gas air compressor build

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kevbo22

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So I gave myself a Christmas present this year a bought a eastwood versa cut 60amp plasma cutter. Only thing is I dont have a big a** air compressor to run it. To get enough air I would be looking at a 240v air compressor to run, and I am not going to wire in a new one or spend that much money on a new compressor.

So I decided I would build a gas powered one instead. I plan on using a motor that came of my monstermoto mini bike. Its a 79.5cc 3hp. I have read a lot about gas powered air compressors and am a little worried it wont be enough power. But if its not i'll drop a 212 on it. I really dont understand why a 3hp electric motor would be more power than a 3hp gas motor. an electric motor rated at 3hp pushing 3600rpm and a 3hp gas motor pushing 3600rpm should be the same??

Found a good tank on craigslist for $20. And when I went into harbor freight, they had a 3hp 10cfm compressor pump on clearance for $85. I talked the manager down to $40!!!!:thumbsup:

The pump has a max rpm of 1050 and has a 12.5" inch pulley. The motor is 3600 rpm so had to figure out the pulley size for the motor for correct rpm on the pump. I decided to use a 3.5" pulley on the motor which is 1008 rpm.

I will be using a Pilot Discharge Unloader Valve Check Valve all built into one that i found on amazon. Its pretty cool, it has the check valve built in and once it hits 125psi it unloads the air from an exhuast port. I also got a bullwhip that plugs right into it that make the engine go to idle speed when it hits 125psi.

Will be running 1/2" line to tank and 3/8" out to plasma with a filter and desiccant dryer.

The tank I purchased has a bent axle and doesnt sit level cause the front legs are uneven. So I am cutting off the bent axle and welding a new one on and will cut the front legs down and weld a plate up to make it a little more sturdy and level.

Right now I am just waiting on a couple parts that should be here any day. So far I have fixed the axle, front legs and have painted black. Once I get the rest of the parts, I will weld a new top for the motor and pump and start plumbing everything in.
 

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Denny

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Be careful welding on a pressure vessel like that. A bad weld could cause the tank to rupture and level you're house. :oops:

Denny
 

ezcome-ezgo

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Very cool project. I have no experience with this kind of thing, so forgive my curiosity - but won't running the pump so close to it's max rpm just risk premature wear?
 

mckutzy

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Compressor builds are great... Until you start welding stuff onto it..
Unless you have any skill/knowledge welding pressure vessels(air tanks ect) you shouldn't even think of it...
I hate to say that this is a project that you'll just have to accept a loss on(the tank that is) and start over.... That is a huge liability and is dangerous...
 

kevbo22

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Be careful welding on a pressure vessel like that. A bad weld could cause the tank to rupture and level you're house. :oops:

Denny

Compressor builds are great... Until you start welding stuff onto it..
Unless you have any skill/knowledge welding pressure vessels(air tanks ect) you shouldn't even think of it...
I hate to say that this is a project that you'll just have to accept a loss on(the tank that is) and start over.... That is a huge liability and is dangerous...

Hey guys. not welding on the tank. The only welding I have done so far is on the axle which is attached to 3/4" tubing that the manufacturer welded on. The top plate I will be welding on is also not on the tank, it will be welded to the old motor mount.

I have welded bungs in compressor tanks before without issue.

---------- Post added at 10:34 AM ---------- Previous post was at 10:33 AM ----------

Very cool project. I have no experience with this kind of thing, so forgive my curiosity - but won't running the pump so close to it's max rpm just risk premature wear?

More than likely yes. But also not necessarily. Good compressor oil and frequent changes may give it a longer life. Time will tell.
 

kevbo22

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Well I finally got the belt in the mail today, so this week I can weld up a mount and hopefully get this thing going. Hoping to have it running by next week.
 

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kevbo22

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Well I was side tracked on this build!!:censored: A pipe burst on super bowl sunday that I had to fix before I could get around to this. Little sheet rock work. I will have to sand and apply another coat it looks like before it will come out right and texture is smooth. But compressor is still on!
 

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kevbo22

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Got a little side tracked with work. Finally got to work on the compressor again. Got it all done except the plumbing. I will finish it tomorrow.
 

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kevbo22

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Got all the air lines plumbed in. Fired it up and it worked great...until the tank pressure hits 40psi, then the engine dies. Just doesnt have the power. As I mentioned in my first post, when I researched this build I found that this motor may be too small. I can confirm that a 3hp pump will need more than 3hp gas motor! I have read that you need to double the hp for every electric hp you need. I have to much in it now, gonna have to go get a pred 212. Other than the lack of power at 40psi, it runs great!!
 

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kevbo22

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Must have something to do with Torque.

I dont have any scientific data on it, but you must be right. Its strange, I assumed a gas motor would have more power than an electric one.

When I was looking into this build I read all over that gas compressors need double the hp of an electric motor, I just couldn't believe it. But I am a believer now:oops:.

Oh well I still managed to get a $800-$900 10cfm compressor for about $250 once the 212 is in.
 

kevbo22

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Got the 212cc pred on!! Works great. Has the power, fills the tank in no time. The unloader works as its supposed to.

So I can confirm that a gas powered compressor pump needs more hp than an electric powered pump. The 6hp 212 works fine on this 3 hp pump.

If anyone ever needs/wants to build one, here is a part list:

Unloader:
http://www.amazon.com/Pilot-Dischar..._&refRID=037CCT1F1DTDSA26G00W#customerReviews

Throttle whip:
http://www.amazon.com/Throttle-Cont...C_UL160_SR80,160_&refRID=1NS65WBC7Z8FQE7KBKWH

Regulator:
http://www.harborfreight.com/125-PSI-38-in-NPT-Air-Flow-Regulator-with-Dial-Gauge-68231.html

PSI guage:
http://www.harborfreight.com/air-tools/air-tool-accessories/160-psi-14-npt-dry-gauge-68249.html

pred 212cc pulley:
http://www.amazon.com/Chicago-Die-3...&sr=8-5&keywords=chicago+die+cast+pulley+3.5"

Compressor pump:
http://www.harborfreight.com/145-psi-3-hp-twin-cylinder-air-compressor-pump-67697.html

Pump air whip:
http://www.amazon.com/gp/product/B0..._m=ATVPDKIKX0DER&pf_rd_r=15G172T25XZ6SPAP359A

To determine your belt size:
Belt size =(O.D. pulley + O.D. flywheel x 1.57) + (center to center distance of pulleys x 2)

Example: ((5.375" + 13.625") x 1.57) + 12.5" + 12.5" = 54.83" belt needed (55" belt)

Belt needed is a 4L/A belt
 

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Grape Ape

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Been designing compressor packages for 20 years. When changing from electric to gas or diesel you have to de rate the engine. Depending on the type of compressors could be up to 3X the electric motor size or as little as 1.5X.
 

karts

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If my compressor pump required 5hp 700rpm
How much power do I need for gas engine?

---------- Post added at 12:29 AM ---------- Previous post was at 12:18 AM ----------

12 .5hp?
 

kevbo22

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If my compressor pump required 5hp 700rpm
How much power do I need for gas engine?

---------- Post added at 12:29 AM ---------- Previous post was at 12:18 AM ----------

12 .5hp?

from my understanding you would need 10hp gas minimum (Double the hp rating of electric). A 420cc predator would do it, then you would determine your pulley sizes to reach the 700rpm.
 

Grape Ape

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It depends on the type of compressor, diaphragm, piston, vane, etc. when I have a compressor package that normally requires 5HP Electric Motor I use a 7.5HP gas / diesel engine but I deal with high pressure reciprocating compressors compressing up to 6000 psi (low volume high pressure)
 
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