerely
richard
PS. I been away from this site too long! Missed all this last page. :( Great work Greg they are really nice! :D Nice straight-lining on the front plates!
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Link to "Rebuilding the Oly twins... a saga"by mogogear on Mon May 21, 2007 7:27 pm

Not much dialog on this post........- I just got my box I have been waiting for.!!!!!!

Three new items for the 85

More about the specifics on who made them, what etc and some process pictures of their making on another day. Suffice to say that with these - I completed the machines except for the body panels and a few screws and tweaks here and there. They got water today, switched on, NO shorted circuits--YEAYYYYYY! :D :D

They warmed up, pressurized, flushed the groups and I turned them off. 8)

So this side by side shot is a little like a before "Baubles" and after "Baubles" -African Ebony in a form I have had drawn on my wall for about a year- This style is what was on the first picture I ever remember seeing when I did a Google search for LEVER ESPRESSO..... a little over a year ago. ...... I like old school.... And I always liked the boiler cap.....


Image


Image

G' Nite
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Link to "Rebuilding the Oly twins... a saga"by timo888 on Tue May 22, 2007 7:04 am

espressme wrote:Hi Tim,
I would not suggest a soft thin material for a shim. Any small contaminants may get lodged into it and become abrasive in the extreme. A very hard material or at any rate a bit harder than the sliding part is good. It should be firm and properly shaped so as not to cause undue wear into one portion of the machine's anatomy.There are exceptions to this rule but the materials are unobtainium in cost and are made for machine tool rebuilding. Think $100 up!^^^

The piston rod itself might be plated with Magnaplate® or the group head wear area also. Even the inside of the cylinder / group.Only one wear surface. It is a Teflon® impregnated wear material that is plated onto/into the substrate and there are food safe versions I have used for specialized medical equipment. It is similar to the hardcoat plating inside the real high buck professional French cookware. It protects aluminum or other surfaces from darn near anything.


Hi Richard,
The specific wear-issue I was trying to solve is the deformation of the slot in the fulcrum mount and the wearing thin or even the wearing-through of the brass at that location. The abrasion there is much exacerbated by the thousands of pounds of force applied to the hardened steel pin and then to the brass, via the lever. If Delrin is harder than brass (I think it is), it might make a decent slot liner. I don't know how thin it can get before it looses its strength. Perhaps something like this, but less ovoid and more lozenge-shaped:

Image

Teflon-coating of the piston cylinder is something I would consider; you know the EPA's take on brass in potable water systems.... :wink: I have been reading about electroless nickel-teflon coatings, but will look for Magnaplate.

BTW, the company that originally said it would take on the job of replating my boiler has gone incommunicado. Can you recommend another who might have experience with Magnaplate?

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Magnaplate

Link to "Rebuilding the Oly twins... a saga"by espressme on Tue May 22, 2007 7:38 am

Hi Tim,
posted the answer on Vintage boiler's thread.
edit:
http://www.home-barista.com/forums/vintage-boilers-metals-t4065.html#44544
Enjoy,
richard
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Link to "Rebuilding the Oly twins... a saga"by mogogear on Tue May 22, 2007 10:06 am

timo888 wrote:... If Delrin is harder than brass (I think it is), it might make a decent slot liner. ......
Regards
Timo


I think the roller made out of Delrin would be the thing to try- should be easier to make and would be - even though harder= possibly less abrasive? Or am I out in the far pasture eating Loco -weed?
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Link to "Rebuilding the Oly twins... a saga"by espressme on Tue May 22, 2007 10:39 am

mogogear wrote:I think the roller made out of Delrin would be the thing to try- should be easier to make and would be - even though harder= possibly less abrasive? Or am I out in the far pasture eating Loco -weed?

Delrin is an offshoot of Nylon®6, (a white somewhat oily feeling material that is slightly flexible.) It is not as hard as cycolac or plexiglas. It gets its value from the slight flexibility, shock resistance, and slipperiness. It does not absorb any water as Nylon® can. It is often used in bearings for consumer home mixers and such and as the bushings for electric knives.
As an example, the Delrin® pin could be cut with a hand held dykes ( diagonal cutter.) It does shear easily. Meaning it would leave the two ends in the fork and the middle in the group with a half hearted drop of the lever. There are plastics we have used that would do the job thing ^^$200 per ounce.
enjoy!
richard
hey, lets move this somewhere else so the twins can be center stage!?!? :)
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Link to "Rebuilding the Oly twins... a saga"by timo888 on Tue May 22, 2007 2:50 pm

espressme wrote:hey, lets move this somewhere else so the twins can be center stage!?!? :)


Richard,
They have center stage, whether this ancillary subject of how to protect the slot from wear stays or goes. The reason we are talking about how to retrofit the slot is that Greg went to extraordinary lengths to repair the problem of a slot deformed by years of use, as his photographs early in the thread attest.

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Link to "Rebuilding the Oly twins... a saga"by espressme on Tue May 22, 2007 3:42 pm

timo888 wrote:Richard,
They have center stage, whether this ancillary subject of how to protect the slot from wear stays or goes. The reason we are talking about how to retrofit the slot is that Greg went to extraordinary lengths to repair the problem of a slot deformed by years of use, as his photographs early in the thread attest.

Regards
Timo

I acknowledge your point of view! :)
sincerely
richard
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Link to "Rebuilding the Oly twins... a saga"by timo888 on Tue May 22, 2007 4:23 pm

espressme wrote:I acknowledge your point of view! :)


We will have to get you an air-marshall's badge, Richard. :wink:

But seriously, I see the discussion of the deformed slot and how to prevent it as an outgrowth of Greg's restoration thread, not as a hijack.

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Link to "Rebuilding the Oly twins... a saga"by mogogear on Tue May 22, 2007 11:31 pm

A small back step here on a detail that might help those with the older style power switch.

Old Style switches are serviceable!!

So if it doesn't work- take it apart!

This switch is actually a double set of contacts that act like a relay. When I powered up for the first time- the light in the power switch lit up fine, but switching to the "on position" provided nothing. Before you start thinking you wired wrong, the element is burned out, the thermostat is tripped, or what ever you might think- use a OHM meter and see with the power off and unplugged that you get continuity from opposite sides of the switch when turn to the "on " position. If not- you may need to service the contact points.

If you remove the switch from the escutcheon, you will find that it is held together with one small 1" long screw across the back. Do not take the metal brackets of fthe front (rocker) part of the switch. There are little steel balls in it and they are challenging to re-install and almost impossible to replace- they are not the size of BB's! @#$%$%1! Unscrew this screw and the ceramic back portion of the switch will come off- ATTENTION!-make note of the up/down orientation - it can be installed either way.

Check out the points alignment and mating surfaces. You can unscrew the small screw holding one of the contacts, and leave the movable portion in place. This will allow you to polish the surface with some very fine sand paper- 400 or so. Back together in the reverse and check the continuity again before re-installing..

Sorry there is no accompanying picture- but the "Heads Up" was just to remind you to start with checking power at the source and move forward one step a t a time...

Ok- go get em LMWDP members!

No where was I? Oh, yeah, I was about to pull my first test shot and see if this was all worth it.
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