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Date:  9-26-2009
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Elevator Counterweight Part 2

Once I got the lead home, I weighed them and found that I had about 25 lbs total. That included the can and all the steel clips and impurities on the weights. Over a couple of evenings I decided to use my blow torch to remove the impurities (like oil & grease and the steel clips). I could have just left all of that for the melting process and skimmed them off the top, but I liked the idea of NOT having flaming, popping, petroleum products in my molten lead. Once I had removed the steel clips, the can weighed 23 lbs. That is what you saw in the picture on the last page. I only need about 5 or 6 pounds per elevator.
The Avipro manual suggested putting a couple of screws into the tubing to give the lead something to “hang onto” once it is cast in place. Those screws can be seen in the first photo.
In order to make the forms for the weights, I cut three quadrilateral sort of triangles of plywood and C-clamped both elevators and the plywood together, as seen below. I had to really make sure to clamp it tight in the area around the welds, but the rest of it sealed up nicely.
So I put the elevators on my saw horses, positioned a drip pan below them in anticipation of missing my mark, and began heating the lead on a hot plate and with my blow torch. When I started to pour the lead the elevators started to tip due to the imbalance. I placed a brick on the elevator to keep it down.
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Extra screws installed

Extra screws installed

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Ready to pour

Ready to pour

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