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Thinkkker
Thinkkker UltraDork
9/1/21 10:48 a.m.

My Dad has already said he was gonna stop by this Saturday at the house.  He's a 40+ year electrician, so I should at least have mine up and powered on.  Then to figure out how to use it!

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/10/21 8:43 a.m.

More tooling! I picked up a carbide insert facemill, a set of parallels, and a set of angled gauge blocks. Total price was right around $100 (thanks, China!)

The mission? To create a pair of wedges for my dad's Bugeye Sprite suspension.


 

Success! Note: I didn't drill the hole in the middle; he did that by hand after mocking everything up. I'd say these came out pretty well for a first attempt at something like this.

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/10/21 8:52 a.m.

Next up: Let's build an axle! A buddy asked me if I could make something that would transmit power between two of these flanges 10" apart.

I ordered a dividing head, but now I'm at my first roadblock: How do I figure out what these splines are, and what I should cut to match them? Anybody have any guidance here?

zordak
zordak Reader
9/10/21 9:02 a.m.

1st count the number of teeth. 2nd determine the tooth shape. It looks like they are 90 deg. 3rd using 2 small dowels try to get a pitch diameter, easy if there are an even number of teeth. If the teeth are 90 deg. tip the head of the mill at 45 deg then use an end mill to cut the teeth in the shaft. Make a test piece first to refine the process. This is a very ambitious project for someone just starting out. 

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/10/21 11:16 a.m.

Well, I'm nothing if not ambitious.laugh

Do I need to pick up something like this before I proceed?

zordak
zordak Reader
9/13/21 9:08 a.m.

They would help, but a couple of correct sized dowels would work. Just find a dowel that touches the sides of the teeth and not bottom out or not just sit on the top.

ShawnG
ShawnG UltimaDork
9/13/21 9:40 a.m.

Use a couple drill bits that are the same size.

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/17/21 10:13 p.m.

We started on the axle tonight, and successfully finished a prototype. Success!!

WonkoTheSane
WonkoTheSane GRM+ Memberand UltraDork
9/18/21 7:11 a.m.

Very cool :)

Mr_Asa
Mr_Asa PowerDork
9/18/21 10:34 a.m.

Is the test piece just for fitment, or are you actually gonna use aluminum?

zordak
zordak Reader
9/20/21 8:57 a.m.

Cool.   You might want to stone a small radius on the end mill for strength. 

TVR Scott
TVR Scott GRM+ Memberand SuperDork
9/21/21 12:49 p.m.

Jeez, Tom, you've really aged.  The beard came in nicely though.

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/21/21 2:05 p.m.
TVR Scott said:

Jeez, Tom, you've really aged.  The beard came in nicely though.

Apparently all of my friends are incapable of operating a camera. That's Johnny from Nine Lives Racing. He earned the very important job of operating the dividing head.

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/21/21 2:05 p.m.

In reply to Mr_Asa :

Just a test piece for fitment; waiting on a carbide endmill to make the real thing out of 4140.

preach (fs)
preach (fs) Dork
9/21/21 2:44 p.m.

Late to the thread but very cool.

A buddy of mine, who later became Howe & Howe's shop foreman, was a trained machinist as was his father. When I met him they had a small machine shop at his dad's house with pretty much just a lathe and a band saw.

He was later tasked to get rid of the substantial amount of metal around his dad's property so started making metal runs. One run he dropped off $x amount of metal, but saw the head of a Bridgeport sticking out of a pile of metal. He was friends with the guys at the scrap yard and they helped load the complete BP onto his trailer. He ended up paying under $50 for the machine since it was offset by the amount of metal he had just dropped off. It ended up needing a motor and the table adjusted to less than a thou tolerance.

It was 3-phase and they did not have 3-phase so he got a converter. He said something about sometimes having to spin the lathe or something to get enough power for bigger jobs, but I do know understand any thing electrical over 12v so I never got the gist of what he was saying.

One of my current good friends just put a milling machine and a lathe in his shop 10 mins away. I just have to ask to use it.

Smitty54
Smitty54 New Reader
9/22/21 6:48 a.m.

I ran into a deal when a friend had to liquidate his shop, got a Gorton Master Mill, about half again the size of the Bridgeport. Got it cheap, because it has an odd ball taper making it hard to get tooling. Soon there after I picked up a 16" x 42" lathe with a ton of tooling for the price of the 1" Jacobs chuck that came with it. It's big enough to do 15" car wheels, and the drive shafts for the small sports cars I mess with. It takes a while to sink in but once you realize with a lathe and a mill you can make anything including more lathes and mills, it is very empowering and confidence building. Enjoy!

Smitty54
Smitty54 New Reader
9/22/21 12:39 p.m.

In reply to Tom Suddard :

I'm an electrician, but I have been trying to learn machining for many years. When I heard one of the machinists was retiring I would go and see if he wanted to sell any of his tools or consumables. Twice I was able to buy a shoebox full of end mills for $20.

Tom Suddard
Tom Suddard GRM+ Memberand Director of Marketing & Digital Assets
9/27/21 1:52 p.m.

I don't have much of an update to report (been sidetracked getting the new lathe up and running) but I did go to an auction this past weekend and picked up a few more papercuts, errr uhhh I mean "Goodies."

First up, a set of gage blocks. Not complete, but plenty good enough for now. For $40 I'm content with my purchase.

I also bought $40 worth of files, which wasn't the best deal in the world but considering I own one (seriously, one file) seemed necessary to avoid a late-night file shopping trip whenever I eventually get frustrated enough to buy more.

I also bought this tapping head for $60. I have no idea if this is a good deal or not as it's the wrong taper for my mill, but it's cool as hell and I figured I'd at least be able to put it on eBay for what I paid if I gave up on using it.

And finally something I bought on eBay, not at the physical auction. Depending on how you value my time, this was either a waste of $80 or a discounted way to be able to tram my mill quickly and accurately.

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