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These Songs were written by Cougar Jim and is
How to Build the Cougar Jim Pro X
We will start this bow Press with the main body. The tubing for the main body and the arms is 1-1/2"x1-1/2" x 095 Wall thickness. The length is 40"
Next is the arms. Cut them to 12" and then cut about a 1/4" off one corner as shown below.
I use a bench belt sander to round off the corners but you can use a grinder or anything that will work.
Next we will drill the pivot holes. I drill 1/2" holes because I insert a 1/2"OD with 3/8" ID bushing to prevent the arms from moving side to side. You can drill 3/8" holes and use 3/8" bolts.they work quite well until they wallow out the holes and start to wobble back and forth. Measure back from the tip of the arms 3/4" to drill pivot holes. Drill the holes just off center 1/16" toward the bottom to make sure they don't hit the main body when they pivot up.
Next we will build the stands. The 2 plates are 7-1/2" long and 2-1/2" wide. x1/8" thick. Drill two- 3/8" holes for mounting to bench. Measure 1-1/2" from one end to make the bend. Be sure to drill the holes before you make the bend.I drill both at one time.
Next clamp the plates in your vice one at a time and bend at the 1-1/2" mark to 90 degrees.
I built this bender which makes it very easy to bend these plates. It didn't take but about 10 minutes to build it but you can use what ever you like and will work. After making the bends cut two pieces of 1-3/4" x 1-3/4 x 095 1-1/2" long. They will be welded to the stands to slip on the body at each end. Before you weld them on, drill a 3/8" hole in the center of each one and weld a 3/8" nut over each hole. I use a 3/8" bolt to align up the nut.
Next we will build the large sliders. You will need 4 plates 4" long x 2-1/2" wide. I drill all four at one time. Drill the 5/8" hole 3/4" in from the top and side as shown below. Drill the 3/8" hole 1-1/2" down from the top and 5/8" in from the side .
Clamp the plates on to the 1-3/4" x 1-3/4" slider with a set of clamps and line them up. Next place them in your vice and cut one of the 5/8" round stock rollers, 7" x 5/8" through both plates and line them up with a small square. This is critical to prevent warping your Bow limbs. I cut the corners of the plates off for looks, You don't have to cut them, it is optional.
This is a good time to check your arms for Clarence. Place one of the arms in the slider with a 3/8" bolt and raise it up to make sure it does not hit the top of the slider. If it hits just grind some material off the rounded edge.
Now build the small sliders. Use the same technique for the small sliders as the large ones.
Use 1-1/2 inch wide x 3-1/2 inch long x 1/8 thick.
You can round the edges on the small sliders or leave them square.
This is the press without the jack. I will show you how I rebuild and mount the jack next.
This is the jack with the factory mount still on it.
After grinding off the mount and cutting off the wheel we replace the crank with 7 inches of 1/2" hot or cold roll.
Then cut a piece of pipe with a 1/2" ID, 3 inches long and mount it 1-1/2"onto the original crank then drill and tap set screw hole of any size that you can find a set screw to hold it on to the 7" extension shaft. Also drill an indent on the extension shaft for the set screw to seat into.
Drill a 5/8" hole in the top of the jack and cut a piece of 5/8" hot or cold role 4" long for the pressing straps. Then drill a small hole near the end for a keeper pin.
Next cut two pieces of plate 2-1/2" or 3" wide X 2-1/4" for the Jack mount. Grind out the half circle to fit the jack body and drill two 3/8" holes to mount to main press body. I place the plates on to the press body and drill mounting holes to make sure they lineup.
Place two washers under the plates so the plates don't fit so tight you can't get the jack on and off the press body.
Clamp the Jack onto the mounts and weld them just on one side each. (top plate top side, bottom plate bottom side) Be sure to square up the jack with the press body.
Cut your rollers out of 5/8" round hot roll or cold roll, 7 inches long and then put 4-1/2" of 5/8" I D rubber hose or clear hose on one end like the photo below.
The pressing straps are 30" long by 1-1/2" wide by 1/8" thinkness with 12- 5/8" holes in one end and 1 in the other end.
This is the two jack mounts welded to the jack.
This is the finished press.
As you will see some of the measurements will conflict with the drawings. This is OK since I have made some changes with the build along. The measurements does not have to be exact just close.