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Cross Over Tube for Pizza Oven

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  • Cross Over Tube for Pizza Oven

    My friend John’s brother Dave owns a bar in Northern Michigan, which is an economically depressed area. He has an industrial pizza oven that was purchased in 1984. Over time the cross over tube has rusted out and the welds holding one of the two brackets have rusted off. The oven manufacturer is still in business, but doesn’t sell the cross over tube as a replacement part. A new double oven similar to this one would cost $26K. Pizza ovens are very hot. The pilot light ignites flames in a cross over tube, which lights four burners.

    1. Burner assembly
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    Before John retired, he owned a Fluid System Engineering company, so he asked one of his former technicians Harry bend up a replacement tube.

    2. Old and new tube assemblies
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    3. Rusted tube
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    The first step was to make the brackets. I like to scribe shape of the bracket as well as the hole and slot locations. I find that this gives me a second check on locations and dimensions.

    4. Scribing bracket
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    5. Cutting out bracket
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    6. Sanding edges of bracket
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    7. Center drilling bracket
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    For non-critical slots I like to drill a hole in each end of the slot and then plunge the cutter into one hole, make a pass then increase the depth of cut on the other end before returning to the starting hole.

    8. Drilling bracket
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    9. Milling slot
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    I typically use the power of the mill using the back gear to reduce speed, to tap the holes, because I don’t own a tapping head. For thru holes I use spiral point taps, which push the chips ahead of the tap and through the back side of the hole. For blind holes I use spiral fluted taps which pull the chips out of the hole.

    10. Tapping holes
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      11. Brackets done
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      I really like to use hog mills to square up stock, because they cut fast and leave a decent finish.

      12. Squaring up crimp tool
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      13. Drilling crimp tool
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      I chose to bore the hole in the tool for the tube and for the crimp area in the same setup to assure that they would be concentric. I had a 3/8” reamer which I used for the tube bore in the tool. I didn’t have a .340” reamer, so I bored the hole for the crimp portion of the tool.

      14. Boring crimp tool
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      15. Reaming crimp tool
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      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Colchester 15" Lathe
      16" DoAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        16. Crimp tool 1st op reamed
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        17. Installing dowel
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        18. Using center finder
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        19. Reaming crimping tool

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        20. Crimp tool done
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        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Colchester 15" Lathe
        16" DoAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          The swivel fitting on the end of the cross over tube is actually just a standard barb fitting. The tube was crimped loosely to hold the barb fitting in place, but still allowing it to rotate for installation. The barbed fitting has an .040” orifice in the end, which acts as a jet which accelerates the air as it leaves the fitting. This creates a low-pressure area, which in turn creates a vacuum. The cross hole through the tube near the end of the barbed fitting allows air to suck into the tube. This means that gas doesn’t leak out of the small space around the barbs, but instead sucks in air past the barbs.

          21. Crimped barb fitting
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          22. Crimp Mark on old tube
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          I drilled a larger hole most of the way thru the orifice and just drilled the .040” hole through the last 1/16”.

          23. Orifice pieces
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          I used my arbor press to install the orifice.

          24. Orifice press fit
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          25. Orifice installed
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          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DoAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            26. Arbor Press with crimping die in place
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            27. Crimping swivel fitting
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            28. Fitting crimped
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            I had to rotate the waist of the Bridgeport to allow the tube to pass the left end of the table.

            29. Setup for drilling holes
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            I installed tight fitting blocks in the Tee slot and then bumped the 1-2-3 blocks against them. (a red arrow points to one of the blocks.)

            30. End view of setup
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ID:	617989
            Smith Oxyacetylene Torch
            Miller Dynasty 200DX
            Lincoln SP-250 MIG Welder
            Lincoln LE 31 MP
            Lincoln 210 MP
            Clausing/Colchester 15" Lathe
            16" DoAll Saw
            15" Drill Press
            7" x 9" Swivel Head Horizontal Band Saw
            20 Ton Arbor Press
            Bridgeport

            Comment


            • #7
              I used a parallel against the back side of the 1-2-3 block to set the position of the tube.

              31. Parallel to set tube position
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              First I center drilled a drill point and then I drilled the 112 holes with a #76 (.020”) drill.

              32. Drilling hole
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              33. Close up of hole
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              34. Crimping end of tube
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              35. Tube crimped
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              Smith Oxyacetylene Torch
              Miller Dynasty 200DX
              Lincoln SP-250 MIG Welder
              Lincoln LE 31 MP
              Lincoln 210 MP
              Clausing/Colchester 15" Lathe
              16" DoAll Saw
              15" Drill Press
              7" x 9" Swivel Head Horizontal Band Saw
              20 Ton Arbor Press
              Bridgeport

              Comment


              • #8
                I used my Fireball Tool magnets to hold everything in place for welding.

                36. Setup for welding
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                Here is a picture of me welding the brackets.

                37. Welding brackets to tube
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                38. Brackets welded
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                39. All done
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                40. John holding the completed cross over tube
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                John plans on going to the Upper peninsula in two weeks to visit his brother and to install the new cross over tube.

                -Don
                Smith Oxyacetylene Torch
                Miller Dynasty 200DX
                Lincoln SP-250 MIG Welder
                Lincoln LE 31 MP
                Lincoln 210 MP
                Clausing/Colchester 15" Lathe
                16" DoAll Saw
                15" Drill Press
                7" x 9" Swivel Head Horizontal Band Saw
                20 Ton Arbor Press
                Bridgeport

                Comment


                • #9
                  Did you go back with stainless?

                  I envy the patience you have in documenting your work.

                  Do you have a DRO on the Bridgeport?

                  Comment


                  • #10
                    Originally posted by ryanjones2150 View Post
                    Did you go back with stainless?
                    No, John's friend Harry just used the tubing that he had on hand.

                    Originally posted by ryanjones2150 View Post
                    I envy the patience you have in documenting your work.
                    Thanks.

                    Originally posted by ryanjones2150 View Post
                    Do you have a DRO on the Bridgeport?
                    Yes, my Bridgeport came with a Mitutoyo DRO with glass scales.
                    It works great but doesn't have the features of the DRO Pros one that I purchased for my Lathe.

                    41. Bridgeport with DRO

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                    -Don
                    Smith Oxyacetylene Torch
                    Miller Dynasty 200DX
                    Lincoln SP-250 MIG Welder
                    Lincoln LE 31 MP
                    Lincoln 210 MP
                    Clausing/Colchester 15" Lathe
                    16" DoAll Saw
                    15" Drill Press
                    7" x 9" Swivel Head Horizontal Band Saw
                    20 Ton Arbor Press
                    Bridgeport

                    Comment


                    • #11
                      Nice Job again Don..............But all I'm really interested in is....... How is the Pizza?

                      Comment


                      • #12
                        Originally posted by tarry99 View Post
                        Nice Job again Don..............But all I'm really interested in is....... How is the Pizza?
                        David's pizza place is called Nutini's and it is in Hancock Michigan. Dave makes great pizzas. He would have to be doing something right to be in business for 35 years. Stop by if you are ever in the Houghton / Hancock area. Tell them Don and John sent you.

                        -Don
                        Smith Oxyacetylene Torch
                        Miller Dynasty 200DX
                        Lincoln SP-250 MIG Welder
                        Lincoln LE 31 MP
                        Lincoln 210 MP
                        Clausing/Colchester 15" Lathe
                        16" DoAll Saw
                        15" Drill Press
                        7" x 9" Swivel Head Horizontal Band Saw
                        20 Ton Arbor Press
                        Bridgeport

                        Comment

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