A Coffee Roaster Worth Saving: Restoring the 1950s Otto Swadlo Cooling Tray
This video documents the complete redesign and fabrication of a custom 316 stainless steel cooling tray for a 1950s Otto Swadlo coffee roaster at Connoisseur Coffee in Redwood City, CA. With no replacement parts available and the original tray fatally cracked, I set out to create a modern replacement—one that preserved the soul and function of the original.
Over the course of four months, I measured, notated, and prototyped using SketchUp and AutoCAD, ultimately finalizing the design in AutoCAD for precision manufacturing. Each prototype was tested for tolerances using feeler gauges and digital calipers until the fit was perfect. Several design flaws in the original were identified and improved to ensure long-term durability and thermal stability.
Once the final CAD file was ready, I sourced the cutting through H2O Precision, Inc. in Hayward, CA—an excellent local shop specializing in waterjet cutting.
H2O Precision, Inc.
WATERJET CUTTING SERVICES
📍 2748 Cavanagh Court, Hayward, CA 94545
📞 (510) 781-0746
📧 [email protected]
After receiving the raw 316 stainless steel parts, I carried out all final machining by hand. Using transfer screws and a portable drill press attachment, I located and drilled blind holes, hand-countersunk over 500 vent ports, and polished the entire tray to a mirror finish. Final installation required just two days of downtime for the roaster.
This build is about respect for craftsmanship, precision, and legacy machines that still have more to give.
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