New Tower From Scratch (part two) Repost from fieldlines July 15, 2010, 02:03:32 AM »
Following on from part one here
http://www.anotherpower.com/board/index.php/topic,109.0.htmlEach section has two tight fitting pipes inserted into the leg ends like a dowel, its mate has a single dowel, the three dowels ensure the sections only fit together in one position. the dowels also differ in length by 1-2 inches this to make aligning them easier as only one dowel at a time has to be inserted. The sections are the pulled together and three bolts fitted through the cross members. Now is when you see if the accuracy has been worth the effort! the bolt holes all aligned perfectly. This is tricky to explain so hopefully the next pix will help.
Next job is to fit the diagonal braces cut from the 1/2 re-bar and again double welded in place. The cross bracing incorporates a ladder on one side and is very securely welded. The cross members form every other step in the ladder, the diagonal braces all go the same direction to leave foot room on the ladder rungs zig-zagging would have partially obstructed the rung.
Thats the first section completed just three more to do! each section is basically identical except for the hinge on the bottom and the stub mast on top. Assembly of each section is pretty quick and only takes a couple of hours.
The base of the tower is a simple pipe in pipe type hinge, I took a pic but seem to have lost it!
The stub mast is 4in dia x 12ft long and is inserted 2ft into the top mast section, centred and securely welded in place. At this point I also made and fitted guy anchor points from re-bar.
Thats about it just needs cleaned,de-burred and painted, this is the bit I hate, I detest painting but it had to be done.
Job done all painted up and prettyfied! and straight as a die!
So there you go thats how I did it, all in from the steel being carried into the workshop until it was carried out again with its paint dry was four days not to bad.
This is the forth lattice tower I have built over the years, the others were for ham radio antenna and nowhere nearly as stiff as this one has turned out. Previous towers I built in 20ft sections in a 20ft jig and without cross-members, building the jig was as much work as the tower. The use of the cross-members saves building a huge jig and the 10ft sections are a lot easier to handle. Next year I will be extending this tower by at least another 20ft and it will be pretty easy to reach for the jigs and just make another two sections
Total cost for this tower inc steel,mig wire, paint and cutting disc etc is just under £200 ($400)
Next job is to fit the tower to its base and raise it, I ordered a new winch a few weeks ago and it finally arrived it is 12v 12000lb and will live on the front of my old Land Rover Defender but I need to build and reinforce the bumper and chassis. I could just use the Land Rover in 1st low but I like the control of a winch plus this winch has a radio remote control to keep me out of the kill zone, we will see soon how it works out. The winch bumper I built for it took 6 days to complete, I thought at the start a couple of hours would do it lol. Heres one last pic of the winch on my old Land Rover, Defender she is 19 this year and still going strong.
So thats another project done and dusted, next task is to lower the 10ft turbine and tower and replace the tower with this one and my 12ft turbine. The 10ft machine and tower have been promised to my wife, she wants a couple of lights and a radio in the poly-tunnel, a small water feature pump and some led garden lights. Thats if it ever stops raining!
Was it worth the effort? I think so but I will let you all decide that for yourselves!
Russell