Santa Arrived Late

I did remind Santa he was supposed to arrive on a sled powered by reindeer wearing a red suit and with a white beard.  Wearing a yellow hi-viz jacket, helmet riding a e-trike wasn’t appropriate.

A large bundle of presents were delivered.

Three router bits and a box of various sized Forstner Bits. 

The third package contained a Shimano left hand hydraulic brake handle.

Buying one from a local bike shop would have cost a fortune.  Eventually I found an online seller at a reasonable price (reasonable to me!).  The handle will replace the combined brake and gear change handle on the bike.  The current combination works the front derailleur which is going to be removed as part of the conversion to e-bike.

The last package contained a replacement drive cover for the e-bike motor.  The existing cover is made from plastic and is a sealed unit.  The new cover is made of aluminium and has a grease port.  Having the grease port will (hopefully) mean I don’t need to strip the drive to re-grease the gears.

Red arrow in the above photo points to the grease port.

Whilst the new cover is certainly superior to the old I was concerned about the open grease port.  Dirt and water might enter through it and grease might be pushed out.   I decided to modify the cover making the port larger with a 2.5mm drill bit and then threading it with a 3mm Tap.  I then ground down a stainless steel M3 machine screw ensuring the screw was just long enough to be flush with the inside face of the cover.

The original plastic cover was then replaced.

I’m now waiting on the delivery of some rivet nuts before installing the e-bike equipment.  The rivet nuts are required as part of the process of mounting the battery to the bike frame.

Jan attempted another swim this morning.  Apparently it was like being in a spa tub without the bubbles.  The temperature is still in the very high 30’s with the land is retaining much of the absorbed heat during the night.  There have also been several forest fires; some caused by arsonists!  A family in our suburb lost their home and contents on Christmas Day when their gas BBQ was left unattended for several minutes catching fire.  Not what you want on Christmas Day!

More Heat

Today we get a reprieve as the forecast is only 39°.  The previous four days have all been over 40.  Each morning Jan has only briefly entered the pool claiming to be driven out by the hot water!  Consequentially much of our time has been spent inside with all the air conditioners running.  Unlike some other suburbs we have been fortunate there have been no electrical power outages.  I have considered what action we would take if that happened.  The first task would be to get the Kipor generator operating and save all the food in the freezer.

Over Christmas we both saw the “teaser” photo on TV suggesting Catherine, Duchess of Sussex might be playing the piano. Immediate thought was “What going to happen in California?”   Later that day Harry & Meghan’s lovely family Christmas card appeared…… along with some text below which included

 …”we have made donations on your behalf to several organisations…….[organisations listed]”.  I cringed and immediately thought of Matthew Chapter 6 Verses 1 –6.  If you don’t know your bible, this is the link to the relevant part.

Matthew Chapter 6

As we now know, Catherine can play the piano.  I believe someone in California has booked Triangle lessons.  <yes… petty of me!>

I’m reconsidering the project to make a solar water heater for the pool.  The cost of materials is rather high and I’m now thinking it might be better to source some second-hand solar collectors from a residential solar hot water system.  However that doesn’t mean I have nothing to do.  All the air has gone to the top of the tyre on the rear wheel of my new bike.  I shall have to dredge though the memory bank back to aged 10-12 and recall how to fix the problem.

Jan tells me Jo <nb Hadar> has been doing a rain dance for us.  It’s not working. “Try Tap Dancing instead of Waltz Jo!”

It’s 235 days since beer, chocolate or ice cream passed my lips (if anyone apart from me is counting :-).  I’ve lost 15kg and my A1c count is now 6.7, down from 7+ back in May.  The doctor seems pleased, however I’ve decided to keep losing weight with an intermediate goal of 82kg.  It hasn’t been hard and I haven’t been hungry.  All I’ve done is reduced the carbohydrate and sugar intake replacing it with protein and fats.  Jan has been eating the same as me and hasn’t lost a gram.  She considers the situation most unfair.  If we get marooned on an isolated Pacific Island then I know who will last the longest.

Merry Christmas

Merry Christmas to our readers.  For any who aren’t in Perth please think of us tomorrow as we manage our way through a 40+C heatwave.  Boxing Day isn’t looking any cooler  Being frozen in on a narrowboat sounds like bliss!  

Cricket news and more boring project comments

Any UK readers who are cricket followers might be interested to know it has been reported in the Australian media that the Federal Police have launched an investigation into the English Cricket Team.  Not for a breach of the COVID regulations; but rather following an allegation that a group of Englishmen are masquerading as professional cricketers!  I don’t follow cricket so can’t comment on the veracity of the article.

Now for the boring part.

Jan has been able to sell both my Triton saw bench and router table, along with all the attachments.  This has raised sufficient funds to purchase a router lift.  I didn’t want anything hugely expensive but it must be able to take my old router which is a Casals VCE2000.  Eventually the choice came down to a Sherwood lift from Timbcon or a Carbatec lift from Carbatec.  Looking at the photos of both I could see they were the same .  The only difference being one was branded Sherwood in orange and the other branded Carbatec in blue.  There was a $200 price difference so I opted for the cheaper Carbatec version.

Fitting the router lift is the final part of the work bench project.

There was a slight concern when I arrived at Carbatec and asked to purchase the router lift only to be told they had none in stock.  Their website said different and after some prompting the sales assistant went and checked. “Oh yes, there is one in stock which must have arrived this morning”!

I used the saw fence to parallel up the lift drawing its outline on the MDF top before making a cut out template.

The distance between the outer edge of the router baseplate and the cutting edge of the bit was 79mm and I therefore made the template 79mm larger than the lift dimensions.  The router lift has rounded corners and I hunted around to find a bit with that I could use to cut the rounded corners.  Fortunately I found a Forstner bit.  I used the drill to cut out the corners.

Then it was a case of using the router to cut a 6mm deep rebate in the MDP top before doing a test alignment.

Next I added a 12mm timber beading around the inside of the template and used the router to cut through both the MDF and plywood sheets to create an opening for the lift.

A final test fit with the lift before removing the template

All that remains is to fit the Casals router to the underside of the lift.  I’m still waiting for the T-Track and router fence to be delivered.

Sweet

I woke this morning and promptly remembered I had a dental appointment at 9AM.  There I was seated in my chair reading the news when Jan murmured “Do you feel any different?”  OK, I was rather engrossed in the news and the antenna didn’t twitch.  Then the question was repeated in slightly different terms.  Antenna started vibrating furiously and mind raced.  Jan was asking whether I felt any older!  Penny dropped.  I always try to go to the dentist on my birthday.  It’s something I carried on with after leaving the sadistic army who used to schedule your annual dental appointment on your birthday.  It was my birthday and “Oh God”….. our wedding anniversary!  Yes, we married on my birthday.  Then I remembered it was our 50th anniversary!  That’s when I surmised the dental appointment was going to be the less painful activity.  Actually I jest.  Jan appears to have taken my memory lapse in her stride.

Several months ago Jan decided to buy some small baking dishes.  There was nothing suitable in Australia and she eventually ordered them from the UK.  I did mention they look precisely the right size for individual lemon-meringue pies.  Well Jan baked two in her new dishes.

I only got to eat one.  I haven’t eaten anything sweet for seven months and it was delicious.  Unfortunately I only got one as Jan gave the second to the dog.  I thought that was most unfair as I don’t eat the dog’s food!  Does this mean the dog and I are now equals?

Today I examined the Chinese made motor for the e-bike conversion.  After removing the cover to the gears I could see they had been a little mean with their grease.  This isn’t unusual as I’d noticed the same issue with the wheel bearing grease on the Chinese camper trailer.

After removing the old grease I repacked the gears with good quality automotive being grease.  I also noticed the cover plate was made from thin plastic.  I need to do something about that!

The cable connectors between the motor and battery look “suspect” and I think I’ll probably replace them with a pair of yellow ‘bullet’ connectors.

On a more positive note I’ve disassembled the battery mounting plate and realised I can probably fit the plate to the bike frame without modifying it.

Jan and I have decided we will have a homemade version of the Wetherspoons ‘Big Breakfast’ for our anniversary meal.

A Delivery

It was so hot yesterday I gave up working in the shed and retreated to the air-conditioned front room.  More progress has been made on the workbench with all the drawers completed.  They need adjusting and two require handles.  The 16 wooden drawer knobs I saved from the old chest of drawers have been used, but I had to modify some of them to make them fit.

There have been second thoughts about fitting the Thicknesser into the bench.  The original plan was to have it on a 180deg rotating mechanism allowing it to be concealed when not required.  Last night I had second thoughts wondering if fitting it to the bench would restrict use.

 

The two lower drawers have been made and fitted in the front.  I need to adjust them and fit a some of cheap handles.  The router lift has yet to be installed. 

The Thicknesser was planned to be positioned here and rotate into the compartment below when not required.  The four drawers have been fitted at the end of the bench with three larger drawers on the opposite side.  I’ve made some wood screw storage bins from scrap plywood.

I’m not sure what I should do with the narrow vertical compartment beside the intended Thicknesser compartment.  Perhaps I’ll just add a base and use it as casual storage.

My thoughts are already turning to another project.  Probably the solar water heater for the swimming pool?  However today we received a delivery.  An order from China.

The size and weight immediately suggested the parcels contained the parts I’d ordered to convert my bike to an e-bike.  Yes, I know you can purchase e-bikes!  But they are expensive and there’s more fun in making one.

Road e-bikes in Australia (and UK) are limited to a 250Watt motor and a maximum speed of 25km/h.  I’ve bought the parts to make a pedal assisted e-bike.  This means I need to be pedalling for the motor to assist up to a maximum speed of 25km/h.   No pedalling = no assistance.  Go faster than 25km/h and no motor assistance.

What are the components

A – Central hub motor and gearing rated at 250W

B – 20Ah 36V lithium battery

C – Pedal cranks

D – Combination electric headlight and horn

E – Digital display and electronic controller

F – Chain drive

G – Various cables for gear change; hydraulic brake control and throttle

H – USB programming cable (so I can modify the factory settings).

If I’ve correctly done my research and ordering the various suppliers should have provided all the necessary components to modify the bike.

I’ve opted for a large capacity battery which should provide a maximum range of 100km.

I hadn’t realised when I selected it, but the battery has a usb port for recharging a phone.  This might be useful if there is a problem with the bike and I need to call for assistance.

After examining the removable mounting baseplate from the battery I realised the two mounting holes in the aluminium plate will not align with the mounting bolt holes on the bike frame.  However after turning it over I could see a further two mounting slots in a second aluminium plate.  I might be able to dismantle the battery baseplate and access these holes.

The bike currently has 24 gears.  Eight on the rear wheel cassette and three on the central hub.  Converting the bike means I will lose the three front gears along with the derailleur replacing them with one gear.  The bike will go from 24 gears to 8.  But I will have the motor for assistance and theoretically I’ll need to exert less energy. 

The motor comes with three power setting controlled from the display controller, so I’m back to 24 gears.  However I’d also read the motor actually has nine power setting, six of which are inactive and concealed.  By purchasing the usb controller cable and downloading a configuration app for my phone I hope to access and unlock these addition six power settings.  Time will tell if my research is accurate.

Watching the domestic and UK news I noted in the UK shortages get blamed on BREXIT, whilst here it’s COVID and a lack of overseas backpacker labour.  We’re already been warmed up for the next excuse.  A shortage of Adblue diesel additive, which it’s alleged will force many freight trucks (lorries) off the roads.

 

Second Prototype

I’ve finally completed my second joinery prototype.  It’s just a question of deciding whether I should make a third prototype.

I decided to get a bit “arty” and fixed my old army hat badge to the top of the case.  With this prototype I used concealed hinges and neodymium magnets for the catch.  Last time I cut the felt lining with a knife and as a result the edges were slightly frayed.  This time I dismantled one of Jan’s safety razors and used one of the blades.  This provided a much cleaner edge.  I also appear to have got the internal dimensions right.  The only part of the case which isn’t to my satisfaction is the join between the lid and the base.

After two days of 40°C the mercury is back into the mid 20’s and I can return to the workshop.  Whilst I insulated the shed ceiling a walls during its construction, it faces north and the full afternoon sun hits directly on the north facing roller door making the interior rather hot.

It’s rather ironic that here in the west we are experiencing a heat wave and wild fires whilst on the opposite side of the country they have torrential rains and flooding.

Positives and a Negative

Oh dear, another week has passed since the last blog update.  Slow progress has been made on the work bench.  The height adjustable saw shelf and saw mounts were fitted early in the week.

 

Then I realised it might be prudent to make some amendments to the sawdust collection compartment.  I made a second inspection hole and cover with the idea that it would make access to the table saw exhaust easier.

With that completed the sheet of 18mm plywood was fitted to the bench top followed by the 18mm sheet of MDF .  The table saw could then be fitted and adjusted.

The next step was to complete the installation of the mitre saw which will fold down when not required.

It was temporarily held in place whilst I completed the adjustments to ensure the saw surface was plumb with the bench top.  Then I fitted catches to hold it in the working position.

The last step was to make the cover plate to conceal the saw when it’s stored.

A length of 4” flexible hose has been purchased to complete the dust extraction system and that will be the next task.

More bike accessory parts have arrived from China.  I’ve now fitted the saddle storage bag, pump, water bottle holder and a front stem extension (the blue piece below the handlebars.

 

I needed the extension as I found bending over was hurting my back.  The bike has given me the freedom to extend my area of exploration but unfortunately I’ve overdone the exercise and injured my left knee.  It’s making crunching and loud clicking sounds whilst also being rather stiff (the knee… not the bike).  No bike riding at this time.  That’s the negative news! 

The infamous Australian bulldust has been mentioned in an earlier post.  It’s very fine and gets everywhere!  Two weeks ago I was washing the 4WD when I realised there was dust throughout the engine compartment.  After looking online I found a set of car detailing brushes on AliExpress.  They arrived today.

I’m rather pleased with their size, quality and price.  Now I have another job!

Hot and Expensive

We’ve just experienced a few hot and sunny days.  The early onset if summer?  The birds have seized the opportunity to cool down by running around under the lawn sprinklers whilst I managed to snap a photo of a water vole mermaid in the back yard.

The next project will be a shade sail over the pool.  I’ve already completed the basic design using Google Sketchup.

It will need to be able to extend and retract as it will only be used when the mermaid is in the pool.

Yesterday the postman delivered some items for my new bike I’d purchased from Aliexpress. 

Total cost, including delivery, was just over $30.  I could buy the same items from local bike shops for $150.  I’m not adverse to buying local but a 500% mark-up is almost extortion.   I’ll buy local when it’s made locally!

Yesterday I was reading the news when I noticed an article from the UK where several Conservative MP’s were expressing the disapproval of the Home Secretary’s performance regarding illegal boat arrivals and suggesting all arrivals be processed in the Falkland Islands.  I hadn’t realised some of my casual blog readers were British MPs.

I suggest Priti and Boris are playing politics with the issue.  The French do not want any boat people back and won’t stop them from leaving.  The French Navy even escort boats to the UK maritime border.  Under international law the UK is then obligated to rescue them.  It’s a waste of time and money attempting to stop the boats.  In my opinion the problem will only be resolved when crossing the maritime border doesn’t result in a landing in the UK.  Doing this will break the people smuggler business model.  Moreover, I suspect the cost of transporting boat people to the Falklands is considerably cheaper than paying the French.  The UK government would only need to do it for a year and the problem would be resolved.

 

Repurposing

You never know when something you are considering throwing away might prove useful.  When living on Waiouru the lack of space meant it was almoist impossible to keep “stuff” that might prove useful one day.  Back on land I’ve been keeping (hoarding) anything that just might be needed at a future date. 

Today was that date!  Three cupboard doors have been fitted to my new workbench, all requiring handles.  I had one plastic bathroom handle several decades old that was surplus to a bathroom renovation.  There was also a box of round wooden drawer knobs salvaged from an old lowboy. Rummaging around in another former ice cream container I found an On/Off switch that could be used to control the planned router lift.

 

Some time was spent with the multimeter working out the switch mechanism.  With that sorted a hole was cut in the side of the router compartment.

The plastic cupboard handle can be seen adjacent to the hole for the switch.  In the last compartment you can also see the steel drawer runners.

I could buy a $2 mounting block but as there was plenty of scrap timber I decided to make one.

Actually I made a second to cover the rear of the On/Off switch.

The switch has an inbuilt safety function.  Obviously pressing the green button powers the connected appliance and the red button will cut the power.  The switch has an additional terminal which prevents the attached appliance from automatically restarting should the electricity supply fail and then reconnected. 

A couple of cable clips to be fitted and this part of the project is complete.

The next step is to install and plumb the bench top sheets.