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Pendulum Twin-Dasher Churn: A Swinging Weighted Lever Rocks a Beam That Works Two Half-Dashers Alternately
James O. Merrill of Chichester, New Hampshire, received US 23,986, dated 10 May 1859, for an oscillating churn light enough to be worked by a child. A weighted pendulum behind the frame rocks a shaft; on its front end a beam rocks, and two links from the beam's ends work two dasher arms up and down in turn through slots in a guide bar. Each arm carries a half-round dasher pierced with holes, so the two halves fill the barrel. The two-piece cover is held down by a thumb screw.
This rung builds it full size in timber over a 20-litre bucket.
Intermediate
About 2 days
Instructions
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How far the dashers move
How far the dashers move
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Two dashers worked in turn, before it
Two dashers worked in turn, before it
Mitchell's lever worked two dashers in turn; Merrill's weighted pendulum keeps them going with less effort.
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Read US 23,986
Read US 23,986
"... the operator oscillates the lever L, which communicates the motion through the vibrating shaft M, the vibrating lever E, the auxiliary levers F, F', to the dasher arms G, G', thus producing an alternate reciprocating action of the dashers N, N'".
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Base and frame
Base and frame
Cut a pine base A 720 x 520 mm. Stand two side pieces B B' of 44 x 70 mm timber 960 mm tall, 400 mm apart, 200 mm from the base's back edge, with diagonal side braces I I' and front braces H H' to the base. Screw top braces C C' (444 x 60 x 22 mm) across the front and back faces of the side pieces at the top, and bore both 21 mm in the middle, 30 mm below their top edge.
Materials for this step:
Pine Board2 pieces
Softwood Timber 70x70mm4 pieces
#10 x 3" Wood Screw30 pieces
Wood Glue1 pieceTools needed:
Hand Saw
Cordless Drill
Spade Bit Set
Clamps
Spirit Level
Tape Measure5
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Shaft M, lever E and pendulum L
Shaft M, lever E and pendulum L
Screw a hardwood bearing block 80 x 80 x 18 mm, bored 20.5 mm, over each hole. Cut a 20 mm steel shaft 310 mm long and pass it through both. On its front end fix a hardwood lever E 400 x 60 x 20 mm at its middle with a bolt across, drilled 8.5 mm 150 mm each side of the middle for the pins c. On its back end fix the pendulum L, a hardwood bar 50 x 20 mm, 810 mm long, 60 mm below its top. Glue a 24 mm dowel handle h into L 180 mm below the shaft and bolt an 8 kg kettlebell to its foot as W.
Materials for this step:
Hardwood Board2 pieces
Wood Screws8 pieces
Steel Bar Stock1 piece
Hex Bolt Assortment3 pieces
Nylon Insert Lock Nut3 pieces
Hardwood Dowels1 piece
Wood Glue1 piece
Kettlebell1 pieceTools needed:
Hand Saw
Cordless Drill
Drill Bit Set
Spade Bit Set
Hacksaw
Adjustable Spanner6
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Guide bar J, arms G and links F
Guide bar J, arms G and links F
Bolt a hardwood guide bar J 444 x 40 x 36 mm across the side pieces' fronts on spacer blocks so it stands 70 mm in front of them, 530 mm above the base, and cut two 27 mm square slots through it 40 mm apart. Cut two hardwood dasher arms G G' 25 mm square and 580 mm long, drop them through the slots, and drill each 8.5 mm 20 mm below its top. Cut two links F F' 30 x 14 mm with holes 282 mm apart and bolt each from a pin c on E to a pin g on an arm, with washers and lock nuts so they turn freely.
Materials for this step:
Hardwood Board2 pieces
Hex Bolt Assortment6 pieces
Flat Washer8 pieces
Nylon Insert Lock Nut4 piecesTools needed:
Hand Saw
Chisels
Cordless Drill
Drill Bit Set
Adjustable Spanner7
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Barrel D, covers, dashers and thumb screw
Barrel D, covers, dashers and thumb screw
Stand a food-grade 20-litre bucket on the base under the arms. Cut two half-discs N N' 240 mm across from 12 mm plywood, each with three 34 mm holes, and screw one under each arm's foot. Cut two half-round covers m m from 12 mm plywood to fit the bucket's top, notched for the arms. Bolt a cross brace K 444 x 40 x 30 mm across the side pieces' fronts 440 mm above the base, drill it for an M8 rod 72 mm behind the arms, and run the rod through a nut in K with a wing nut on top as the thumb screw i, down onto an oblong block l laid across both covers.
Materials for this step:
20-Liter Bucket1 piece
Plywood Sheet2 pieces
Wood Screws6 pieces
Hardwood Board1 piece
Hex Bolt Assortment2 pieces
Threaded Rod1 piece
Hex Nut1 piece
Wing Nut1 pieceTools needed:
Jigsaw
Hole Saw Kit
Cordless Drill
Drill Bit Set
Screwdriver Set
Adjustable Spanner8
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The build in 3D
The build in 3D
FreeCAD model of this build, a quarter of the barrel and covers cut away: the base and frame with its braces, shaft M with lever E in front and the weighted pendulum behind, links F, the arms in guide bar J, the two half-dashers in the barrel, and the thumb screw on its block. It was checked at five pendulum angles from -12 to +12 degrees.
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Churn
Churn
Lift the front cover, pour in about 10 litres of heavy cream at about 15 °C, checked with the thermometer, put the cover back and turn the thumb screw down on the block. Swing the pendulum by its handle about 12 degrees each way and time it: the half-dashers rise and fall in turn. When the butter comes, slacken the screw, unbolt the dashers, pour off 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 Cream10 l
Coarse Sea Salt1 piece
Water1 pieceTools needed:
Leave-In Probe Thermometer
Stopwatch
Digital Kitchen Scale
Stainless Steel Mixing Bowl (Large)10
10
Troubleshooting
Troubleshooting
Pendulum churn troubleshooting.
Flow
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History and honest limits
History and honest limits
**James O. Merrill** of Chichester, Merrimack County, New Hampshire, assignor to Wm. A. Swain, US 23,986, 10 May 1859, "Churn". He meant it to take the labour out of churning, adapted to the strength of a child, and claimed the pendulum and weight with the shaft, beam, links and the two alternate dasher arms. He gave no sizes or weight: the frame, the 8 kg weight, the 12 degree swing and every size are ours.
Materials
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Tools Required
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Design Files
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