We had to build a pulley system. check out my pictures under large projects - spring after. The first picture shows one in use. This was a very crude design, since then I have refined it but it effectively made a 30 pound machine feel like a 4 pound machine. There is still a little fatigue because you have to move the machine. After eight hours though your guy won't feel like he's going to call in sick the next day.
Use a cable system similar to a nautilus machine. Balance the machine with weight by trial and error. The smoother the cable the easier it will be to move it. If you use a square fitting at the bottom with a round vertical pole you can get a little swing out of the arm and it will allow you to work on up to 50 feet at a time. You still need to finish with a 0-1500 hand machine and 5X. I like pure oxalic but very few know how to use it properly.
The idea here guys is to reduce operator fatigue and save money by eliminating man power. I originally built two of these simple machines for that job and was about to buy another machine from intertool. I only needed one because when we put it into production we were moving so fast that the other one would have actually slowed us down.
And the beautiful thing is that I designed it drew it on a piece of paper, took it to a metal fabricator, and he had them built the next morning for $400. The pulleys and the cables were separate but the whole thing was less than $500.
We estimated that it saved us 2 weeks of labor or approximately $8,000 in profit.
