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Starlifter Driver
Reged: 01/23/08
Loc: Fort Worth, Texas, USA
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5716328 - 03/06/13 12:50 PM
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Beo, spend the 12 bucks and replace it, it'll drive you mad if you don't! Besides who knows what kind of weird vortex it'll create, you'll hear it whispering to you when it's dark and quiet.
But I disagree, Beo. As long as it isn't causing a problem, leave it there. A little self deprecation is good for the soul. 
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1965healey
The Snarkster
Reged: 06/23/07
Loc: San Antonio, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5717058 - 03/06/13 06:54 PM
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Is it just my iPad or are a lot of the recent photos not loading? I'm getting lots of little blue boxes w/ ?'s and no pix.
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: 1965healey]
#5717362 - 03/06/13 09:57 PM
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Quote:
Is it just my iPad or are a lot of the recent photos not loading? I'm getting lots of little blue boxes w/ ?'s and no pix.
Hmm. Works for me, but then again... I post them all as linked images, so you may be experiencing a delay or other problem between CN and my web host, but who knows...
Beo
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5717546 - 03/06/13 11:59 PM
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Wednesday, February 27th:
Went out to feed the animals and check for any damage from the major wind storm that hit Central Texas on Monday the 25th, with 70 MPH (hurricane force) wind gusts. It made a bit of a mess of my remaining covered piles of construction supplies:
But I was thrilled to see that the only evidence of anything on the observatory was a bit of an upturn to the corners of the felt on the roof!
Although the tarp and boards covering the 6' door opening was moved around quite a bit at the bottom, and the landscape was scoured of all loose mulch, etc., much of which ended up inside the observatory!
Not only all the mulch, but also that black mat was outside the observatory on Sunday!
I stayed late and worked on the electrical for a while, getting the main feed connected into the breaker box and mounting the box permanently. Not exactly easy with these big 4/0 aluminum cables!
Beo
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5728003 - 03/12/13 12:08 PM
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Ok, trying my new format for posting images. Clicking on the image will take you to the full side image, while clicking the link underneath will take you to the associated web page.
Friday, March 1st, 2013:
Took a day off to have a long weekend. Spent the morning getting those darn 4/0 cables connected to a big breaker that wasn't really designed for them.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Putting a conduit over the 6' door frame to allow routing power across. Meant to leave a gap in the header and forgot, but there's plenty of room above the door frame.
Visit the corresponding Orion Ranch Observatory web page.
I started with roughly the same setup I used on the first door to help hold the door in place when I stand it up. Of course that didn't work because the door is an out-swing door and can't be installed without opening the door!
Visit the corresponding Orion Ranch Observatory web page.
Of course the bigger problem turned out to be the clear opening! The standard requirement of door width + 2" didn't work here. The door frame exterior dimensions were the same 74" as the clear opening.  Thus I had to knock out the jack stud on one side and replace it with a 1x4, moving the existing 2x4 to the other side, since a portion of the header still extends outside the frame.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
I heard some rustling while I was working on the double doors and discovered a dove had decided it likes my observatory! I'm not sure if it came in before the double door was up, or thought the door knob opening was a nice place for a nest.
Visit the corresponding Orion Ranch Observatory web page.
Finishing up the evening with the door partially installed, shimmed, and braced.
Visit the corresponding Orion Ranch Observatory web page.
Note the small pieces of 2x4 used to hold things in place.
Visit the corresponding Orion Ranch Observatory web page.
Beo
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hm insulators
Post Laureate
Reged: 01/22/07
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5728248 - 03/12/13 02:06 PM
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Glad the windstorm didn't do too much damage to your new observatory!
We had some crazy weather Friday afternoon over in the eastern part of the greater Phoenix area. Many of the spring training ball games got stormed out.
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: hm insulators]
#5729708 - 03/13/13 05:29 AM
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Saturday, March 2nd, 2013:
Finishing up the door. Unfortunately with the out-swing design, the hinges are out past the framing structure of the building and it's very difficult to get the anchor screws into the meat of the building. The top also needed to be pulled up to the framing, but again is too far away for a screw to make it all the way through the spacer to the header. 'twas a bit of a pain! I've installed an old door knob temporarily. Once I get everything painted I'll install the permanent ones.
Visit the corresponding Orion Ranch Observatory web page.
Details of the top and bottom capture for the fixed door. Again, with the gap to the header, there's not much meat to hold the door, so the spacer had to be placed to attempt to address that. You can also see where I buggered up the gasket a bit on one of the screw holes that are hidden under the gasket.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
I had to chip a bit of the slab away to insert the bottom catch in the threshold. I'm going to have to figure out what I'm going to come back and do to fill in under the lips of the thresholds that hang off the edge of the slab. I note on my house they did that with bricks on the back porch, but of course my house is brick sided. I plan to pour porches on both entries, but didn't plan on it being level with the slab. I could presumably put the pressure treated expansion joint there and make it above the top of the porch, but that's not ideal. Suggestions welcome.
Visit the corresponding Orion Ranch Observatory web page.
There's a bit of a gap at the top, but the door frame is square. It appears that the door may actually a bit warped, since there's a bit of a gap at both top and bottom, but the temporary doorknob isn't very tight. The real one should pull up tighter.
Visit the corresponding Orion Ranch Observatory web page.
Marking off vertical and horizontal lines for stud locations and tops of siding.
Visit the corresponding Orion Ranch Observatory web page.
The first full piece of HardiePlank in place
Visit the corresponding Orion Ranch Observatory web page.
First few rows going up:
Visit the corresponding Orion Ranch Observatory web page.
Necessity's Child: In order to get this full 12' length piece in place under the window without breaking it, I had to rig a temporary support that would let me finish the cuts in place and then attach it. The Hardie material is just too weak to stand that much stress on a cut piece like this.
Visit the corresponding Orion Ranch Observatory web page.
Making pretty good progress as the sun goes down.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Finished up around the rear vent. This looks pretty good as-is. Chances are I won't bother with any trim around it. Just caulk it well.
Visit the corresponding Orion Ranch Observatory web page.
Working after dark. It's getting late, I'm getting hungry, but I'm SO CLOSE!
Visit the corresponding Orion Ranch Observatory web page.
So, I kept working and managed to finish off the entire west wall!
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Beo
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Midnight Dan
Postmaster
Reged: 01/23/08
Loc: Hilton, NY, Yellow Zone (Bortl...
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5729804 - 03/13/13 07:44 AM
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Hi Beo:
What's the purpose of the 4-gang breaker at the top of the box? I thought a standard 220v service just used a 2-gang main breaker.
-Dan
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5729888 - 03/13/13 09:01 AM
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Sunday, March 3rd, 2013:
Spent the morning cleaning up the used AC unit for the south wall of the observatory, inside and out. That took some work!
Visit the corresponding Orion Ranch Observatory web page.
My wife showed up about the time I was finishing mounting this unit in the wall, so I drafted her to help with putting up (most of) the south wall siding. Things went considerably quicker with a second pair of hands to hold an end in place while I nailed it.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
I actually quit early this day (it was still daylight) since I was at a good stopping point and had to be up at 4 AM to head to the airport the next morning!
Saturday, March 9th:
It was scheduled to rain all weekend, but of course it ended up with only a bit of drizzle and started clearing by about 5:00 and was pretty clear on Sunday. Unfortunately I was already pretty tired from my trip and had to head out of town again Sunday evening, so I was limited in what I could do.
My rack gear rails arrived while I was out of town.
Visit the corresponding Orion Ranch Observatory web page.
I bought two four-foot and four six-foot lengths I bought from Standard Steel Specialty Co. (great price compared to McMaster Carr or Grainger, but they don't take credit cards) to give 32 feet of total length. The racks are 12 pitch, 20 degree pressure angle, 1 inch wide.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Detail on the 12 pitch, 20 degree PA, 28 tooth pinion drive gear I bought off Amazon to attach to my drive motor.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
And with the gear sitting on one of the racks:
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Drilled the first set of holes in one of the short racks. Making a 1/2" hole to provide some adjustment for a 3/8" bolt.
Visit the corresponding Orion Ranch Observatory web page.
Here's the drill setup to control the position of the hole. I step drilled the first couple of holes, but decided that was actually less effective because I couldn't keep good oil on the larger bit as I drilled since it would go down the previous hole. Not to mention that switching back and forth between bits for each hole was a hassle and took considerably long. So I finally just went for the 1/2" bit all the way, stopping to add oil every mm or so.
Visit the corresponding Orion Ranch Observatory web page.
A few hours later, all the racks are drilled with holes ~ every two feet.
Visit the corresponding Orion Ranch Observatory web page.
Adding a pair of bearings to the motor drive box to capture the rack against the pinion. This motor drive is salvaged from a positioning product we manufacture at our company. I directed the design of it years ago and wrote the firmware for it, so I can pretty much turn it into whatever I want it to be. The rack will actually run an inch or so away from the motor box, unlike what's pictured here, but this was just for fit.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
The next step would be to start mounting things on the roof, which would require opening things up and moving stuff around. Given the (non-existent) threat of rain, and that I was tired after a week of travel and the prospect of my next trip, I didn't want to get into a potentially long process. Instead I spent a bit of time finishing fixing up the old used AC unit by repairing the condenser coils.
Before:
Visit the corresponding Orion Ranch Observatory web page.
After:
Visit the corresponding Orion Ranch Observatory web page.
Hey! I'm finally caught up on my posts! I'm looking forward to getting home and getting back to work. I probably won't get a lot done this weekend though, since I don't get back until after midnight Saturday night.
Beo
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Midnight Dan]
#5729896 - 03/13/13 09:07 AM
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Hi Beo:
What's the purpose of the 4-gang breaker at the top of the box? I thought a standard 220v service just used a 2-gang main breaker.
-Dan
Hey Dan:
It's a 200 Amp drop, so apparently they use parallel 100A breakers to get the 200A rating. I'd think there'd be a problem with the potential of current hogging causing one breaker to dominate, but presumably the delta's small. Basically I oversized everything against possible future need (I will be running a workshop off of this one day), so I don't really expect to ever push this thing anywhere near a limit.
Beo
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snommisbor
sage
Reged: 06/15/09
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5730021 - 03/13/13 10:17 AM
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Beo,
You gonna have a star party christening when you get this thing done? It looks really nice.
You know I met you several years ago at the Austin Under the Stars and you were the one that told me to get a CGEM as the mount. Which I of course did along with the C-8 that came with it. Those are long gone now but I always have you to thank for putting me on the right path.
I enjoy visiting your site.
Rob
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: snommisbor]
#5730145 - 03/13/13 11:38 AM
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Beo,
You gonna have a star party christening when you get this thing done? It looks really nice.
You know I met you several years ago at the Austin Under the Stars and you were the one that told me to get a CGEM as the mount. Which I of course did along with the C-8 that came with it. Those are long gone now but I always have you to thank for putting me on the right path.
I enjoy visiting your site.
Rob
Thanks Rob,
With a Tak and a TEC what a path it's been! Congrats on the scope growth. What a hobby, huh?
I'll eventually have to have some sort of AAS get together, but who knows when. Even once I'm functional, it'll take some time to really be DONE! (And I know, I'll never really be done...)
Beo
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5759193 - 03/26/13 09:14 PM
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Sunday, March 17th, 2013
Got home from Germany about about 1:30 AM Sunday morning, but I couldn't let that prevent me from using a decent work day. Working on the north wall siding, I had to start with installing the new fancy AC unit that I bought for the warm room. It has both heat and cool modes and is designed for through wall installation. The shell is installed first.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
AC core installed in the frame.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Spent the rest of the evening putting up siding. Stopped a bit early to try to look for comet PAN-STARRS at sunset.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Saturday, March 23rd, 2013
I actually planned on doing some electrical on Wednesday evening after work when I went out to feed the animals, but discovered that the outlet boxes I'd bought were too deep for the wall thickness and paneling I'm using. It would have been ok for drywall, but not for the thinner wood paneling. So I installed the whole-house surge protector in the breaker box and then used the evening as an opportunity to take back all my extra materials and pick up a few other things.
Saturday morning was drizzly, so I used the opportunity for some interior work. I installed one outlet so I'd have power in the observatory separate from the warm room, allowing me to clear the extension cords out of the doorway.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Adding the first of the insulation to some of the blind sections that won't be accessible from the inside.
 Visit the corresponding Orion Ranch Observatory web page.
Finishing off the Quiet Brace insulation board.
Visit the corresponding Orion Ranch Observatory web page.
Covering everything with house wrap.
Visit the corresponding Orion Ranch Observatory web page.
Installing the final door. It's another exterior door that divides the observatory from the warm room. This is the door that was apparently replaced twice because the first one was damaged on arrival, the second was MIA, and now this one has a small dent at the base too! Not worth trying to get fixed though.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Finishing the north wall siding. Quite a bit of flashing to add here. Hopefully it works!
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Sunday, March 24th, 2013
Starting on the east wall siding. Stopping for a late lunch.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Time to install the last piece!
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Finished the east siding a while before dark.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Adding the first corner trim. Amazing how much difference a bit of trim makes!
Visit the corresponding Orion Ranch Observatory web page.
Finishing up the south wall trim in the dark. Sort of. Had a bit of a problem with the bottom piece of trim under the AC. Too dark to fix easily.
Visit the corresponding Orion Ranch Observatory web page.
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rockethead26
Carpal Tunnel
Reged: 10/21/09
Loc: Indiana, USA
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5759674 - 03/27/13 07:41 AM
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Most impressive. Wish I had the skills.
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csa/montana
Den Mama
Reged: 05/14/05
Loc: montana
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5759850 - 03/27/13 09:37 AM
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Unbelievable how much you've accomplished recently! That is a most impressive observatory; more like a home! 
Can't go wrong when a Dove blesses it!
Thanks Beo, for sharing all the great pictures for all of us to follow along with you!
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Jeff Smith
sage
Reged: 04/06/10
Loc: Chicago
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Re: Orion Ranch Observatory - Construction Begins!
[Re: csa/montana]
#5759994 - 03/27/13 10:58 AM
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Love it! Very tidy.
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Starman27
Post Laureate
Reged: 01/29/06
Loc: Illinois, Iowa
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Jeff Smith]
#5761552 - 03/27/13 11:38 PM
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Outstanding build!
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hm insulators
Post Laureate
Reged: 01/22/07
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Starman27]
#5775466 - 04/03/13 12:36 PM
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Now you can go grill yourself some steaks and pop a cold one!
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Lord Beowulf
Pooh-Bah
Reged: 10/13/08
Loc: Cedar Park, TX
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Re: Orion Ranch Observatory - Construction Begins!
[Re: hm insulators]
#5778834 - 04/05/13 12:17 AM
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Thanks all. Not quite time for the celebration yet, but I'm getting close!
Evening of Wednesday, March 27th, 2013:
Doing some electrical work, adding the outlet boxes in the warm room as well as the first external box.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Saturday, March 30th:
Fixed the sagging end beam permanently with a 16' 2x10. The center is now the highest point, allowing for some loading.
Visit the corresponding Orion Ranch Observatory web page.
Cutting a keyway in the gearbox drive shaft.
Visit the corresponding Orion Ranch Observatory web page.
And with the drive gear installed.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Here's a shot of the interior of the motor drive system, showing the gearbox, three-phase motor with encoder feedback, three-phase variable speed drive, DC power supply, and power filter.
Visit the corresponding Orion Ranch Observatory web page.
Went ahead and braced the other end although it didn't really need it at the moment. Then finished up the drive rail down the middle.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Installing the first 6' gear rack:
Visit the corresponding Orion Ranch Observatory web page.
And installing a 240V circuit for the drive:
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
Test fitting the drive system:
Visit the corresponding Orion Ranch Observatory web page.
Visit the corresponding Orion Ranch Observatory web page.
The drive floats on a couple of 8' 2x4's elevated so that the motor stays horizontal. It can move up and down several inches and only have a degree or two of tilt. Pillow blocks to either side will provide the lateral support when the drive is engaged.
Visit the corresponding Orion Ranch Observatory web page.
Close up of the motor and drive control circuitry.
Visit the corresponding Orion Ranch Observatory web page.
And finally, a special treat for those who've stuck with me this long in this post. Here's a video of the drive closing the roof using the 12' worth of rack I had time to put up.
Enjoy!
Beo
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seryddwr
Innocent Bystander
Reged: 02/19/10
Loc: I don't know, you tell me.
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Re: Orion Ranch Observatory - Construction Begins!
[Re: Lord Beowulf]
#5780310 - 04/05/13 06:35 PM
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WAHOO! I was just thinking of Sousa's "Stars and Stripes Forever" during that. It is indeed getting close to celebration time!
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