Wayne, I feel your dilemma: it must be simple and cheap, yet effective and efficient. Fully concur on your idea of using off the shelf parts or even machinery. Shredding the bale is no option, I understand. Would cutting 6 inch thick slices (like slicing bread) off the bale and feeding the slices through a tedder help? May be looking at some pics may help; try: http://www.google.nl/search?q=fluffer+hay+OR+straw+OR+cotton&hl=nl&as_st=y&tbm=isch&ei=E1lgT9fdHojOhAed4rDCBw&start=168&sa=N Would such a machine help: http://www.rowserakes.com/fluffer2.html
Usually, poor quality hay will be difficult to "fluff", especially when baled wet. But then, this hay is no good for horses(?) anyway, so there is no money to be made there and you should not try to devise a process/machinery able to rebale poor hay.
I've seen processing units for making boards of a mixture of wood wool and cement (wood wool cement board). Wood wool is nasty stuff and distributing it evenly is comparable to the process you are looking at. Large rotating drums are used to pull the wood wool onto wide conveyor belts. On the outside of the drum "shark fins" are welded. The rotation of the drum is such that the wool is "stroked" by the hypotenuse of the triangles (shark fins) rather than "pulled". Hope this helps; may have more ideas/suggestions later. Hendrik
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Today's Featured Article - Third Brush Generators - by Chris Pratt. While I love straightening sheet metal, cleaning, and painting old tractors, I use every excuse to avoid working on the on the electrics. I find the whole process sheer mystery. I have picked up and attempted to read every auto and farm electrics book with no improvement in the situation. They all seem to start with a chapter entitled "Theory of Electricity". After a few paragraphs I usually close the book and go back to banging out dents. A good friend and I were recently discussing our tractor electrical systems when he stated "I figure it all comes back to applying Ohms Law". At this point
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