An Addition to the Type Foundry

Posted on by kpmartin Posted in Equipment Acquisition, Repair, and Maintenance, Kevin, Monotype Type and Rule Caster — 2 Comments ↓

Two years ago I found out that this Monotype caster, fitted for strip casting, was available for free in the Toronto area.
Unfortunately, at the time, I had no room for it and needed to expand our shop space to make room. Much more unfortunately, through a misunderstanding, the owner thought I was not interested in it, and started giving it the (very slow) heave-ho.

The pot controller was removed to make a decorative display, and cutter/stacker was removed to reduce the machine’s bulk and subsequently misplaced. The caster then spent a year outdoors before I picked it up just this week.

Here’s how it looks now:

A very sad state. It is fortunate that the machine had been coated with a machinery storage coating (“Cosmoline”) so the rust has not gone very deep.

My collection of spares should be enough to make up a pot controller, and I have a cutter/stacker in rough condition that I can fit to the machine, so I have the makings of a working strip caster. As well, the former owner will look around to see if the cutter/stacker is still around.

This is actually a Monotype Type and Rule Caster sometimes inexplicably called an “Orphan Annie”, fitted with the attachments for continuous strip casting. It is marked with the improbable serial number 5000:

L-R: Left rear table corner, Rear end of rear pin block, Left end of front pin block

The fact that the same serial number appears on several places implies that this truly is the machine’s serial number, improbable though it may seem to have a number that is an exact multiple of 1000. Unfortunately there does not seem to be any easily-found serial number index or census of machines for Monotype equipment.

I have a series of old parts manuals from various years and I may try to match specific parts against these to determine when the machine was made, but for now the main goal is to chase out all the water and protect against further rusting.

An Addition to the Workshop

Posted on by kpmartin Posted in Basement Workshop, Kevin — No Comments ↓

I just purchased a new-to-me machine for my workshop:This is a DoAll DH-612 manual surface grinder. Based on the serial number this one was made in 1959 and that may have been the first year of production for this model as I have found no references to earlier serial numbers.

The machine needs a good cleaning, and I’m hoping the ways (the surfaces the work table slides on) are in good condition, though if not they can be refurbished.

It is partially fitted with DoAll’s patented (US#2470350) “Cool Grinding” feature which injects coolant into the grinding wheel itself (which is porous) so there is a positive flow out of the working surface, lifting away grinding swarf better that the typical flood coolant system would. By “partially fitted” I mean it has the special coolant control valve and the special grinding wheel flanges required, but otherwise no provision for coolant: No pump, no tank, no hoses, minimal splash shielding, but all these can be made up from generally available items.

This big issue is that the motor runs on 550V 3-phase power, and all I have available is 240V single-phase. A VFD would be able to run a 3-phase 208/220/240V motor but not a 550V one. Some combination of VFD and (auto)transformer(s) might be able to do the job. My first thought was to step the 240V single-phase up to 600V and use a 600V VFD but VFDs in that voltage range require 3-phase input. Another possibility would be to use a 240V VFD and a 3-phase autotransformer to step up to 550V but this would be bulky and the VFD might not like the transformer on its output. There is also the concern that using VFDs (which generate high-frequency electrical harmonics) on older motors can cause issues with the motor lifetime because current is induced in unexpected places like the bearings causing them to wear prematurely, and voltage spikes can also cause premature insulation breakdown.

The grinder has an integrated spindle and direct-drive motor, so I will have to disassemble part of this to allow me to fit a pulley and mounting for a single-phase 220/240V motor to use belt drive. On one other DoAll model (VS-612) the motor can clearly be reversibly disassembled leaving the bare shaft, but on this machine removing the existing motor may be a one-way trip.

Once I have this working I hope to be able to use it to recondition Monotype parts, particularly worn wedges (which determine the width of the cast type) and worn moulds (assuming I can first build up some replacement metal). I might also try to modify some display mould blade insert kits to allow me to cast unusual sizes like Didot-point-sized type. The Didot point (0.0148″) is slightly larger than the almost-American point (0.0138333…″) the Monotype system usually works in, so I currently have to cast Didot-sized type faces on the next size up of type body.

Although this post is tagged “Basement Workshop” this grinder is very much never going anywhere but ground level!

Inside the Beast

Posted on by kpmartin Posted in Beaters, Equipment Acquisition, Repair, and Maintenance, Kevin — No Comments ↓

Last year we purchased a new-to-us Noble & Wood Cycle Beater for beating pulp for papermaking. It has, since then, been sitting in a corner in our shop taking up space. This was mainly because we also had so many other things also sitting around in the shop taking up space that there was no room to work on the beater.

Since then we’ve managed to develop another storage area so there is actually space to move the beater into the middle of the room and remove its top cover.

The cover is a heavy lift for one person in proper posture, but removing it from the beater would require lifting the cover almost at arm’s length, and overcoming not only its weight but also some friction between the cover and the beater roll.

Now that we had room to get the forklift next to the beater we’ve finally removed the cover to have a look:

Inside the beater, Behind the roll, the vertical rod is the adjustment for the minimum gap, and behind that, the pulley for the lifter auger.

This is a view of the roll from the outfall side. The interior of the tank may have been originally galvanized but that has eroded away over the years allowing some rust to form. The beater bars appear to be bronze, and the spacers are wood, perhaps mahogany or maybe teak. They are a bit loose right now but when the beater is in use the moisture makes them swell to a tight fit. They don’t really provide any structural support to the beater bars, but they limit the size of the cavity between the bars to control the overall pulp flow.

One of the wooden spacers seemed particularly loose so I undid the two stainless steel wood screws that retain it and had a look underneath.

One of the beater bar spacers

Under the spacer showing the wooden roll core and one of the holes from the wood screws that retain the spacer

The core of the roll also seems to be a fairly substantial hunk of wood, which the wood screws bed into. The spacer still seemed loose after replacement, so this may require more investigation.

After inspecting the roll, I used the forklift to raise it on its pivots to reveal the bedplate, but foolishly neglected to take any photos of this. There were some lumps of dried pulp to remove, and more surface rust that will have to be dealt with. The bedplate itself looked good, and also not easy to remove as it seems to have been bedded into some sort of tar or pitch to hold it solidly and seal any leaks.

With the roll raised I removed the seized minimum-gap adjustment and this is now soaking in penetrating oil. I have to get it unseized, and also make a handwheel for it so the operator can set a specific gap.

The next step would be to actually remove the roll and its support frame, detaching it at the pivots, and also remove the auger assembly, to give full access to the tank. Then I can bring it outside, clean out the rust, and I would like to try to repair the galvanizing, assuming that’s what it is. The good surfaces inside the tank have a dull grey colour which could be zinc, or perhaps it was tinned so the coating is tin or a tin/lead solder.

This beater has plenty of nooks and crannies that could trap pulp, causing two problems: Trapped pulp holds water and encourages rust, and it also will contaminate the next beater batch if a different pulp is used. This means that being able to do a full cleanout easily is important, and this would require removing the lid and lifting the roll. For doing this regularly it would seem worthwhile to fit the beater with a small hoist, maybe some sort of jib crane, that can lift the cover, swing aside to put it down, and then raise the roll. But for now the forklift will have to suffice for this.

Grimsby Wayzgoose, April 26th, 2025

Posted on by kpmartin Posted in Grimsby Wayzgoose, Past Events, Us — No Comments ↓

The Grimsby Public Art Gallery will be holding their Wayzgoose Book Arts Fair on Saturday, April 26th, 2025, hosted by the Gallery and extending into the Grimsby Public Library space.

This gathering of book artisans has taken place annually since the first event in 1979. Participants offer demonstrations, items for sale, and plenty of conversation about what they do and what they make, with topics including papermaking, marbling, bookbinding, printing, and small press publication.

the Papertrail will have a table at the Fair, selling a selection of new and used books, marbled and handmade paper, and supplies and tools for the book arts, including hand papermaking, marbling, bookbinding, and letterpress.

The fair takes place at the Grimsby Public Library building, 18 Carnegie Lane, Grimsby, Ontario, and runs from 9am to 5pm.

Admission is free, and free parking is available at both the front and rear entrances of the library as well as any of several nearby municipal parking lots. If you want to use public transit, the library is less than a block away from the Grimsby GO station.

As an added bonus I (Kevin) will be turning 65 that day. Sorry, no cake for everyone…

New and Improved Spam Comments

Posted on by kpmartin Posted in About this blog, Humour, Kevin — No Comments ↓

This blog has always received a stream of spam comments, generally consisting of easily-recognized banal statements about how the post was really helpful, or well-written, or some such other positive comment, but with no actual reference to the topic of the original post.

Because new commenters are moderated, you never see these comments, though I have to deal with them when they pile up. There is no point banning the commenter because they are just using throw-away email addresses anyway.

However, just today I found three of a new class of comment wherein the text appears to have been created by generative AI to give the appearance of being relevant to the specific content of the post. They all contain some rather open-ended question, and end with an invitation to visit a web site.

Here is a sample, posted to 2020 Wayzgoose Anthology:

The diverse contributions highlight the enduring significance of print culture in an age of digital media, showcasing how printmakers continue to push the boundaries of their craft while staying rooted in tradition. What was the most challenging aspect of curating the 2020 Wayzgoose Anthology, and how did the editorial team ensure that the collection balanced both historical context and modern interpretations of printmaking? Visit us <redacted web link>

The wording almost seems to make the question rhetorical, inviting a visit to the web site to get an answer. Which is a good thing because my original post never implied I had any editorial involvement in the Anthology so I would be utterly unable to answer such a question.

The same poster made such comments on three very disparate posts on this blog, making it even less likely that they are real comments from a real person.

Of course, there is an infinitesimal chance that one person read all of this blog in one day, and felt the need to ask such questions on three completely unrelated topics, and has the near-supernatural ability to enter three such comments in a period of three minutes, and has a very unnatural way of expressing themselves in English. If this is the case, commenter, I apologize for doubting your authenticity, and invite you to refute my judgement in a comment on this very post…

BOUND Book Arts Fair, December 1st 2024, Downtown Toronto

Posted on by kpmartin Posted in BOUND Book Arts Fair, Past Events, Us — No Comments ↓

December 1st, 2024, we will be at the BOUND Book Arts Fair, at the Arts & Letters Club, 14 Elm Street, Toronto. We will have our stock of marbled and handmade paper for sale, as well as an assortment of other materials and book for papermaking, marbling, bookbinding, and other associated book arts.

The fair features around 3 dozen vendors of supplies for the book arts and finished works, including paper, cards, notebooks, and small press publications.

The fair runs from 11am-4pm, and admission is free. The venue is just off Yonge Street, two streets north of the Eaton Centre, and the nearest subway stop is Dundas on Line 1 (Yonge/University).

Previously-unseen Casting Problem

Posted on by kpmartin Posted in Font Casting, Kevin, Monotype Composition Caster — No Comments ↓

I ran into this casting fault when making a font of 36-point Lanston #675 Bodoni Ultra. I’ve never had this happen before and I haven’t seen this problem mentioned in any of the literature.

The type is developing, for lack of a better term, a zit. The problem gets worse in successive casts and if the caster (or at least the pump) isn’t stopped the next zit is big enough to break off, prevent seating of the matrix on the next cycle, and cause a large low-pressure squirt of molten type metal.

It would appear that the matrix is lifting off the face of the type before a thick enough skin has formed to contain the pressurized metal and entrapped air. This allows the metal to squirt out onto the face of the type. Bodoni Ultra seems particularly prone to this because of the deep sharp-edged counters.

For other less bold faces the same conditions might result instead in a sort of bulging face on the type, where the pressure pushes the face up but does not penetrate it.

This can happen when the matrix becomes hot from repeated casts, which is why casting starts off fine but eventually this happens. A solution would be to run the caster a bit slower to allow complete hardening of the metal, but when I tried this I started getting nozzle freezes instead.

I think another cure would be to take steps to keep the mat holder cooler so it can sink some of the matrix heat.

This casting run was using an English display mould and the special 49A holder for using Lanston matrices on the English mould.

A similar problem, known as “bleeding feet”, can occur if the jet is cut off before the metal is sufficiently hardened, allowing a similar blob of metal to squirt out of the foot of the type.

Improved Monotype Parts Storage

Posted on by kpmartin Posted in Monotype Composition Caster — No Comments ↓

Over the summer we’ve been fixing up another storage room and it is finally finished enough to start storing things in it!

The first thing to go in is my collection of Monotype parts. Up until now these cases have been stacked up on a pallet making them difficult to access, especially when the pallet itself has been moved into a corner to get them out of the way.

They are now instead on heavy-duty shelving, making them much easier to access and keep organized.

This also removes one big obstacle from the store/workshop proper.

Marshville Heritage Festival, Oct 31st-Sept 2nd 2024

Posted on by kpmartin Posted in Past Events — No Comments ↓

This Labor Day weekend the annual Marshville Heritage Festival will be held in Wainfleet, Ontario, on the grounds operated by the Marshville Heritage Society next to the Wainfleet Arena at 31943 Park Street.

The Festival features attractions including a classic car display, old tractors and other farm implements, and an old sawmill. Up until 2022 this mill was steam powered, but a lack of a licensed boiler operator who has the time to get the steam plant up and running from a year’s disuse means it will probably be powered by an electric or gas motor instead. There are also demonstrations of other crafts such as weaving and candy-making, musical entertainment, plenty of kids’ activities, and lots of food.

The attractions include the print shop featuring a working Whitlock newspaper press operated by the Mackenzie Printery and Newspaper Museum. The Printery will also be operating a Ludlow Typograph to cast single lines of type for visitors, and will offer various printing-related items including old cuts, typecases, and printed ephemera in trade for donations to the museum. A small Adana tabletop press will be set up so visitors can print their own keepsake bookmark, and our year-at-a-glance calendars (printed on the Whitlock) will also be available.

The fair is open 10-5 each day and admission is $8 for adults, $7 for seniors, free for children under 10, with plenty of free parking (enter off Side Road 20).

(Un)Plugging Cooling Water Passages

Posted on by kpmartin Posted in Equipment Acquisition, Repair, and Maintenance, Kevin, Monotype Composition Caster — 1 Comment ↓

One of the moulds for my Monotype Composition Caster, specifically the type U Lanston display mould fitted for 36 point body size, had completely blocked cooling water passages. This would seriously limit how fast the caster could run, even more so than the already slow speeds recommended for such large type.

There is a tool which can be attached to the underside of a mould, which fits two small cylinders to the cooling water ports, allowing one to install a small piston and, by striking this with a hammer, force liquid through the cooling passages under high pressure. This is often useful for minor blockages, but seemed to have no effect on this particular mould.

In order to clear out the passages, I disassembled the mould well beyond the recommended amount, even removing the intermediate base from the main base. This is not a recommended procedure because it loses the factory-set alignments of the parts. It is, however, the only way to reach all the water passages, or at least to understand how they are connected. Now that I know their layout I may find it possible to clean them without this extreme disassembly.

In the process I’ve mapped out the water and oil passages, something to be documented in a future post perhaps.

The cooling passages are a series of drilled holes that intersect within the parts of the mould, with brass screws plugging most of the drill entry holes. Together these holes join to form a continuous single path for water flow through the mould.

Clearing the passages involves drilling into them as was done at the factory, but this time the drill removes the blockage (probably mostly consisting of iron oxides and old oil) rather than steel. Unfortunately, most of the brass screws were either filed flush to the surrounding surface and so had no screwdriver slot any more, or were sufficiently seized in their holes, that they had to be drilled out too.

This leaves the problem of replacing the screws, the main point of this post. Read more ›

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