3.2 – BrushDestructor Machine

A New Class Of Brush Clearing Machine

Weed Wacker,BrushDestructor-6 (600x420)

This new machine will not be called a trimmer, a weed eater, a weed wacker or brushcutter, it will be the first of a new class, a BrushDestructor class and will be for heavy duty land clearing, weed control & fire hazard reduction. Below is the first prototype built up of parts from different manufacturers and a custom made longer shaft. It may not look that different from any other brush cutter, but what this machine has cleared will blow your mind.

This is the custom made machine that you can see in the video above; it is powered by a 35cc Honda  GX35 – 4 stroke engine, an extra long heavy duty shaft for reach and balance, a loop handle from a back pack brush cutter to give a wider swing, a Stihl heavy duty gear head and guard.

BrushDestructor Prototype 1

It will be the only brush cutter with a guide face to stop the branch bouncing around, so that you can cut through that branch as if you were using a skill saw.

There have been no major improvements to the brush cutter in 15 years and over the last few years I have been offering to help manufacturers improve their machines, but in every case not one of these manufacturers has had the courtesy to even reply to my emails. And this applies to Honda as well, Honda makes the best engine, bar non and I am probable responsible for promoting the sales of more Honda brush cutters world wide than even Honda themselves and even they have not replied to any of my emails.

So it is now time that I produce a new heavy duty brush clearing machine designed specifically, to work with the BrushDestructor blade to get the most from this blade.

I get lots of emails from people, wondering when the new machine will be on the market, unfortunately development and tooling cost are very high and I have no idea when it will happen.

I have been asked buy some customers if they could get a machine like mine, that can be seen in the photo and video above and in many of the other video on this site.

So if I get enough interest from people wishing to buy one of these machine, I will get some made. At this stage I am not sure of the cost, but it will be under AU$1000. To proceed with a minimum order run, I am going to need an expression of interest from at least 100 people and at that stage I will be able to give a firm price before going ahead.

This machine will have the same Honda GX35 engine and heavy duty extra long shaft as you see in prototype below and as I can afford it, I will make my ball swivel hitch, loop handle, vibration reducing trigger control handle, gearhead and guard. As these parts get made, they will be able to be easily retrofitted to this interim brush cutter.

If you think you might be interested, please send me an email and I will add you to the list and keep you informed. Or if you think you know someone who might be interested, please forward this page onto them.

What will make this machine special;

IT WILL HAVE A SPECIALLY DESIGNED GEAR-HEAD, to get the most from the power and torque of the Honda GX35 4 stroke engine. Read Why Here. It will also incorporate an anti-vibration rubber mount between the gear-head and the shaft. This is to help reduce blade impact shock being transmitted up the shaft and to reduce engine vibration being reflected back up the shaft.

Gearhead, HeavyDuty, BrushDestructor

The gear ratio will be 1.5 : 1 meaning the engine will do one and a half revolutions to one revolution of the blade, which will help reduce overall brush cutter vibration. I have been working on the design of this gearhead for over four years now, but have not had the resources to get it manufactured.

Gearhead, HeavyDuty, BD - 1-2.4-1 (600x361)

This gearhead will not be lubricated with grease like all gearheads from other manufacturers, but with a high quality Hypoid Gear Oil. When researching hypoid gears, I found a paper that says hypoid gears should not be lubricated with grease over a curtain speed and of cause brush cutter gears exceed this speed. This means that with the high speeds, the grease is spun out against the housing walls and the gears are not lubricated properly leading to a much shorter life. Hypoid gears are smooth and quite running because the meshing gears are half rolling, half sliding action. To get long life from these type of gears, requires a continuous supply of a high quality and pressure grease or oil.

IT WILL BE DESIGNED TO TOTALLY ELIMINATE, the problem of long stringy grass wrapping around the gear-head and stalling the brush cutter. Read & Watch More Here 

Gearhead, HeavyDuty, BD - 1-2.4-4 (600x560)

This can only be achieved by the gearhead, guard and blade all working together in unison to prevent this annoying problem.

IT WILL HAVE A HIGH STRENGTH GUARD, that will be able to withstand any punishment that the BrushDestructor blade can throw at it.

Gearhead and Guard - BrushDestructor Clearing machine

The exterior shape of the gearhead and the guard will be designed in unison to completely solve the very annoying problem of long stringy grass wrapping around the gearhead and stalling the brush cutter. The BrushDestructor Blade that will come with this machine, will have low flat anti-fouling blades that will shear away any tough stringy grass that tries and wraps around the gearhead. The design of the guard-gearhead combination will also make it easy for long grass to fall over the top and out of the way saving on power being wasted dragging long or wet grass inside and around the guard.


One other problem, especially as far as the EU is concerned, is the issue of ejected material and possibly parts of a shattered blade flying out and injuring someone. Now the very nature of a brush cutter means that it is not possible to cover the whole blade with a guard as with a mower, but this design will minimise this problem as much as possible. The sloping outlet of the guard will deflect objects down towards the ground where they cannot be a threat to bystanders to the right side of the operator.

BrushDestructor Gearhead and Guard 2

IT WILL COME IN A RANGE OF THREE SHAFT LENGTHS, to suit the height of different operators. It will start with a standard 28mm outside diameter aluminium shaft, but I will be investigating either a custom extruded aluminium or carbon fibre shaft for stiffness and vibration reduction. Because of the higher gear ratio of this new gear head, the torsional loads on the solid steel drive shaft will be much less. Using a high quality torsional spring steel, I should be able to get the drive shaft diameter down to 6mm, possibly even 5mm. The pulses from the engine firing will be absorbed by the torsional spring drive, to give a smoother delivery of power to the gears in the gearhead.

Many brush cutter with the power this machine will have, have solid steel shafts with diameter of 8 and 10mm in diameter. The weight savings of the smaller diameter shaft will help offset the weight gains of the heavy duty gearhead and guard.

The longer shaft will add extra safety for the operator as it will put the spinning blade further out of your reach, should slip or stumble and you will be able to clear a greater area with its much wider sweep.

IT WILL ONLY BE AVAILABLE IN A LOOP HANDLE VERSION, to give better and safer control of the machine. The unique spiral design of the loop handle will provide a good grip in the normal position and on either side and reduce vibration to the hand. Read Hear To Find Out Why

Handle,Loop,Spiral,BrushDestructor 6

This design will also allow you to get a wider swing than can be offered by most bicycle handle brush cutters, when clearing long grass and weeds on flat ground.

IT WILL A HAVE CUSTOM DESIGNED CLUTCH AND ANTI VIBRATION HOUSING, since there has been no improvement to this design since the first brush cutter came out over 16 years ago. This custom housing will also incorporate a counter balance weight, that will perform three jobs.

Housing,Clutch,Honda-35cc-3 (600x225)

FIRST, it will help offset the longer shaft and the extra weight of the heavy duty blade, gearhead and guard.

SECOND, this weight will be low down under the engine, to put the centre of gravity back through the centre of the shaft. This will stop the brush cutter wanting to roll upside down if you let go of it when it is still suspended from the harness. This can be very dangerous, as it can leave the exposed spinning blade facing upwards without a guard covering it.

THIRD, this weight will act as a vibration absorber, helping to soak up vibration that gets past the engine-shaft rubber isolator. It is not really possible to soak up engine vibration with a rubber isolator alone, extra mass is required. With a car, the engine is perhaps about one tenth the weight of the car and so engine vibration only has a very small affect on the car body itself. With a brush cutter, the reverse is the case, with the engine weighing much more than the shaft of the brush cutter. This means the engine, easily shakes around the shaft and handle grips of the brush cutter.

I discovered this after adding counter balance weight to the engine base plate of the second brush cutter on which I tried to improve the balance.

Counterblance Weight - Husqvarna (600x313)

Adding extra weight to the engine did slightly absorb engine vibration. But the extra weight of the engine, means more vibration gets transferred of from the now heavier engine to the lighter shaft and resulting in more vibration to the handles which was not the desired outcome. I discover that to get the desired vibration reduction, the counter balance weight needs to be added to the shaft.

IT WILL HAVE ANTI VIBRATION TRIGGER CONTROL HANDLE, designed with silicone isolators to reduce vibration transmitted from the shaft to a minimum. This is to suit the longer operating hours faced by those with larger properties and commercial operators.

Trigger Control Handle - BrushDestructor Clearing machine

IT WILL COME WITH A STRONG BALL SWIVEL HITCH, with four screw to clamp tightly to the shaft so that it does not move from its correct centre of balance position. The hitch is bottom weighted so that the mounting hole is always facing upwards and the bottom is shaped so that you can hold you hand on the underside of the hitch to easily align the mounting hole with the harness hook. This solves a very annoying problem with this style of swivel hitch.

BrushDestructor Swivel Ball Hitch

The ball shape will also provide a good pivot and rolling surface against the harness mounting plate as you swing from side to side and rotate the brush cutter on either side.

Hitch,Ball,Swivel 4

IT WILL NOT COME WITH AN ENGINE, but will have a clutch housing to suit a Honda GX35 4 stroke engine. You will have the choice of either buying and fitting a cheap Chinese copy Honda engine you can purchase online. Or preferably going to your local Honda dealer and buying a certified Honda GX35 4 stroke engine that meets the regulations of the country you live in and that comes with the Honda 4 year commercial warranty. This will make the new BrushDestructor machine, more affordable in the South American, Indian and Asian markets, where because of affordability issues encourage a high use of the cheaper Chinese copy Honda engines.

The long term plan will be to provide this machine with an electric motor fitted as standard. The electric motor technology is available now, and I think that within the next couple of years we will see portable battery technology improve to the point where it can easily run a powerful electric motor needed for the job, for at least 1 hour.

EMF FIELDS FROM ENGINE,  is something that I will be looking at eliminating. I have been aware of Electro-Magnetic Fields for some time now, because of the time I spend in front of a computer, but Electro-Magnetic Fields is not something that I would have associated with brush cutters and I don’t think anyone else has made that association either. Below is a picture of my Honda brush cutter running at about half revs and on the EMF meter you can clearly see that the magnetic and electrical fields are maxed out. Yet the High Frequency Waves are not registering anything, as we live in an area with no mobile coverage and we have no blue tooth in or around the house.

BrushDestructor - Electromagnetic Fields from Brush Cutter Engine (600x338)

What causes these fields is the engines ignition system, there is a very powerful magnet spinning around that creates an unnatural alternating magnetic field and the electrical field comes from the build-up in an electrical charge in a coil to the point that it caused a charge to jump across the spark plug. What makes this such a problem with a brush cutter, is that all of this takes place within a few hundred millimetres of you kidneys and liver, where all of your blood is flowing through for filtering and cleansing. I cannot think of another garden or power tool for that matter, where the source of such large EMF field are so close to the body for such long periods of time.

I had started feeling short of breath like someone with emphysema, but after an x-ray cleared any lung problems, I then suspected that it may be from high exposure to EMF. There are various affects that EMF can have on the body and the one that is relevant here is the affect it has on our blood. The high water and iron content of the blood makes it the perfect absorber of EMF and conductor of electrical charges.

If you have read my page on Hand Arm Vibration Syndrome, you will have read how vibration can cause capillary veins to restrict reducing blood flow. Now if your blood viscosity is thickened, it becomes increasing more difficult for the blood to pass through many of the millions of capillary vessels  depriving those areas of much need oxygen and the removal carbon dioxide waste.

Clumping of red cells called rouleaux effect, and is where red blood cells clump together making the blood thicker. The two main negative effects of this, is that the red blood cells can no longer effectively absorb and carry oxygen to all parts around the body and pick up and remove carbon dioxide and other wastes to be transported to the lungs, liver and kidneys for removal from the body. The other problem caused by these large clumps of red blood cells is that it makes the blood thicker and more viscous, making it difficult to travel through capillary blood vessels and depriving those areas of blood. The picture below shows on the left what normal red blood cells looks like, it has a good viscosity and is easily pumped around the body by the heart. The picture in the middle taken with a scanning electron microscope, shows how the red blood cells have all clumped together from the higher electrical charge in the blood. The picture on the right shows where the blood was so thick, that the pressure of it being forced through small capillary veins has ruptured that vein.

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If left unchecked, this can lead to all sorts of health problems, with the most immediate problems being heart attacks and stroke. A much thicker viscous blood is more likely to drag plaque loose from artery walls where it can cause a blockage somewhere else.

I was able to get hold of a powerful microscope where I checked my own blood and it was indeed like the photos shown in the middle. This microscope did not come with a camera, but I found an image that exactly resembles what my blood looked like in that microscope and is shown below.


I now believe the best way to solve vibration and EMF problems is with a battery powered electric brush cutter.

Weed Wacker,BrushDestructor-8 (580x160)

By placing the motor in the head and direct driving the blade, reduces parts, sources of vibration and if there are any EMF from the motor, it is far enough away from the operator to be of no consequence. The battery pack at the other end will counterbalance the brush cutter. The motor technology is available now and is affordable. The battery technology is improving in leaps and bounds and will very quickly be able to run a heavy duty brush cutter in excess of an hour and will become more affordable in the next couple of years.

IT WILL BLOW AWAY ALL OTHER BRUSH CUTTERS, including the commercial machines from Stihl, Husqvarna, Shindaiwa and Echo. Because unlike these other manufacture, where brush cutters is just a drop in the ocean of their overall business. My business is only brush cutters and I will always be striving to improve the design to the point that no other manufacturer can keep up. Read Echo Review Here.

WHEN WILL IT BE AVAILABLE? I have had a number queries from people wondering when this new machine will become available, but of cause funding is a major hurdle here. I do not have the resources of the larger manufacturers that I had offer to help. To satisfy customers that want this machine as soon as possible, I will be making it available in stages.

FIRST STAGE, will be fitted with the new gearhead and guard on a longer standard shaft, with off the shelf loop hand, swivel hitch, trigger control handle and clutch housing.

SECOND STAGE, will be fitted with a new clutch housing with the features mentioned above. The clutch itself will need no upgrading as the gear ratio of the new gearhead will halve the stresses placed on the clutch and this should last the life of the machine.

THIRD STAGE, will be the custom designed high strength 28mm shaft, with small diameter spring steel drive shaft. This will also incorporate a new heavy duty swivel hitch which will be fixed in the correct balanced position. It will not be able to slide out of this correct balance point like the current hitches on many of the available brands.

FOURTH STAGE, will be fitted with the vibration reducing spiral loop handle. This will be customer adjustable up and down the shaft to suit the arm length of customers.

FIFTH STAGE, will be the fitting of an anti vibration trigger control handle. This will also have a limited amount of adjustment to suit the arm length of customers.

SIXTH STAGE, work with Electric motor and battery suppliers to develop a long lasting battery powered power unit to drive this new BrushDestructor.

BACKWARD COMPATIBILITY, will mean all of these parts will be available individually and those that have purchased the earlier first or second stage machines will be able to upgrade to include any or all of these newer parts at a later stage.

I wonder how many of these features will suddenly start appearing on other brands of brush cutters, especially those that ignored my emails. just remember, you read about them here first.

Please come back to this page as there will be a lot more details to come on the new BrushDestructor Machine.


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