Assembly and method for forming a mast for guiding a drill drive in a horizontal directional drilling machine

1. An assembly for forming a mast for guiding a drill drive in a horizontal direction drilling (HDD) machine, which assembly comprises:

a mast body extending between a first outer end and a second outer end with a generally U-shaped cross-section;

a mast cover having an upper side with a recessed surface extending substantially continuously in a longitudinal direction between the first outer end and the second outer end of the mast body, the upper side substantially closing the mast body, the recessed surface being recessed in a direction toward a bottom wall of the mast body;

a set of two or more racks having gear teeth configured to co-act with pinions;

a first set of fasteners releasably connecting the racks to the mast cover;

and a second set of fasteners releasably connecting the racks to the mast body.

2. The assembly according to claim 1 , wherein the mast body is provided with support surfaces for the racks.

3. The assembly according to claim 2 , wherein the mast body is provided with bent edges which form the support surfaces.

4. The assembly according to claim 2 , wherein the assembly further comprises a set of two or more strengthening strips placed against the support surfaces.

5. The assembly according to claim 1 , wherein the first set of fasteners are bolts.

6. The assembly according to claim 1 , wherein the second set of fasteners are bolts.

7. The assembly according to claim 1 , wherein the mast body includes the bottom wall and first and second side walls standing upright from the bottom wall to define the generally U-shaped cross-section.

8. The assembly according to claim 7 , wherein the bottom wall and the first and second side walls are formed from a single metal plate.

9. The assembly according to claim 1 , wherein the mast cover includes a first outer side coupled to a first lateral end of the upper side, and a second outer side coupled to a second lateral end of the upper side.

10. A method for forming a mast for guiding a drill drive in a horizontal direction drilling (HDD) machine from an assembly, which assembly comprises:

a mast body extending between a first outer end and a second outer end with a generally U-shaped cross-section;

a mast cover having an upper side with a recessed surface extending substantially continuously in a longitudinal direction between the first outer end and the second outer end of the mast body, the upper side substantially closing the mast body, the recessed surface being recessed in a direction toward a bottom wall of the mast body;

a set of two or more racks having gear teeth configured to co-act with pinions;

a first set of fasteners releasably connecting the racks to the mast cover;

and a second set of fasteners releasably connecting the racks to the mast body, which method comprises the following steps of:

a) connecting the racks to the mast cover;

b) placing the mast cover and the racks on the mast body; and

c) connecting the racks to the mast body.

11. The method according to claim 10 , wherein the method further comprises the step of selecting an assembly which further comprises a set of two or more strengthening strips for placing against the support surfaces, wherein step c) comprises the following sub-steps of:

c1) placing the strengthening strips against the support edges;

c2) connecting the racks to the support edges and the strengthening strips.

12. The method according to claim 11 , wherein step a) further comprises of placing a plurality of racks adjacently on one or both longitudinal sides of the mast cover and wherein step c) comprises of connecting the strengthening strips to the support edges such that in assembled state of the mast one or more of the strengthening strips overlap the adjacent racks.

13. The method according to claim 10 , wherein the mast body includes the bottom wall and first and second side walls standing upright from the bottom wall to define the generally U-shaped cross-section.

14. The method according to claim 13 , wherein the bottom wall and the first and second side walls are formed from a single metal plate.

15. The method according to claim 10 , wherein the mast cover includes a first outer side coupled to a first lateral end of the upper side, and a second outer side coupled to a second lateral end of the upper side.

16. A mast for guiding a drill drive in a horizontal direction drilling (HDD) machine, formed from an assembly comprising:

a mast body extending between a first outer end and a second outer end with a generally U-shaped cross-section;

a mast cover having an upper side extending substantially continuously in a longitudinal direction between the first outer end and the second outer end of the mast body, the upper side substantially closing the mast body;

a set of two or more racks having gear teeth configured to co-act with pinions;

a first set of fasteners releasably connecting the racks to the mast cover;

and a second set of fasteners releasably connecting the racks to the mast body.

17. The mast according to claim 16 , wherein the mast body includes a bottom wall and first and second side walls standing upright from the bottom wall to define the generally U-shaped cross-section.

18. The mast according to claim 17 , wherein the bottom wall and the first and second side walls are formed from a single metal plate.

19. The mast according to claim 16 , wherein the mast cover includes a first outer side coupled to a first lateral end of the upper side, and a second outer side coupled to a second lateral end of the upper side.