FUJ-219 Magnetically Assisted Ionization fusor

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Maciek Szymanski
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FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

In the other thread I’ve started discussion about fusor with magnetically assisted ionization. Here I’m going to put the pictorial documentation of the design and building process.


Main chamber assembly drawing:
F8F2BA7C-1F9A-4581-91B7-3F4C6141C9C1.jpeg

Anode assembly/parts drawing:
17E77106-3842-4E4B-B6CB-0853F7FDFBE7.jpeg

Chamber end caps, stainless sphere for anode shell and main sealing o-ring:
D2E4C638-3C83-4C79-8B2F-D9976EB424CB.jpeg
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Richard Hull
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

You are off to a good start. Love that ancient RPN H-P calculator.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Richard Hull wrote: Sat Mar 21, 2020 1:06 amLove that ancient RPN H-P calculator.
I realny like doing things old school way. After many years of working with high-end 3D cad systems manual drafting is a very refreshing experience.


As the solenoids must be quite exactly positioned in line one with other and with the ports in the anode, the actual shape of the shell must be known precisely. The caps I’ve received do not follow the EN-10253-4 dimensions so I’ve to cut the fitting template to transfer the profile to the drawing:
9DC7E626-E7CF-4888-A0B9-B679B75CB777.jpeg

The less rounded shape is actual profile. The other is drawn as in the standard. Now the port center points coordinates can be obtained for machining:
E4408100-F965-40B6-BF46-63F022C7F35E.jpeg
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Old school to say the least. I have a separate ASDD degree that I got on a lark back in 1967 (Associate Science Drafting and Design). I learned drafting thinking that it would be a useful skill. It is, of course, but the computers wiped out the old big boards with the attached drafting "machine", tedious 'inking in", etc. I have a box filled with drafting implements, triangles, protractors, french curves and such. I will, on rare occasions, haul them out and do a pretty drawing when it is warranted. I use Microsoft's paint now as a crude drawing program and all my circuit diagrams are drawn using the free Express PCB circuit drawing program. 90% of such product is used and posted here in my FAQs and some postings.

Still, I love to see the old drafting efforts done by a master.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Today I’ve found time to do some machining. I’ve made all the openings in the anode shell. For now I’m a bit limited because of the pandemics. I can’t use the big lathe and welding equipment at my work, so no way to make the big outer shell parts. With my small lathe I can do only the anode parts and solenoids.


Oldschool as always. No DRO, no CNC just dials and calipers.
1EB569C6-FA95-42A4-8366-442C3156F42D.jpeg
1EB569C6-FA95-42A4-8366-442C3156F42D.jpeg (98.64 KiB) Viewed 6592 times

Not much left from the original stainless sphere.
4E308B8A-9BB9-43A5-8C71-18FB2912C8F1.jpeg
4E308B8A-9BB9-43A5-8C71-18FB2912C8F1.jpeg (86.87 KiB) Viewed 6592 times

Machined anode shell. It still needs some finishing:
74CB510D-C5F2-4858-85F5-ECEDAC7DBCB5.jpeg
74CB510D-C5F2-4858-85F5-ECEDAC7DBCB5.jpeg (67.53 KiB) Viewed 6592 times
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Very, Very nice work! I always like to see interesting ideas turned into hardware. You are one of the "doers". As always, I look forward to your insightful and interesting posts.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Thanks Richard! Definitely I am a “doer”. All long and pointless discussions are not something for me - my approach is always “lets build it and test - we will know more and improve it afterwards”. It’s also a reason for which very big and complex projects (like a skyscraper or a big tokamak) are very hard for me to imagine.

In the meantime I’m doing some slow progress:

The beam ports, junction sleeve, stalk and feed through are machined and temporarily assembled.
770D43C9-51B5-4387-BBB2-23B8EB5A5030.jpeg
770D43C9-51B5-4387-BBB2-23B8EB5A5030.jpeg (68.32 KiB) Viewed 6438 times

496597E5-D1A1-4C86-AC72-E0DA7D34A273.jpeg
496597E5-D1A1-4C86-AC72-E0DA7D34A273.jpeg (64.29 KiB) Viewed 6438 times

866966C6-CA6B-401A-99D6-37E4FE5B229E.jpeg
866966C6-CA6B-401A-99D6-37E4FE5B229E.jpeg (68.92 KiB) Viewed 6438 times
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Nice work! Wish I good do stuff that nice. (I probably could, but I'm too lazy)

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Just finished the work at the drafting board. The work in metal maybe a delayed by pandemics restrictions.


Upper half or the chamber:
1EB689AC-A191-412B-BE16-7E6504589269.jpeg
1EB689AC-A191-412B-BE16-7E6504589269.jpeg (65.94 KiB) Viewed 6323 times


Lower half of the chamber:
71D1DA70-B4E8-4B23-9816-5E50655D7D42.jpeg
71D1DA70-B4E8-4B23-9816-5E50655D7D42.jpeg (63.54 KiB) Viewed 6323 times

Solenoid core parts:
36618452-9F4D-4299-ABCF-7CBFA25DAE95.jpeg
36618452-9F4D-4299-ABCF-7CBFA25DAE95.jpeg (59.76 KiB) Viewed 6323 times
81E2226E-DF11-408D-9765-C44BAFA4F44B.jpeg
81E2226E-DF11-408D-9765-C44BAFA4F44B.jpeg (48.99 KiB) Viewed 6323 times
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Today I was finally able to do some welding. So I’ve at last the cathode assembled with mesh widows and ion apertures. The most problematic was tapping 16 M2 holes in the stainless steel. As always, just after assembling it I’ve an idea to improve the cathode openness - it is possible to add two more mesh windows with the beam apertures in the middle of them. But anyway I would like to test the current design.



Cathode parts ready for welding.
627442AF-60B4-4DF9-A029-5CB4FB2F8130.jpeg
627442AF-60B4-4DF9-A029-5CB4FB2F8130.jpeg (121.69 KiB) Viewed 6222 times

The complete cathode shell after welding.
B87FADCB-FBD0-4512-93A7-4014FB60840A.jpeg
B87FADCB-FBD0-4512-93A7-4014FB60840A.jpeg (106.31 KiB) Viewed 6222 times

The complete cathode assembly with the meshes in place.
CB92FF9B-2DAD-4614-9601-6D2C45ED0A72.jpeg
CB92FF9B-2DAD-4614-9601-6D2C45ED0A72.jpeg (60.68 KiB) Viewed 6222 times
373F5323-4B35-460E-BAA6-F0BC42ECF52A.jpeg
373F5323-4B35-460E-BAA6-F0BC42ECF52A.jpeg (52.24 KiB) Viewed 6222 times

Maybe it will not work, but at last it looks nice.
426BEC51-2706-421F-AC26-B8087FD62041.jpeg
426BEC51-2706-421F-AC26-B8087FD62041.jpeg (92.72 KiB) Viewed 6222 times
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Maciek, once again, super quality work. The last image of you with your creation is great! Thanks for all the images as you proceed in your efforts. Pictures are always worth a thousand words.

I love the old dial phone in your image. Rare in the U.S. now. 100% of the phones in our home are rotary dial phones still on the 'twisted pair"! To call for services or the government, we have to use our cell phones to push the myriad of routing command button presses forced upon those in need. At a monthly HEAS meeting, one time, a young girl brought by a visitor had to call home. I pointed to the wall mount rotary in the lab. she had no clue of how to use it. Her dad went over and instructed her how make a call on it. Later I heard that she excitedly told her mom about using the "really old telephone".

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Once I was very involved with photography. Then, when the digital cameras and especially phones with camera become popular I’ve given it up - I’ve feeling that there is so much photographic images everywhere, so there is no sense for me to take one more. But lately I’ve realized, that most of the photos are made quickly and absently thus very often are useless afterwards. So for some time I’m trying to do high quality photographic documentation, take care for proper lighting, background etc. I’m really upset, when at my work I see illustrative photos in publications taken with a smartphone camera with a dirty lens, crooked, with a photographer’s shadow on the subject and random junk in the background.

The phone is connected to the twisted pair and operational. This is first telephone my parents had.
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

I will say I did a lot of wet photography back before digital. (3 Nikons with many lenses. and 2 4X5 sheet film cameras.) It forced a bit of discipline on me due to costs, even though I developed and printed 100% of my own photos back then. I waited until 1997 to leave wet photography as the digital cameras were, at that time, of sufficient resolution for casual photography. I feel you still must have a formal digital camera of good quality to call yourself a photographer. I have never and will never use my 15 year old flip phone to take an image. For one thing, I don't know or care to know how to even use it. I have two digital cameras and I use my oldest Sony camera set on 1024 X 768 for all fusor images posted to keep them under 1 mega byte. My latest super Canon camera can be used for insane resolution images. I rarely use it because it is rare I see something I want or need to use it for. Adequate is good enough for me here at fusor.net, but I do use a real camera.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Today I’ve chance to use the big TOS lathe, so I’ve finally started to build the main chamber. The flange was made from a laser cut blank, which was machined from both sides. On the inner hole a shoulder was machined to accept the straight tube segment. Then the whole thing was TIG welded: first all parts were stitched in four points from the outside, and then a tight weld was made from the vacuum side in few centimeter increments (four seams 90 degrees apart, then another four in between and in the third pass the gaps were filled to complete the seam). For just aesthetic reason I want to do also the outside weld between the cap and the straight tube.

Practical remarks for those planning machining and welding stainless steel parts. SS is not easy for machining. I’s best to use the carbide cutters for SS. The chips tends to be extremely sharp, hot and springy. Always wear the eye protection! When cleaning machine from the chips it’s good to wear heavy leather gloves - the long chips have razor sharp edges that can cut deeply through your hand without notice.
Welding SS with TIG is not difficult as long as you have in mind it’s very high thermal expansion. Welding by small evenly spaced increments with some cool down between consecutive operations helps to minimize deformation.

Machining of the o-ring mating surface:
70A0BED7-C91B-4F42-8558-4EBC0BCE85D3.jpeg
70A0BED7-C91B-4F42-8558-4EBC0BCE85D3.jpeg (155.11 KiB) Viewed 5527 times

Flange ready for machining the inner shoulder. The triangular wire holds three textolite spacers between the chuck and the part:
A52D644D-BB4D-465A-972D-753CDCC0ACDF.jpeg
A52D644D-BB4D-465A-972D-753CDCC0ACDF.jpeg (168.27 KiB) Viewed 5527 times

The upper shell parts ready for stitching:
4E85AE31-7216-4B6E-95CC-C4D17100C5F3.jpeg
4E85AE31-7216-4B6E-95CC-C4D17100C5F3.jpeg (59.82 KiB) Viewed 5527 times

Apparently a bowler’s hat:
4BD62321-59E5-47CE-AEF0-2C9F83BFC36F.jpeg
4BD62321-59E5-47CE-AEF0-2C9F83BFC36F.jpeg (62.67 KiB) Viewed 5527 times

The parts after first two passes of welding:
914E079D-366F-46AD-A845-19CA51C47910.jpeg
914E079D-366F-46AD-A845-19CA51C47910.jpeg (110.32 KiB) Viewed 5527 times

The seam between the flange and the straight tube finished:
207F623B-3762-45D9-80D1-04B49CBA6A86.jpeg
207F623B-3762-45D9-80D1-04B49CBA6A86.jpeg (125.46 KiB) Viewed 5527 times
Last edited by Maciek Szymanski on Fri Apr 17, 2020 4:42 pm, edited 1 time in total.
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Yes, tack welding with TIG is a must with all standard thin or low thermal mass metal items. Then, longer seams can be made after cooling and checking for dimensional stability. Your flange looks relatively thin and surely must remain flat and sound.

This is why conflat flanges and most all manufactured flanges of ISO or other standards are so incredibly thick. This allows for total, full, one pass, machine welds without the possibility of warping or misalignment of critical vacuum sealing.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

After break for other issues and return to normal work schedule I’ve finally returned to the construction process. Today I’ve machined the flange for the lower part of the chamber. What is left is the groove for the sealing o-ring.


Machined flange after the lathe was all cleaned up from all the chips.
1B5C2F83-A387-4AA4-8ABF-DC03874BE4EB.jpeg

Cutter ground for machining the o-ring groove.
4712321A-2AD5-4848-ACFC-0FB2D94D8727.jpeg
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Nice, big, serious lathe. I am glad to see you back at work on your fusor. You are doing it the "hard way", from scratch. This is how I made fusor III. It was difficult, a nightmare, but totally successful and the first fusor that I made that did fusion. It used indium wire as a gasket. I actually learned how to use a milling machine which I purchased used on fusor III. Great work and far better finished than my fusor III effort.
You are obviously a first rate machinist and have the big tools at hand to do the work. I love seeing such work being done by skilled hands.

After fusor III, I swore I would use standard conflat and ISO fittings for the rest of my life to avoid needless work. I figured I worked for about $1.12 per hour as a machinist, versus purchasing a proper set of 8-inch conflat rings at full list price which were ready to accept the 6" SS hemispheres that would be used for fusor IV. Cheaper and faster in the long run.

I attach an image from 1999 fusor III labors. It was stupid, in hindsight, but I wouldn't trade the learning experience at my milling machine for cash money. Learning due to the "hands-on-imperative".

Richard Hull
Attachments
FIII const (3)LBL.jpg
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Making custom vacuum components is part of my job at Institute. With my fusor chamber I’m hoping to test some tricks and solutions for vacuum systems I can use later in other projects. But machining SS can be a nightmare.
Looking at your photo I’ve realized that I’ve never worked on the “Bridgeport style” milling machine - they are quite rare in Europe as we tend to use “Deckel style” tool room milling machines instead. The global world is not as global as it seems at first glance.

BTW - is theat small round object on the post on the left side of the rotary table a fan for blowing the chips? A brilliant idea indeed!
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Yes, it is a small high CFM fan for chip removal and a tiny amount of forced air cooling. I applied oil every so often as well. SS machining is all about sharp tools and critical speed control. The work was tedious and time consuming. After two solid steam fittings being hollowed out, I just threw the high speed cobalt steel tool in the trash and bought a new 1/2-inch replacement tool. It gave its life for fusor III.

In the image, I have already cut out the solid center disk, ( a nightmare), and am cutting the weld lip to receive the 6 inch hemisphere retaining it for welding where the lip, itself is the source of welding fill. No SS rod feed needed.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
User avatar
Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Today I’ve welded the lower part of the chamber. It needs some seam backside cleaning an all the ports can be fitted.



Lower half of the chamber:
188B887E-9090-4928-BBC1-B983EEF1C2EC.jpeg

Detail of the flange with the o-ring groove:
B7B9B100-3027-4531-8BE3-3B98B2830EA7.jpeg

Chamber halves fitted together. The back sides of the seams will be ground and the additional outside seam added.
3974C7A6-EE1D-4F65-89CF-7E5CB733247A.jpeg
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

Today I’ve cleaned up the back side of the seam (outside of the chamber) and placed the back seam on both halves of the chamber. I’ve also layed out the positions of port holes according to the drawing and prepared the flange for the diffusion pump connection.
Now I have to find the way to swap the milling machine table with the double pivot universal one for boring the inclined holes.


Laying out the chamber centerline:
BB93B11B-E2E1-49E3-A4E3-C60E96257D15.jpeg

Laying out the ports:
3A9F0217-9B9B-49E4-BBC3-951E1D9D4CA6.jpeg
Chamber with back seam placed an the diff pump flange:
B3F8997E-E9A3-49DE-975F-85101229E8CD.jpeg
Last edited by Maciek Szymanski on Tue Jun 30, 2020 2:16 am, edited 1 time in total.
“Begin at the beginning," the King said, very gravely, "and go on till you come to the end: then stop.” ― Lewis Carroll, Alice in Wonderland
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Doing major machine mounting changes can be tough and time consuming to do one particular job. Finally, you realize you have to put the machine back into the "normal" manner of use once you are done. More trouble and hassles. But, it has to be done to proceed. Thanks for the continued updates and discussion on what you must do to keep moving on in the effort.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
User avatar
Maciek Szymanski
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Maciek Szymanski »

After quite a long break (I’ve to do some work at my apartment, move my lathe form friend’s workshop to my garage and spend a week in Prague setting up the measurement system for a p-b laser fusion experiment.) I’ve returned to building the fusor. Finally the simplest tools proven to be the best. A hand drill,a cold chisel and some good files made the work faster than messing up with mill setup. Tomorrow I hope to weld the lower part and pump down the bare chamber.

Drilling out the opening perimeter with a hand drill may look very tedious in the times of 3D laser cutters and water jets, but if you have an old, heavy, high geared drill and the cobalt drill bit for stainless steel it takes half an hour including cleaning up with a good sharp file.
1B97EA63-55AB-4895-B38E-547A8462AF33.jpeg


Lower part of the chamber with all the ports ready for fitting and alignment before welding.
DE3BDA91-6746-4873-9AA3-87936E72C4B8.jpeg

Upper part with cathode installed. The shielding of the cathode stem is not in place yet.
DE38E204-6BFB-42A2-A7FD-4931F44011F7.jpeg
529A8A56-EDFC-46A9-A47D-87E7D530D095.jpeg

Cathode as seen through the viewport:
2498D9A1-3749-4FDD-8B50-2AA7F8E57B03.jpeg

The look along the magnetic ionization line.
267B2511-8367-4300-A3DA-D6624924B623.jpeg
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Richard Hull »

Your effort and reporting are quickly becoming the finest amateur fusor implementation and presentation ever seen over the 22 years of Fusor.net! Your abilities are many! The admission that common tools are often the best or a last resort for those not immediately equipped or have access to top level machining is important to others here. Falling back on common tools is no disgrace and often the only way to be sure of special fittings via careful attention to detailed work.

Thanks for keeping us updated on your amazing effort. We all look forward to your doing fusion with your device. Going slow really shows in the beauty of the finished product.

Richard Hull
Progress may have been a good thing once, but it just went on too long. - Yogi Berra
Fusion is the energy of the future....and it always will be
The more complex the idea put forward by the poor amateur, the more likely it will never see embodiment
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Steven Sesselmann
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Re: FUJ-219 Magnetically Assisted Ionization fusor

Post by Steven Sesselmann »

Makiek,

Beautiful work and photography, well done on trying something new.

Steven
http://www.gammaspectacular.com - Gamma Spectrometry Systems
https://www.researchgate.net/profile/Steven_Sesselmann - Various papers and patents on RG
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