Machinery designer and die maker by day, mad scientist the rest of the time

 

restored high school chandelier
Restored chandelier at Cleveland Heights High School

(Courtesy of HGR Customer and Guest Blogger Christopher Palda)

Christopher Palda

How I became an HGR customer

I heard of HGR Industrial Surplus mainly from word of mouth. I used to deal with McKean Machinery where my boss sent me until it was bought by a New York firm and they got rid of the odds and end. As a result, they lost some customers. Many people that buy the little stuff at HGR see the large ticket items and send others they know who need these items. Employees left McKean to start HGR; so, it was a natural transition. You’ll see some of the things I’ve bought at HGR mentioned in the story below.

Recently, my workplace bought a MIG welder at HGR for the construction of Dan T. Moore Company’s plastic extrusion and rolling machine that is the size of a room. It’s for extruding plastic and rolling it into film. What they had at the welding supply store was not what we needed. We required a 100-percent duty cycle machine that could run all day long and found one at HGR.

What I do for work

I’m a die maker and do die repair, hydraulics, welding, machine tool wiring, basically an industrial maintenance technician who handles anything electrical, hydraulic and mechanical. I work for Mahar Spar Industries. A spar is the main strut in a sailboat, and the founder’s name is Mike Mahar. He started out making spars and sailboat masts in his garage in his spare time, and the business evolved from that point. Many ask me the origin of that unique name. I’ve been there for 20 years, and prior to that I was at NASA Glenn Research Center doing composite metallurgy research for jet engine applications and at the same time on a joint project working at Cleveland State University doing metallurgical research in the chemical engineering department where I built the metallurgy lab.

Some of the things I’ve built

One of the items that I am proud of that mostly came from HGR is a hyperbaric chamber. My doctor said that it would be helpful for my health to use one, but medical insurance wouldn’t cover treatments for this off-label use that was proposed; so, I came to HGR and built my own from used air compressor parts for pennies on the dollar. A new one for medical purposes costs $75,000. They usually are purchased by hospitals and medical facilities to treat diabetic patients with wounds that won’t heal, necrotizing fasciitis, carbon monoxide and cyanide poisoning, and scuba diving accidents and are used in clinical studies and trials to increase brain function in people with autism and a few other applications. I am a diver, but luckily haven’t had an accident yet and have not had to use it for that purpose. It cost me about $4,000 to build mine. By dumb luck I found a medical air compressor at HGR normally used in a dental office for the chamber along with a $1,200 medical oxygen regulator for $15 that just needed to be rebuilt. It basically functions as an isolation chamber, and you breathe pure oxygen through a mask as the oxygen regulator increases its output by using the chamber pressure as a reference point.

compressor tank from HGR before it was converted into a hyperbaric chamber
compressor tank from HGR before it was converted into a hyperbaric chamber
hyperbaric chamber side view
outside of completed hyperbaric chamber
inside of handmade hyperbaric chamber made from surplus at HGR Industrial Surplus
inside of finished hyperbaric chamber

 

 

 

 

 

 

 

 

 

 

 

 

 

 

bike trail cutting machine
bike trail cutting machine

We do projects for the Dan T. Moore Company, who also is an HGR customer. Dan believes Cleveland doesn’t have enough bike trails; so, he dropped off a small bulldozer and wanted it converted into a bike trail cutting machine. With our custom attachment it became something that looked like a bulldozer, meat grinder, snow blower hybrid. Some of the hydraulic parts came from HGR. He also wanted to build a steel mill in Bolivia at one point in the past, and we were doing a mockup of the process. We needed a large blower. His people were going everywhere else looking for stuff. I found one at HGR that looked and roared like a jet engine that was 125hp, and it worked great!

bakery oven
bakery oven

Additionally, I do maintenance work at a bakery that has a huge electric oven made in Italy that you can’t get parts for; so, you have to manufacture the parts yourself. Its internal electric flash boiler caramelizes the bread giving it that hard crust by explosively filling the deck with wet steam at the beginning of each bake cycle. The original boiler could not keep up and self-destructed. I copied the basic design with some improvements and made one five times larger. Some of its parts came from HGR.

I also work for Whitney Stained Glass Studio doing artistic metalwork restoration and conservation along with fabricating window frames. Projects include the windows at Stan Hywet Hall and the restoration of the outside stained glass lamps for St. James Catholic Church in Lakewood after a bird built a nest in it. The owner turned it on, and it caught on fire, which melted the solder. I had to strip the patina to fix it, which is considered a no no because it was covered in plastic. I said, “Watch me age this thing 100 years in minutes.” I stuck it in bleach and salt water and put power to it like in a plating operation and totally corroded the thing in 40 minutes.

welder from HGR
TIG welder from HGR

To put the hyperbaric chamber together, I needed to purchase a large TIG stick welder. I found a Miller at HGR for a fraction of the cost of a new one. It didn’t work and needed a little TLC, but if I buy it and it doesn’t work out it’s nice to know I can return it within 30 days. I got it for the cost of the copper scrap, gave it a bath, found a simple control issue and brought it back from the dead. It pulls 105 amps at 240 when I’m welding heavy aluminum. I would turn it on and watch the neighbor’s lights dim. Is the problem 2B solved or not to be? That’s the question. A trip down HGR’s Aisle 2B for some capacitors solved the problem, and the neighbor’s lights didn’t dim anymore. The effect is like pouring a glass of beer. You want the beer but not the foam. These capacitors get rid of the electrical equivalent of the foam.

You know the big speaker in the opening scene of Back to the Future? I said to a friend, “Cool, let’s build one.” A 5-hp stereo system was born! The neighbor would call me for requests when I fired it up in the summer while he was cutting his lawn as long as I played his stuff. The neighbors didn’t like heavy metal, and that’s when the heavy metal station Z Rock was on the air and when I hit the heavy-metal stage in my development.

Building a fire-breathing dragon for the play “Reluctant Dragon” at a children’s theater in 1985 was a blast. When I adapted an old CO2 fire extinguisher and put red lights in the mouth and eyes, it worked first rate. My electronics business in my parent’s basement when I was 10 or 11 aided in paying for this lunacy.

broken chandelier
mangled chandelier prior to restoration

Cleveland Heights High Schools auditorium has huge 300-pound chandeliers. One of them dropped about 35 feet while they were trying to change the light bulbs and smashed into smithereens — a mangled, twisted mess. Redoing all the artistic metal work was a challenge while many others at Whitney Stained Glass restored the stained glass globes.

Near-death experiences

Back in the caveman days, there were only five TV stations. You had to have a movie projector to watch movies. My dad got two 35mm machines from a drive-in that went out of business and modified the optics to work in a house. We had a movie theater in our basement. I was born with mechanical ability, but I learned and worked with my dad who also was handy and was a self-taught mechanical and electrical and hydraulic engineer. He designed tooling and stamping dies along with pollution control in power plants. I could set up and operate these machines as a kid, and when my dad took off the TV back to work on it I saw that there was what looked like a small roll of film inside the that I thought had the Bugs Bunny cartoons on it. He yelled, “Don’t touch that! That is the fly back transformer and has 15,000 volts on it!’

He fixed the TV but left back off. One day, while I was watching it, the picture got odd. I realized the cat was inside. When I went to grab the cat so she would not get hurt, she jumped out and my hands landed on the flyback transformer and lit up blue. Afterward, I felt like lightning had hit me. I woke 15 minutes later across the room and had a revelation — that’s why it’s called a flyback transformer because when you grab one that is what you do!

Christopher Palda as a child working on a car
Christopher Palda as a child working on a car

Another time, as a little kid in the car at the gas station, I asked my mom why the man had a garden hose and was putting water in the car. Mom said it was gas but she wished it was water because it’s cheaper. At home, I put five gallons of water in the car to save mom money after I noticed the spout on the lawn mower gas can fit the end of the garden hose. We ended up stranded the next time we drove it.

I’ve had eight various experiments with electricity. It’s amazing that I’m still alive. I wondered how a vacuum cleaner worked. My dad explained the process of how it worked starting with electrons moving in the cord. I had to find out what an electron looked like; so, I opened up paper clips and was determined to go to the outlet and pull one out. I had two paper clips, one in each side. When they touched, there was a fiery explosion that burned my hands. I got to see a lot of electrons!

My vaporizer broke when I was sick. My dad fixed it by making a new part on his lathe. I saw how it opened up when he took it apart. When everyone was gone, I took it apart while it was plugged in and threw handfuls of salt at it with water to watch the explosions. The power main want “bang” as everything went dark in the house. A voice from downstairs yelled, “Christopher, what did you do now?”

Jan. 14: HGR’s monthly customer appreciation Saturday sale

We’re open one Saturday per month and offer a full, hot, free breakfast to those who swing by the showroom. Check out the sales!

HGR Saturday Jan. 14, 2017 customer appreciation sale flyer

Machine-tool company retrofits equipment for Amish use

Amish farmer

HGR Frequent Shopper Steve Timothy works full time as a millwright at Charter Steel. Sullivan Machine Tooling is his “side job” that he started in 2013 to build as his future retirement job. It all started in 2009 when he bought a 1977 Lincoln Electric doghouse welder, his “newest” piece of equipment, to make repairs for himself. Since he lives in Sullivan, Ohio, a heavily Amish community, his Amish neighbors knew he could weld and asked him to fix farm implements for them. That’s when he started doing repair work. Sometimes, rather than repairing a piece of equipment, it was easier to buy it from HGR and haul it home. So, Timothy began to buy equipment, fix and resell it, as well as haul equipment for the Amish in his community.

Since Amish do not use electricity, they adapt all electrical shop equipment to run off a line shaft with a belt drive. Some of the most common pieces of equipment that Sullivan Machine Tool has adapted include lathes, drill presses that carpenters and metal workers use, and pantographs designed to engrave jewelry that they convert into finish sanders for carpentry use with a rotary orbital head fit into a column with a moveable arm. Timothy says he has used a drill press for the same thing. In an Amish shop, a diesel engine powers a line shaft that runs the length of the shop under the floor and runs on V-belts. Diesel fuel is used because it is more efficient than gasoline.

In Timothy’s shop, he has a 1926 South Bend lathe, a 1937 South Bend lathe, a 1954 Bridgeport mill, a 1954 Cincinnati Bickford drill press that he bought from HGR, a small press and a car lift, plus all the machinery he is converting and tools in a 26-feet-by-30-feet pole barn. He transports equipment he purchases in an F450 dump truck and trailer with a moveable gantry crane and engine hoist.

He says that an Amish machine shop down the road runs a 17,000-pound shear (purchased from HGR), an ironworker, a press brake, lathes and a radial arm drill press, all nonelectrical. It has a tub on the roof to collect rainwater that is gravity-fed into a faucet sink since only well water with a pump would be used. A sawmill in his town uses a $20,000, three-sided planer for flooring and molding. It can plane flat surfaces, profiles and relief cuts. The planer had separate motors but the owner built belt drives and uses a diesel engine to drive the line shaft.

Sullivan Machine Tool does not advertise in local newspapers or online. All of his business is in the Sullivan and Homerville area and done by word of mouth as one person tells another person during their Sunday socials.

When shopping HGR, Timothy watches and purchase online unless there is something he needs to come up in order to check the condition. Then he makes the trip to transport an entire truckload at once. Currently, he has his eye on two gear hobbing machines that he will either use to make his own gears or sell to his Amish customers. The units are not complete; so, he is trying to solve the problem as to how to complete them to make them functional. He purchased a tool grinder with no attachments, pulled the motor off, and mounted a shaft for a drill press. He enjoys repurposing equipment for use as something other than what it was intended.

Timothy lives on 2.5 acres with his wife. His father-in-law lives on the property next door. He has a daughter who is a vet tech and a son who is a business major at The University of Akron. This man loves to keep busy and says he probably never will retire. Do you have a side job? Are a hobbyist? How do you feel about “retirement?”