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Hinged-Leaf Wing Dasher Churn: Turn One Way to Churn, Reverse and a Leaf Opens to Gather the Butter
Malachi B. Hassler of Columbia City, Indiana, received US 25,410, dated 13 September 1859, for a churn dasher. A crank and a pair of wheels on the lid turn an upright dasher shaft. Two arms through the shaft carry two curved wings: one bowed outward near the shell, one bowed inward near the shaft. A curved leaf hinged to the inner wing lies folded while churning; turning the dasher the other way opens it, and it gathers the butter near the shell.
The patent gives no sizes; every size here is ours.
Intermediate
About 2 days, plus printing
Instructions
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1
Crank, wheels and wings
Crank, wheels and wings
Loading Jupyter Notebook...
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2
Reverse the dash to gather the butter, the same day
Reverse the dash to gather the butter, the same day
France's strips slide over the gaps when the dash is reversed. Hassler's leaf swings open.
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3
Read US 25,410
Read US 25,410
"hinged to the wing (f) is a folding curved leaf (g), so arranged that it may be folded back upon the wing (f), during the process of churning, and when it may be desired to gather the butter; by reversing the motion of the dasher, the said leaf (g) may be opened as shown clearly in Fig. 3, and serve to gather the butter near the shell of the churn, while the wing (f) serves to secure it next to the shaft (d)"
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4
Print the crown wheel b
Print the crown wheel b
Crown wheel, 36 teeth on its face, module 2, with a hub bored 12.4 mm and a cross hole for a pin. PETG, 0.2 mm layers, 40 % infill, 4 walls.
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5
Print the pinion b'
Print the pinion b'
Spur pinion, 12 teeth, module 2, with a hub bored 12.4 mm and a cross hole for a pin. PETG, 0.2 mm layers, 40 % infill, 4 walls.
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6
Print the outer wing f'
Print the outer wing f'
The outer wing: a ribbon 36 x 12 mm turning a quarter round at 112 mm from the shaft as it falls 200 mm, convex outward. Print with tree supports. PETG, 0.2 mm layers, 40 % infill, 4 walls.
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7
Print the inner wing f
Print the inner wing f
The inner wing: a ribbon 30 x 12 mm bowed in towards the shaft as it falls 200 mm. Print with tree supports. PETG, 0.2 mm layers, 40 % infill, 4 walls.
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8
Print the leaf g
Print the leaf g
The leaf: a curved ribbon 26 x 8 mm that lies on the inner wing's middle. Print with tree supports. PETG, 0.2 mm layers, 40 % infill, 4 walls.
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9
Shell A and lid A'
Shell A and lid A'
From 20 mm hardwood make a box 300 x 300 mm and 450 mm deep inside, its four sides carried 100 mm below the bottom and cut with an arch 180 mm wide, so they stand as legs. Glue a hardwood step 60 x 60 x 20 mm in the middle of the floor with a 20 mm hole 15 mm deep. Make the lid 380 x 380 mm in two halves, split 30 mm off centre, bore the larger half 13 mm in the middle, and give the smaller half a knob. Fill the box with water overnight so it swells tight, then empty it.
Materials for this step:
Hardwood Board3 pieces
Wood Glue1 piece
Wood Screws30 pieces
Hardwood Dowels1 pieceTools needed:
Table Saw
Jigsaw
Cordless Drill
Drill Bit Set
Bar Clamp
Try Square
Tape Measure
Water10
10
Gearing on the lid
Gearing on the lid
Screw a hardwood bridge 80 x 56 x 25 mm over the lid's hole and two chairs 44 x 30 mm, 106 mm tall, in a line towards the front. Pass a 12 mm stainless shaft down through the bridge and lid, with the pinion pinned on top and a 16 mm square hardwood pin glued on below the lid. Pass a 12 mm stainless crank shaft through the chairs with the crown wheel pinned on, meshing with the pinion, and a hardwood crank c with a handle on its end.
Materials for this step:
Stainless Steel Rod1 pieceHardwood Board1 pieceHardwood Dowels1 pieceWood Glue1 pieceWood Screws8 pieces
PETG Filament1 pieceTools needed:
FDM 3D Printer
Hacksaw
Files (Hand File)Cordless DrillDrill Bit Set
Screwdriver Set11
11
Dasher shaft d and arms e e
Dasher shaft d and arms e e
Turn a hardwood shaft 40 mm square and 435 mm long down to 18 mm across for its last 55 mm, tapering into the square over the 60 mm above. Cut a square socket 16.6 mm across and 35 mm deep in its top. Chisel a 20 mm mortise through it across where it will stand 260 mm above the box's floor, and another at right angles at 60 mm, and glue in two hardwood arms 20 mm square, 224 mm long.
Materials for this step:
Hardwood Board1 pieceWood Glue1 pieceTools needed:
Wood Lathe
Mortise Chisel
Wooden Mallet
Hand Saw
SandpaperTape Measure12
12
Wings f f' and leaf g
Wings f f' and leaf g
Screw the outer wing from the upper arm's back tip down to the lower arm's left tip, bowed out, and the inner wing from the upper arm's front tip down to the lower arm's right tip, bowed in. Hinge the leaf to the inner wing's edge towards the box's corner with the small butt hinge, so it lies on the wing one way and swings out the other. Stand the dasher's foot in the step, put the lid on so the square pin drops into the socket.
Materials for this step:
Cabinet Butt Hinge1 pieceWood Screws8 piecesTools needed:
Cordless DrillDrill Bit SetScrewdriver Set13
13
The build in 3D
The build in 3D
FreeCAD model of this build, one side and half of another cut away: the shell, the lid with the crown wheel, pinion and crank, and the dasher with its two arms, the two wings and the leaf (shown open). The dasher was turned through 16 angles with the leaf closed and open.
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Churn, then gather
Churn, then gather
Pour about 12 litres of heavy cream at about 15 °C into the box, checked with the thermometer, and put the lid on. Turn the crank the way that keeps the leaf folded on its wing, timing it. When the butter comes, turn the crank the other way so the leaf opens and gathers the butter. Lift the lid off, lift out the butter, drain the buttermilk, wash the butter in cold water until it runs clear, work in a pinch of salt and weigh it.
Materials for this step:
Heavy Cream12 l
Coarse Sea Salt1 pieceWater1 pieceTools needed:
Leave-In Probe Thermometer
Stopwatch
Digital Kitchen Scale
Stainless Steel Mixing Bowl (Large)15
15
Troubleshooting
Troubleshooting
Hinged-leaf churn troubleshooting.
Flow
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16
History and honest limits
History and honest limits
**Malachi B. Hassler** of Columbia City, Indiana, US 25,410, 13 September 1859, "Churn". He claimed "the arrangement of the hinged curved leaf (g) in combination with the wings (f, f',)". The patent gives no sizes; every size here is ours. The wings' exact curves are read from his drawings; ours are printed.
Materials
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Tools Required
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Design Files
6This blueprint makes
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