Chuck

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Yes indeed.
 
Those batten strips need to be a "press-fit" into the grating.   Not too loose and not too tight.  In order to get it just right because the tolerences are so tight.  Just run the battens through some sand paper.  Just once or twice and try it again.  You will know when its right.  It will fit really nice. Dont ever force it because of impatience.  AND this is what holds the grates together although I would still apply a wash of diluted yellow glue.
 
these parts are made just a hair larger or within a close tolerance to what is needed.   It would have been far worse to make them even a hair smaller than needed and loose.   Even though this would make assembly easier,  it would not achieve the same result.  Pulling the battens through some fine sandpaper is a piece of cake.   The results are well worth the effort.  This would also be true if you were making them from scratch.
 
Chuck
 

 

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank you very much!!!
 
I have started on the pumps today.
 
Basically I started with a 3/16" square and used the 7/10/7 ratio to convert it to an octagon.   You can see how I carefully marked the blank and then filed the piece to shape.   The end was drilled out afterwards.
 

 
I also laser cut the handle from 1/64" thick boxwood.  The handle bracket was made from 3/32" thick stock.   The bracket was tapered where it attaches to the pump tube.  Then it was notched out with a fine file to make it look like a fork.  The handle will fit into this.  But first I must paint the pieces and then assemble them.  Maybe tomorrow.
 
Chuck

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Chuck,very nice pumps. Like the reddish color.

I guess that you - and we - are pumped! They look great, Chuck.

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!

Thank You very much.  The pumps have been completed.   You can see that I decided to paint them red.  Most people leave them natural but I figured I would go all in with the painted look.   The same is true for the pump handles and bracket.  These were made of either wood or metal.   Because most folks leave these natural I figured I would paint them black and make them look like metal.  This is how they were treated on the contemporary model of Surly. 
 

 

 

 
 
All of the pieces were painted before assembly.  Then I used some heavy paper to make the reinforcing band.  Those who have these plans will also notice that I have only used one band.   Yet on the plans there are two.  I have once again seen so many variations of elm tree pumps I figured I would show it both ways.  Those building Cheerful can decide which they prefer.
 
1. transfer the 7/10/7 template lines to each side of the 3/16" square pump tube.  Carefully file the tube to an Octagon using the lines as a guide.  Drill and bore out the top of the tube to a depth of about 3/8".  Carefully use a bit that will leave the pump tube walls not too heavy.
 
2. File and shape the bracket for the handle.   The part that sits against the pump tube is tapered thinner so it fits on one facet of the octagon.  Use a slotting needle file 1/32" thin or less to file the slot in the top to a forked shape.  This will accept the handle.
 
3. Place a 1/16" x 1/16" strip in a dremel to round it off. Using an emery board this takes only a minute.  This will become your pump spout.  Drill a hole into the end before parting off a 5/64" long spout.  Glue it to the pump tube.  All pieces can be painted first.
 
4.  Using some card stock strips wrap it around the tube as shown on the plan to simulate the metal reinforcement band.  One ore two is fine.  The top band should be carefully placed so the notch in the bracket accepts it at the the right height on the tube. So measure its location from the plan.
 
5. Glue the bracket into position.
 
6.  Insert a length of 24 gauge black wire into the hole on the end of the handle.  Like an eyebolt.  Insert the end of this long wire into a pre-drilled hole in the bore of the pump tube.  Adjust the length of the wire until the other pivot-hole in the handle site in the bracket nicely.  The handle should be in the downward position to be correct.  
 
7.  Finally insert a small length of 28 gauge black wire into the bracket hole and through the handle to lock it in position.   Snip it off on both sides so it stand proud of the bracket's surface just a little bit. 
 

 

 
Now its time to start on the winch!!!