The document describes the design and fabrication of a cutter mechanism and assembly for a wire masonry ladder machine. Key objectives were to design a cutter capable of shearing 6 or 9 gauge wire with minimal adjustment, use in-house supplies, and install the assembly in alignment with existing components. A manual mill, MIG welder, torch, saw, and drill press were available tools. Challenges included a budget under $300 and management requests adding complexity. The Bridgeport mill was rebuilt and aligned for critical components. The cutter mechanism holds wire against a carbide tip to cut 10-foot ladder sections, which are then spot welded.

1. Wire Masonry Ladder Machine:
Cutter Mechanism & Assembly Build
Chelan Manufacturing, LockRite Metal Products
Operations Manager
October 2013-December 2013
Supervisor: Erich Weiler, Owner
(425)306-8028
Objective:
 Design cutting capable of shearing 6 or 9 gauge galvanized or stainless steel wire with
minimal operator adjustment.
 Use in house supplies and equipment whenever possible
 Fabricate larger mechanism for holding cutting tool during operation.
 Install assembly in alignment with existing critical components
 Modify other components for feeding wire, guiding machine motion, avoiding lines, etc.
Tools/Equipment available:
 Manual knee mill, variable speed spindle, belt driven
 MIG Welder with gas
 Oxy-acetylene cutting torch
 Friction cut saw
 Drill press
 Most common shop hand and air tools
Challenges to overcome:
 Budget limited to under $300 total material and tooling costs (Set of r8 collets, Kurt vice,
cutters)
 Management requests often added complexity without increasing overall effectiveness
 Repairs should be easily performed by operator with little training
 Use excess inventory for replacing worn-out components
 Tools and equipment oftentimes required alignment and repair

2. Bridgeport vertical manual mill used to make many critically dimensioned components for cutter
assembly. Required rebuild, alignment, and $100 in tooling costs.
Wire masonry ladder machine. Two 6 or 9 gauge (.148”-.203”) stainless or galvanized steel wire
are straightened, while a 3 is cut perpendicular to the other 2 at 6”. A Pneumatic gripper moves
the piece to be spot welded on each side, repeating for each 10’ section.

3. Cutter mechanism holds 9 gauge galvanized steel wire against carbide tip of lathe tool.
Wire “Ladder” product made in 10’ sections

4. Cutter mechanism 3d view
Cutter mechanism front view

5. Cutter mechanism Top view
Cutter mechanism right-side view

6. Cutter mechanism left-side view, showing 2 gauge possible
Cutter mechanism bottom view

7. Cutter mechanism assembly with cylinder
Cutter mechanism assembly with pneumatic gripper

8. Pivot arm used in assembly
Gripper side view, with mechanism

9. Cutter mechanism assembly, grabber, and spot-welders in place
Machine whole view