



To hang the pails on the spiles, we decided to poke a hole in one side of the pail, just below its lip. That way
the pail could be slipped over the spile and it would "catch" on the little hump on the top of the spile. Here's how we
made the holes:
We sharpened a piece of 3/4" electical conduit and used it to punch a hole in the side of the pail leaving about 1/2"
of the rim.
To accomplish this, we clamped a piece of 4" X 4" wood firmly to a workbench and slipped the pail onto it, using the
wood as an anvil.
Then, a few hits on the sharpened pipe (they are called "dinker dies" in the trade) with a framing hammer or bigger,
and Viola!, a hole.
The hole in the pail could be slipped over the spile and would catch on the little hump on the top of the spile.
This worked very well for us.
Earlier in the process, we made those holes by heating one end of the piece of pipe with a torch and pushing the heated
end through where we wanted the hole to be.
This was harder to do and messier, but it had the advantage of leaving a ring of the plastic around the edge of the
hole. We thought this would strengthen the hole but we never had any problems with the pail braking anyway.
The pails we used had a capacity of 4 gallons before modification, But afterwards, with the hole on the side and
hanging at a slight angle on the tree, we figured the capacity was reduced to about 3 gallons. That hardly ever
caused a problem as long as we collected every 24 hours.




December 28, 1995:
The sugar house is up and out of the ground and is basically roofed.

The stand for the 1000 gallon tank is complete.
Cleaning the 1000 Gallon Maple Sap Tank
The west and North sides are ready to side with used steel. The windows have been purchased.

The road is completely surfaced.
We even added enough width for a turn-around. All needed materials are on-site. Our motorhome is parked up at the site,
providing warmth for workers and their "support staff" and providing up to 4.5 KVA of electricity for the
skilsaw etc..
September, 1997:
We have switched over from wood scraps to wood cut and split on our own place. We have had to rebuild the grate system in
the evaporator to handle this kind of wood. In so doing we have increased the evaporation rate from 12-15 gallons per
hour up to 18-20 GPH. We got tired of digging the scrap wood out from under the tarp, especially on nights when it
was raining, so we added a roof 20 feet in length on to the basic 20X24 Sugarhouse. This extra covered area is for
wood storage.
What an improvement!! This is a one year supply of "Sugar Wood"; enough to produce about 60 gallons of syrup.
Improvements to the Finishing House
We built a new floor under the finishing house. We added a shelf that holds 2 150,000 BTU burners to heat up the syrup
for what we call "bulk bottling". Here we store up several runs of syrup and then heat and bottle it all
into special 5 gallon containers. We store those containers at home in the basement until we decide what size
"retail" containers to bottle into.
We have also upgraded our "Bulk Bottling" system with a new support for the filters. The filters are now
commercial syrup filters. We use a 50 micron Orlon outer filter and a matching paper filter inside of that.
You can see that machine in between the two big burners on the shelf in the picture above.
Here's a pictoral summary of our operation.
Two views of our Sugar shack. The left picture shows the west side and the wood storage area.
The right hand picture shows the east side of the sugar shack with the Finshing House and the 1000 gallon storage
tank.
Here's a close up of the east side of the Sugar Shack, showing how the Finishing House is closely coupled to the
Main Sugar House. This way, we don't get wet when we move from one building to the other if it's raining.
Cleaning Pails: The left picture shows a load of pails coming to the garage to be cleaned and rinsed.
The right hand picture shows the pails all cleaned up and stacked to dry before being stored in the finishing house.
Here's me standing in the 1000 gallon tank, again. I am smiling because I just got done cleaning it.
I have to get completely into the tank, where I sit on a 5 gallon pail while scrubbing the top and then kneel while
scrubbing the sides and the bottom.
Here are two views of the trail going south and uphill to the Maple trees. The Cushman Trackster is parked
beside the lowermost collecting station.
The picture on the left shows how we cover our pails to keep water, bugs and debris out of the sap. Many of you
will recognize the plastic bags as being the same bags that are used with the metal pouring frame, which hangs right
from the tree.
But we cut a hole in one side of the bag and stretch it over the pail, instead. This way we can hold a lot more sap
than the bag alone can. This is important on days where we may get a 3 to 4 gallon run!
The right hand picture shows me pouring sap from the "tree" pail into a 5 gallon pail. Note that I don't
have to take the pail off the tree! I simply pivot the pail on the spile, while the folded-over, open end of the plastic
bag acts as a spout.
By the way, you can see that I am dressed in only a tee shirt. Many of these pictures were taken at the END of the
season. They don't show us wading through snow and ice that is 2 feet deep, or collecting when it has been below
freezing when we have to dump big chunks of ice out of each pail.
Here, I am emptying a pail of sap into one of our five collecting stations. The muslin cover keeps out bugs and
debris.
As you have seen earlier in this webpage, these collectors all feed a pipeline that runs directly into our 1000
gallon tank.
Once we have enough sap in the 1000 gallon tank to make a "run", we start filling the sap pan.
The sap runs through a 25 foot lenght of copper tubing that is wrapped around the evaporator's plenum and then into
the pan.
In the right hand picture, Sheran has just finished checking the depth of the sap. We want a sap depth of between
one and one and a half inches before we light the fire.
Just a reminder: This is a one-season supply of wood. For this season, a lot of it was fresh cut, so we mounted a
window fan as you see it and ran it for several months to help dry the wood.
This is a good, hot fire, the kind that will get us a stack temperature in the 650°F range. We add about 20 pounds
of wood every 6 minutes when we are boiling sap. We even use a kitchen timer, so we don't "loose" the fire.
The right hand picture shows the coals that have fallen through the grates. It's too bad that most of that energy
doesn't go into boiling the sap, but if the coals pile up on the grate to much, they choke the flow of air to the
wood.
As they say in syrup making circles: "it's the flames that boil the sap, not the coals!".
Here, I am skimming the froth from the sap. This is a constant job.
Finally, the end of our little "Pictoral", the DATA!!!!.
There's a lot of info crammed into this one spreadsheet, and it's probably only of value to those who are actually
planning to make their own syrup. So, if you are one of those, and you have any questions about that information,
feel free to contact us.
This is our last year for making maple syrup, for now anyway. We are still around, but its a LOT of work, so we have
decided to take a few years off. The equipment has all been put away clean, so all we'd need to do is to clean it all
up and start again.
Ever since we have had our 4 or 5 collecting stations up in the woods, we have had to uncover, repair as needed and
clean those lines every spring. I think there is about 1000 feet of 1" tubing up there now, servicing the 5
collecting stations. About 750 feet of that is laying on the forest floor and is covered by leaves, branches and
up to 3 feet of snow by the end of February. It all has to be cleaned off so it'll thaw and allow sap to run.
We clean thus tubing by pushing cleaning solution (hydrogen peroxide and water) UP the hill, let it stand for a while,
then let it down and drain it out. Then we wash the lines 3 times with plain water.
To do the pushing, I made a syphon tube that goes to the bottom of a 55 gallon plastic drum. The drum is filled with
solution and then compressed air is pumped into the drum to push the solution up hill all the way to the topmost
collector. This takes about 17 psi for the height that we have to get to for the highest collector.
Just at the end of this cleaining process this year, I got impatient that the solution wasn't moving fast enough and
connected an air tank the had 125 psi in it with no regulator. I opened the valve a little, but forgot about it for a
few minutes. BAD IDEA!!! All of a sudden "KABOOM!" The drum split about exactly at its middle and the top
half flew about 100 feet into the air, landing in the snow a couple hundred feet away. The tubing from the collectors
had broken loose from the drum fitting and was snaking wildly through the air, soaking me over and over with the fluid
draining back out of the line! What a mess. Maybe that helped to make the decision to stop for a while.
When people ask us what an average year is like, we tell them that there is no "average" year! Every one is
different and unique.
We made an amateur video (about a one hour DVD)of much of what we talked about here. If you are REALLY interested,
contact us and maybe
we can get you a copy. You just have to appreciate that we made it over a number of years, as we were learning how to
the process ought to work, so you'll have to pay closer attention the the latter part of the tape for accurate
information, and for fewer bloopers.
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