Currently I am building a brick press that will press the bricks to the size I want using the damp powder method. The press is base on the CINVA ram press designed for blocks used in construction in third world countries in the late 1950’s. I am resizing the chamber and adjusting the other mechanical pieces to work with the new size. When I get it all worked out and tested I will probably sell ready made plans for others who want to do it themselves.

Back to the pug mill, I am going to use what is available to me and modify the design accordingly and will post my progress here. Yesterday I priced scrap metal, custom cutting and visited with an old friend who is somewhat of a “Yankee Machinist” , blacksmith and metal worker. He is 88 years old he still works in his shop every day. He said he is not up to helping build the pug mill but will allow me to use his tools (most of them he made) and give adivce. He put together the jolley arm I use based on the plans from the same book and yesterday I gave him some finished plates made with it.

It turns out there isn’t any such thing as 8″ ID thin wall pipe, Harry made his own pipe and his directions are based on that size. I can hower get 8″ OD thin wall pipe and this changes the internal diameter of the pug mill by 1/4″ and all internal parts will need to be resized. Also, I can get the pieces cut at a local steel recycling place with a plasma cutter for $100 an hour and if laid out correctly all the pieces could be cut to size in an hour. So the process begins. My reason for doing this is mainly financial, a new manufactured deairing pug mill costs in the neighborhood of $5000 and I think I can build one for a tenth that price.

The next step is to mount the template on the jolley and set the thickness, I use a couple of Palm Pilot styli placed on the jig and then tighten the bolts (not pictured). I roll out a slab on the slab roller thicker than I want the finished piece and cut it to approximate size. It can be slightly smaller in diameter than the finished piece and will expand when compressed that way there is less waste in the jiggering process.

The finished jiggered plates setting up until they release from the plaster.   

The other side after being removed. They will be placed on their rims to dry. 

Due to the large amount of table space required to dry the jiggered plates the next step in this process will be to build some racks that will allow me to work with many more plates at a time in less space. I am looking at building something between a bat rack and a ware rack that would hold the plaster bats vertical with space between each for drying and storing with shelves above to hold the jiggered plates until they set up. Once they have set up I will move them to a ware rack that I am building with about three inches between shelves. In an area about 6.25 square feet I will be able to dry anywhere from 80-120 plates (depending on size) safely and still have room in my studio to do other work. As a potter I have to wear many hats and it is time to put on the welding hat. I will make the racks with 1″ tubular steel and angle iron with plywood shelves.

My personal goal in this exercise (more…)