Excel Die Filer

I have recently obtained an Excel Die Filer. It runs almost silently. I have had to top up the oil reservoir and have also fitted a Stop/Start/NVR switch. I have obtained a few parallel files which require some modifications to enable me to use them on the machine.

It came with the Saw overarm but not the File Support arm (and roller) or pillar.

The pillar is easy to replicate its just a piece of 1.25" round bar. The roller support arm and the hold down clamp appear from the couple of photographs I have seen to be identical castings but fitted the opposite way to each other on the pillar. The support arm has round bar inserted/clamped in the end which is possibly around 1/2" in diameter and which has a roller on the end. The second casting has a possibly similar sized bar which is belt to form the hold down arm.

Does anyone have any good pictures of these items and could provide me with the dimensions. I would like to try and get a pattern made and have a pair of arms cast.

Thanks in advance.

Colin

If you do get arms cast please make some spares.........

there have been a few threads on here about this style. The pictures in my album are of the bit you already have but I probably took them at the request of someone who only had the roller part. Will have to look back to see who it was.

Baz,

Will certainly make some spares. It would be good to make something that looked and is sized like the original if possible.

My colleague regularly gets bits cast for his cars of some of his machines.

Colin

Will post photos with dimensions in response to Colin's PM.

Geoff - Back working on the Austin at last!

Geoff,

Very much appreciated, and I'm sure others will find them useful.

I have put few photos of my Excel machine in my album.

Colin

Excellent information, Geoff

A great demonstration of the usefullness of a forum

MichaelG.

Geoff,

Have had a look at the pictures. Can I clarify a few points.

Is the main support pillar 1.25" diameter or is it reduced to a smaller diameter above the boss with the downwards projecting pin (pin used for adjusting radial position of the arm).

Is the roller one piece with bearings and the conical shaped machined into it, or is it two loose cones (with or without bearings).

What size bolts are fitted and are they in counterbores in the main boss.

What is length of short boss that pressure finger or roller arm are fitted into.

Is it just an optical illusion that the finger arm looks to be at an angle.

Once again many thanks,

Colin

Hiya Colin

This is my filer although its branded a new wonder it looks the same, interestingly the top support in pic 1 & 3 is different but I have another support in pic 3 which fits as well.

I assume it's this what you require the measurements of? if so let me know and I will take some more pics of the part and some measurements

regards

Paul

Paul,

That's great. I have had some pictures and sizes from Geoff. It is the second picture which has the shaft with the two arms and the boss on the lower end. I would like details/sizes on the boss and the arm in the centre of the picture and the dimensions for the roller etc. The amount of offset between the bore which fits the vertical support and the arm with the bearing would be extremely useful. Pictures of three sides of the arm would be good. It will be interesting to compare them to Geoffs pictures. It looks as though the arm has changed slightly. Maybe New Wonder did some of their own casings.

I will amalgamate them all and then try and make some patterns so as to be able to get some cast.

Thanks,

Colin

My interpretation of Paul's second picture is that the top arm (left most) is a fabricated one.
The arm in his first picture is the saw arm, there should be a spring at the back of the top section that is there to tension a coping saw blade during the upstroke.

I've not heard of the New Wonder version but this design has been copied or branded with a dozen names round the world. In the USA Buterfly is a common one.

Baz,

Yes I agree that is fabricated. The middle arm, which I am collecting details on looks a nice casting.

I have the saw arm, but the previous owner used the saw clamp to hold a file. I spent part of yesterday afternoon grinding the tangs off some new files and thinning the width of the files down so they fit in the clamp mechanism. I now have to decide hold to hold the triangle section file and the small round files. For the parallel round files I was thinking of a small block with a hole drilled for the file and a clamp slot. With luck when the clamp mechanism on the Excel is tightened the block will compress slightly and hold the file firmly. This way it would be possible to slide the file up in the clamp to take account of worn teeth. If this is a no goer, then just a small block with a hole and super glue the file into the hole.

Colin

Baz- spot on

Colin-

dia of wheel is 22.31mm length is 19.21mm

the boss is 38.5mm wide & 38.13 high

the arm casting is 111.2mm long it is fixed to the vertical via a grub screw to enable adjustment.

a 12.7 mm bar fits into this casting which is a total of 141.18mm long of which the last inch is turned down to 6.63mm for the guide wheel, which in turn is held in place by way of a washer & split pin

The amount of offset is approx 13mm

I will take another pic with a rule when I get chance for you

hope this helps regards

Paul

Paul,

Thats great. What is the diameter of the vertical support. I know the bottom is 1.25", but it appears tpoo be narrower on the upper portion.

Could you also possibly take a photo of the plan view of the arm.

Colin

Edited By Colin Heseltine on 26/05/2019 16:57:47

Colin,

I've split your post into Q) and A), easier for me.

Q) Is the main support pillar 1.25" diameter or is it reduced to a smaller diameter above the boss with the downwards projecting pin (pin used for adjusting radial position of the arm).
A) It tapers from 1.29/32 at the base down to 1.9/16 at the top where the 7/8"Ø bar fits into.

Q) Is the roller one piece with bearings and the conical shaped machined into it, or is it two loose cones (with or without bearings).
A) One piece, without bearings, the 1/2" shaft turned down to 1/4" for the roller.

Q) What size bolts are fitted and are they in counterbores in the main boss.
Large boss - 3/8" Whitworth C'bored Small boss - 1/4" Whitworth not C'bored

Q) What is length of short boss that pressure finger or roller arm are fitted into.
A) 1.3/32"

Q) Is it just an optical illusion that the finger arm looks to be at an angle.
A) It's at 90° to the shaft.

Geoff - Audiobook next me thinks 🤔

Hiya Colin

the offset is about 1/2" centers the top bar is 7/8"

regards

Paul

Guys,

That's fantastic responses.

As MichaelG says earlier on this show the usefulness of the forum.

Got to get my act together and draw this up.

Colin

Thanks to all the help I have now drawn up plans for the arms:

Started with some nice Basswood

Found these twins inside.

Just need to make the pattern for the boss which hold the upright for the arms, get them painted and off to the foundry.

This might be a couple of weeks as have a set of new Nitron race shock absorbers and springs to fit to the Caterham seven before week on Thursday.

Whilst making them my Dremel Motosander 1731 (1" belt sander) went pop. Could hear a slight hum from the motor but that was it.

After my issues with my old mill I though immediately "the Capacitor". Open its case and see below:

It says 6 microfarad.  This seems a bit low.  Any thoughts.

Colin

Edited By Colin Heseltine on 13/06/2019 17:45:15

Ordered a replacement Capacitor from Fleabay and it arrived today. 5 minute job to install and very pleased that I now have a fully operative Dremel belt sander.

Colin

I mentioned progress might be slow due to having to fit new shock absorbers to Caterham 7. Well I got them fitted and had a nice weekend driving round the Yorkshire Dales. Got back and couple of days later went to get the car flat-floored (all suspension set up properly. All set up ready to adjust rear shock platforms and found this.

Shocker had ripped rear mount out of De Dion tube. Not deemed safe to weld as could be too much corrosion inside, so now need to fit this.

So Die Filer project slowed down even further.

Colin

I went to collect my casting yesterday morning. Superb quality. Will have a few spares for sales. Took pattern in for the third casting I require and it should be available next week.

Colin