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Gaggia America lever machine - project "lighthouse"

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  • mgrobins
    commented on 's reply
    I can't see the angle on the bolts well, but I wonder if a gusset plate could be fixed along the bottom of the tube and onto the boiler? Could be shaped as desired not necesarilly a traditional triangle gusset . If the boiler wall thickness is a concern a collar would help too.

  • mgrobins
    commented on 's reply
    I replied to the wrong post :P

  • Leverman
    replied
    Regarding stress on the boiler neck: good question! I intend to add a ring of insulation around the boiler and hide a brace inside it.

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  • jwm888
    replied
    Nice work Leverman - something I would love to be able but unfortunately my skill levels are sadly lacking Love those levers

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  • kofekitt
    commented on 's reply
    Looks very interesting - I know it's just a mock-up, but that's quite a bit of weight hanging off that boiler neck, both from the weight of the group, and even more stress when pulling the lever . Will there be more bracing or a frame around the group to boiler junction?

  • IamOiman
    commented on 's reply
    oh that's smart, never thought of using basin wrench like that. On my next gaggia project I'll try that

  • Leverman
    commented on 's reply
    I forgot to mention I used a basin wrench/spanner to get down inside the piston.

  • tompoland
    commented on 's reply
    VERY interesting! Following with great interest.

  • Leverman
    replied
    Click image for larger version

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ID:	928929Not sure what happened during Covid… but time and life seemed to blur into some odd never-land… but I did make progress and am back at it! Progressed to the first rough mock up of a frame. Just experimenting with shape at the moment.

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  • Leverman
    commented on 's reply
    I soaked the whole thing in penetrating oil a few days… then some gentle heating, followed by more soaking in penetrating oil. Then clean it off well and wrap it in wet leather, clamp it in a wooden vice or roughened wooden blocks in a vice then turn the shaft…. Slow and steady it came off!

  • IamOiman
    replied
    What did you do to unscrew the piston from the rack? Is it because this is a newer machine than other groups I've seen? Paul Pratt told me he has never been able to unscrew the piston without damage, which is why I have never attempted to unscrew mine, although he works on really nasty machines sometimes.

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  • monkeysrus
    replied
    Inspiring, I have an old machine i want to fix up.

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  • tompoland
    replied
    Following with interest. Very inspiring.

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  • Leverman
    replied
    Finished spacers. Firm enough to do the job but flexible enough to "do no harm" to the piston. Also will help with disassembly when time for gasket replacement comes. (I hope)
    Attached Files

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  • Leverman
    replied
    Brass spacers in the group were a bit worn, still useable but I figured... let's try something new. So I got a bar of virgin teflon and tried turning them on a lathe... came out pretty nice! Smooth as!
    Attached Files

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