I'm getting to the party late but I wonder if all the proposed work on this press will actually give you anything but a clean sow's ear.
According to the information it needs at least a new cylinder and gauge. $$$
When you're done you will have a small shop press with an extremely limited work envelope. For about the same money you could acquire a brand new 10-ton H-Press from Freight Harbor with plenty of room for most any pressing project.
As for bleeding the system your lines if their correct should have a checkball on both sides and screw together. When you connect the balls are forced open and when disconnected they shut. You would loose maybe a drop of oil from disconnecting. Yes the system would bleed itself. Press hydro lines have a rating of 10k psi not like a typical hydro line that is rated at 3500. That's why they are double the price.
Those threads are definitely rolled over opposite the force of cylinder. I have a enerpac 12t H press with the same cylinder. I went and measured my threads on the cylinder and the OD of threads measured 2.230 with a 14 tpi count. Just for reference. Not 2.0mm like you show.
I definitely thought about the harbor freight option. I wanted something with a smaller footprint. I only paid 90 bucks for the press. They are listed on eBay for a thousand. Even with a new cylinder at $150 I am okay with it. Assuming I can thread in the new cylinder I think this is going to be a nice setup. If not I might have a sow's ear! (Clean)
And the gauge...well that's my fault and now a sunk cost. Hey, it's cheaper than that last end mill!
Robert
If you have a local auto engine rebuilding shop give them a call and ask about hot tanking it. It's usually pretty cheap and if you want it checked for cracks they can do that too.
If it me (you know, the hack) I would thread the cylinder just above the area that goes into the C-frame. Then I would take (at least) a 3/4" plate and bore/thread it to screw onto the cylinder. Drill 2 holes to match the ears on the C-frame and bolt it together. Turn some thick washers to go under the ears to spread the load to the frame.
I could have definitely figured out a way to sleeve or adapt the metric cylinder. If I had any 2.25" stock available I would have. I think I am going to try to chase the threads on it an put it on eBay. Failing that, I will have a cylinder for the next project!
Robert
Out of the derusting bath. That took off most on the remaining paint but did not do a great job on the rust. I hit it with a light coat of primer to prevent the clean areas from immediately rusting.
I really wish I could surface grind that table! I know it is totally unnecessary but it would look great. I may have to resort to sandpaper!
Robert
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