Corny's Setup 2007/08 Season

[Corny]

The development of our setup for the 2006/07 heating season is chronicled pictorially in the following thread: http://forum.iburncorn.com/viewtopic.php?t=2856&highlight=cornys+setup .
It involves a tarped gravity wagon, different incarnations of a screened chute, and vacuum suction and cleaning using a cornvac into a secondary bin plus postscreening using a gravity fed mini-kan_burn. I made some modifications to the system during the summer and after running about 2 ton through it so far, I'm happy enough with it to report it here.

1. I am now going with direct suction from the gravity wagon as shown below. There's a steel 2" drop pipe welded to the underside of the gravity wagon over a 2" hole. The pipe connects to a 2" self cleaning blast gate http://forum.iburncorn.com/wiki/index.php/Vacuum_based_systems#Other_Parts_.26_Goodies_for_Vacuum_Systems which reduces to a 1.5" PVC wide sweep elbow.


2. A grate made of steel rod keeps cobs and large pieces out of my system as shown below. Last year, without this guard, I had clogging problems due to cob pieces blocking the hole I was using to feed a 1.5" hose. So far this year I've had no problem with the larger hole and guard.


3. An overhang was built using a length of 1.5" ABS pipe attached to heavy duty folding shelving brackets. The pipe is skewered and tied onto each bracket. The overhang, when covered by the tarp, keep water from seeping through the wagon's sliding door. This prevents spoilage, door jamming, and blockages from a frozen mass near the door.


4. The tarp drapes tightly over a ridge board, tighter than shown below. (The tarp was loosened so that the picture could be taken). So far the tight tarp on a steep pitch has not collapsed under heavy snow loads. This is our 2nd season doing it this way; and we had record snowfall for the month of December.


5. Makeup air is added through a tee and ball valve. Corn is aspirated to a secondary bin through a 12' ABS pipe, 1.5", and short lengths of 1.5" smooth walled flex hose ( from www.princessauto.com ; http://forum.iburncorn.com/wiki/index.php/Vacuum_based_systems#Suction_Hose ) at each end of the pipe. The rise is approx. 8'.


EDIT 2008-02-10: I have since replaced the widesweep elbow at the wagon with a standard elbow. This brings the makeup air closer to the source. The pull is now excellent. Now the concern, if any, is in keeping the corn from flowing too fast. It's amazing how such a small change can make such a big improvement. There's a pic of the new hookup...


6. Dust and beeswings are removed by a cornvac cleaner (www.cornvac.com) on top of our secondary bin constructed from a barrel with an external cone welded to its bottom ( http://forum.iburncorn.com/wiki/index.php/Vacuum_based_systems#Dimensions_for_55_Gal_Barrel_Internal_.26_External_Cones ) . The bin is finished with primer, gravelguard, and tremclad paint. The gravel guard hides imperfections in the barrel. Our vac (6.5 hp) and various tools reside in the cheapie temporary storage shed in the foreground.


7. Cracked corn is collected for bird feed using a vacuumless mini kan_burn ( http://forum.iburncorn.com/wiki/index.php/Kan_Burn ) at the bottom of the bin. The bin holds 6.6 bushel (370 lb) of corn. The discharge pipe is 2" diameter with a 2" self cleaning blast gate. Last year, we had some blockage problems with a 1.5" drop pipe and 1.5" ball valve. This year we have had no problem.


8. The bin rests on a covered verandah, just outside a door that leads to the room with our stove. It is no big deal to hoof the corn by bucket to the stove from there. For fastidious cleaning, we blow air from the vacuum cleaner while filling buckets. The picture below is from last year with our 1.5" delivery system.

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My motto: "If it doesn't fit, make it fit."
My mantra: It's in the WIKI!: http://forum.iburncorn.com/wiki/index.php/Bixby

[sting]

Good job

Thanks for sharing!
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[kan_burn]

Looks nice, I dig the "cob guard".

Because the suction port is not at the very bottom does all of the "trash" end up at the bottom of the chute?

[Corny]

[cowtrimmer]

Nice chronicle of events and pictures.Thanks for turning me on to those self-cleaning blast gates.

[kappel15]

very nice and well documented corny. the usual great job coming from you.
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Trained Tech.
Sante Fe
Mt. Vernon AE
kan-burn shur-kleenII kap-kleaner

[lilcombine]

Thats a nice lookin setup there Corny. i just keep gathering ideas, to make my setup. The luggin 70 lb bags down the stairs is gettin kinda old.
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_______________________________________
Rob

[Corny]

No shame in the manual method, either, lilcombine. You have a nice setup in the corner, there, and I like the way you mounted the buck with the head turned. Let us know whatever you come up with.

Corny
_________________
Bixby 115 MaxFire.
My motto: "If it doesn't fit, make it fit."
My mantra: It's in the WIKI!: http://forum.iburncorn.com/wiki/index.php/Bixby

[lilcombine]

Thanks Corny. I know there is no shame in it, but I think I can make getting a load of corn alot more "fun". The wife thinks I am nuts for wanting to do something, but she isnt there to help me drag 500 lbs of corn downstairs every weekend
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_______________________________________
Rob

[billyg2000]

Wow that is a nice set-up Corny. Good pics too. I'm still in the design stage of cleaning and moving corn but this group sure has a ton of good ideas for newbies like me to borrow Corngratulations on finding and sharing the easiest way to move corn for your house. I'm impressed
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God Bless; Billy
Bixby MaxFire 115
Google Ron Paul
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[Corny]

I have edited my pics above (at Step #5) to show an improved hookup at the gravity wagon.

The widesweep elbow at the wagon is now replaced with a standard elbow. The pull is now excellent. Now the concern, if any, is in keeping the corn from flowing too fast. It's amazing how such a small change can make such a big improvement. There's a pic of the new hookup...


I'm presuming that the improvement has to do with bringing the air makeup closer to the source. Any other theories?

Corny
_________________
Bixby 115 MaxFire.
My motto: "If it doesn't fit, make it fit."
My mantra: It's in the WIKI!: http://forum.iburncorn.com/wiki/index.php/Bixby

[JBCorn]

You might be on to something Corny. I will find out later today. I am going to send a 10' pipe into the wagon, the air make up will be outside of the wagon. I don't know how well it is going to work but I am keeping my fingers crossed since it is -15F outside right now.
_________________
Quadra-Fire Santa Fe / Mt. Vernon AE /C-1-330 Board with Wall Control/ Shur-Kleen Screener/ Mobile Corn Vac

[billyg2000]

Corny; Nice mod. I believe your theory is right on. The sooner the air is introduced into the flow the sooner the flow becomes diluted and lighter to move. Glad it is all working well for you. I didn't realize it until now that you too are lugging buckets of corn for exercise.
_________________
God Bless; Billy
Bixby MaxFire 115
Google Ron Paul
Supporting Farmers for a Change
The Fear of The Lord is The Beginning of Wisdom

[Corny]

Ya, Billy, I hoof buckets with the best. I don't have far to go, though -- just inside the dor. I'd rather not drill another hole through the wall just to save me that effort. The wall is 3 layers of solid brick. Enjoy! -- Corny
_________________
Bixby 115 MaxFire.
My motto: "If it doesn't fit, make it fit."
My mantra: It's in the WIKI!: http://forum.iburncorn.com/wiki/index.php/Bixby

[corn4myheat]

I ran mine from the attic way floor to the basement
ceiling at the bottom of the steps (steps are directly
below the attic way)
from the top of the ceiling in the basement over to
the 18 gal drum. So from the IBC tote
in the garage to the 18 gal drum saves me from
handling any buckets

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"I built it with my own two hands"