Comments are moderated. Please be patient. It may take some time for your comments to appear.

Thursday, June 18, 2009

How to Use an Edge Finder


I purchased a new edge finder a few months ago. Until now I had been using a wiggler type edge finder. Today was the first chance I'd had to use the new one. In the photo you can see a piece of aluminum that will eventually be an engine base in the mill vise, and the edge finder. I think I have managed to embed an excellent video (not made by me) showing how this type of edge finder is used. Enjoy.


Tuesday, June 16, 2009

Well, That Took Long Enough


I've finally finished the valve rods for the engine I'm working on. They were a bear to do too. I started with hardware store material, and gave up. The stuff was just awful. Better material yielded better results. The parts are by my standards small, and I was worried about being able to finish them at all, which is why I started with these particular parts. Had I been unable to finish them, I would have had to revisit my design.

The threaded portions of the rods are number three threads, and they're a bit less than an inch and a half long, to give some idea of size.

With luck, these little rods will be the valve rods that pass through the steam chest and operate the valve that passes steam into opposite sides of the cylinder, once the engine is finished. As usual, I'm building two engines at once, hence two parts.

The second photo shows one of the rods being turned with its' free end supported by a live center. When turning such small diameters, tool height becomes hypercritical. If your tool is too low, the part rides over it and bends. If it's too high, the cutting edge is held off the part by the metal below it, resulting in high cutting forces that deform or break the part. Either way, you get garbage. You can see some of the fallout from failed efforts at the top of the first photo. I used a steel tool instead of carbide. It gave a better finish on this particular material, and could be honed to a sharper edge.

I've been gone for some months. The entire time wasn't spent making these two little parts. Hopefully, I'll have more time to spend in the shop over the next few months.

Friday, March 20, 2009

OK, I'm Going To Build This


Well, I'm going to try to build this. It's a model vertical double acting single cylinder stationary steam engine of my own design. Bore and stroke, .750 inches. Wish me luck. I'm concerned about some of the smaller parts, and I'll do those first to keep from getting a lot of parts done and discovering that I can't finish things. I'm expecting Brown to deliver not one but five packages in the next few days containing tools and materials from various and assorted sources. It seems there are always a few more tools needed before starting any project, doesn't it? So, in the next few days my three readers should see me making parts. In the mean time, enjoy the pretty picture. If you click the picture, it gets bigger.

Wednesday, February 11, 2009

A Toolpost Adapter for Dremel Motor

Google Analytics has been telling me for some time now that many people are coming to the pages of this blog looking for a way to attach a Dremel motor to their tool post. Here's one way to do it. The nose of many Dremel tools have a ferrule attached by threads in the motor housing. The Dremel people use these threads to affix different attachments to the tools. You can too. I've provided a drawing with dimensions showing how to make an attachment that will allow you to fix your Dremel tool to your tool post. The odd shape of the part allows it to be held in a three jaw chuck for boring and threading. I made mine out of half inch thick aluminum, using my mill. If you don't have a mill, you can do the same thing using a band saw or even a hack saw, if you have the time and patience. It doesn't have to be perfect, just good enough to be securely held in the three jaw chuck. I threaded mine using a tool with a 60 degree point installed in a boring bar. It was the first time I had made any internal threads using my lathe. I did practice on a few pieces of scrap before trying it on my part. If you make one of these, do be careful while turning your threads. The "tail" of the part sticks out from the chuck, and can hit you or the ways or the saddle if you don't pay close attention to setting up your lathe and tooling prior to threading. Always turn things over by hand before starting your lathe with any setup, make sure you have stops installed to keep the saddle from traveling too far in towards the chuck, and keep your fingers out of the way. The last photo shows the Dremel motor installed in the tool post attachment, which in turn has been installed in the QCTP. Keep in mind that this is, after all, just a Dremel tool, attached by it's plastic housing, and have realistic expectations for what you can do with it. As always, you the reader are free to make whatever changes to this design that you please. If you do, I'd very much like to see your results. I'm also interested in seeing what you guys are planning to do with this attachment.

Monday, January 5, 2009

Larger Cross Slide Handwheel


If you are doing any amount of facing with the typical 9x20 lathe, you will soon notice that the hand wheel on the cross slide is just too small. Several other lathe owners have built larger wheels. Now so have I. This particular modification is really easy, and greatly improves the usability of the cross slide. My new hand wheel started out as a piece of half inch thick aluminum, three inches square. I laid out the lines for the features of the parts, and roughed it out with my modified ten inch woodworking band saw. That particular project has worked out really well. I've cut up to three quarter inch thick 4140 steel with no problems, and with reasonable enough speed through the part that the work didn't become tedious. The band saw seems to be handling metal cutting just fine. The rough work piece was held in my three jaw chuck using a 3/8 inch bolt. The head of the bolt is trapped behind the chuck jaws, and passes through the part. The part is clamped to the front of the chuck jaws with a nut. This method works fine to bring a rough part into a mostly round shape, so it can later be held in the chuck jaws, but it's not terribly accurate otherwise. In the photo there are rough areas still on the outer circumference of the part. Those will be removed later while holding the part from the inside recess that has yet to be cut. The part is next held with the outside jaws in the three jaw chuck, and a recess is turned to fit the factory hand wheel. I'm sure sizes will vary from lathe to lathe. I made my wheel so that the factory hand wheel was a sliding fit into the recess. Others have made these replacement wheels so they are pressed on or held in place with a grub screw that bears on the outer surface of the factory wheel. There are certain situations where the new wheel can interfere with the compound slide hand wheel, so it's desirable for the new wheel to be easily removable. Mine slides on easily and is held in place by a button head screw that fits into the threaded hole in the factory wheel where the handle originally fit. The original hand wheel does not have to be pounded or presses into place, is not modified in any way and is not marred by a grub screw. It fits securely, and has no play between the factory wheel and the new hand wheel.

Wednesday, December 24, 2008

Pitkin Donut Base and Clamp


Update: Well, I've been taken to task in the comments by Andy at Workshop Shed about being unclear as to the purpose of these parts, and he's right. They are a new base for the compound rest for my Jet 9x20 lathe, and a new four bolt clamp to match the new base. There, fixed.

In the previous post I mentioned what's being called the Pitkin Donut base on the Yahoo 9x20 lathe group. Mine is well underway, along with a four bolt clamp to match. The drawing shows what they will look like if all goes well and everything fits. I'll have some dimensions and photos of the parts being made later. The clamp is not absolutely necessary. The compound base as designed by Mr. Pitkin used four bolts and four independent clamps. I wanted a single four bolt clamp to hold mine down, just because. I had some problems with interference between the clamp and the rest of the compound rest, so I'm holding off on giving dimensions till I know I have things right and everything fits. Until then, enjoy the drawing.

Update: Things are coming along nicely. I still have to bevel the top of the clamp ring and drill a few holes in the base, but I'm almost done. The original two bolt clamp is at the top of the second photo. Obviously, the new mount is substantially heavier. I think I've also managed to build the new ring clamp so as not to interfere with any part of the upper half of the compound rest, and to make the bolts accessible regardless of it's position.
Last update
: The new base is finished. The third photo shows from left to right the original mounting base and two bolt clamp, what has become the standard four bolt clamp, and the Pitkin donut base and it's new four bolt clamp. The last photo shows the compound rest with the new base and clamp installed on the cross slide. It's important to say here that the bottom of the compound slide does not touch the bottom of the recess in the Pitkin base. The compound slide rests on and is supported by the three inch ring at the top of the base. That's where the added rigidity comes from. You can see this in the last photo, and that's why I included it. I'll end by saying that I made this base and ring out of 4140 annealed, which is considearably more difficult to machine than 1018, which is what I've been accustomed to using and what the first four bolt clamp is made of. 4140 is considerably harder on your tools and bits as well. It is stronger though, and strong is what I was after. I've also updated the first photo with dimensions. All lathes are different, use these dimensions at your own risk.

Wednesday, December 10, 2008

The Things One Will Do


to stay in the good graces of his Mother in Law. The cross shaped part with one arm broken off is the cutter out of an ancient meat grinder/sausage stuffer that had the misfortune to go down the drain into the garbage disposal. The new one is alongside. It's made out of 4140 annealed, and no, I'm not going to bevel the surfaces like the original. It works fine as it is. I've tried it. The healthy chunk of 3/4 thick steel under the parts will soon be a new base for my 9x20 compound mount. I'm going to make what is being called a Pitkin donut mount after a member of the Yahoo 9x20 Lathe Group that designed it. If you have a 9x20 lathe, or smaller, or larger, it's a great group to join even if all you ever do is lurk. There are a bunch of very knowledgeable, helpful guys, and a very active group. Lately they've been discussing alternatives for keeping the shop warm in cold weather, moose in the backyard, and fixing play between your lathe saddle and ways. Something for everybody. I'll have more on the new mount as work progresses.

Wednesday, September 3, 2008

New Compound Rest Gib and Screws


Some time ago I had some trouble with sloppy behavior from my compound rest while trying to make a short Morse taper. I have decided to improve my compound slide gibs and screws. The photo shows the original gib and two part (?!) gib screws on the right. The original gib was made from a cheap piece of skinny oval shaped rolled steel. The three original gib secrews were in two parts, a setscrew with a locknut, and a pointy little nib seemingly designed to wobble around on the end of the set screw. I discovered this two piece business earlier, and replaced the original screws with one piece versions. I have finally gotten around to making a new gib. It's machined out of steel and properly shaped and sized to fit the space between the compound slide and the base. The new gib is on the left in the first photo. The compound originally came equipped with three gib screws. As you can see from both photos, it now has six. I know it looks a little busy, but it does remove the tendency for the slide to rock around when at either end of its' travel. Time and use will tell if this modification was worthwhile. As for now, the slide does seem smoother to operate, with less play. The lathe's saddle slide has also been equipped with only three gib screws. I may eventually look into new screws and a new gib there too.

Thursday, May 22, 2008

Model Steam Engine Cylinder Experiment


This is another one of my experiments to see what I can and can't do. As I said in my previous post, I'm contemplating what my next engine building project will be. Along those lines, I decided to try to make something shaped like a cylinder casting out of a piece of 1 1/2 inch aluminum round. The piece of round was first faced in the lathe to square it and smoothe the ends. I then used the mill to machine three flats on the round to help locate it in the chuck later. I also drilled an offset hole 1/2 inch in diameter. This hole was used to mount the part on what I'm going to call an arbor for lack of a better word. The first photo shows the part on the arbor, installed in a chuck mounted on my rotary table. I've just started milling the square projection that will become the base for the steam chest. The second photo shows the part with the square projection finished. I've started machining the round outside of the cylinder that intersects the square projection. I ran into a little trouble here because I wasn't working from a drawing, and I hadn't really thought through what I was trying to accomplish. As a result, I did end up with a round cylinder, with a square projection on the side, but by the time I had figured how to get a round shape with a good and flat surface finish, I had a smaller cylinder than I had wanted, by about .050". Yeah, I know, that's a lot. The third photo shows the finished part, and the arbor I used to mount the part in the chuck. The projections on the arbor cylinders are very slightly tapered, and are drawn tightly into the hole in the aluminum cylinder by the threaded rod. Other than the part being smaller that I had planned, because I got ahead of myself and didn't plan enough, I did get what I wanted. I'm working in the dark here, so if any reader has suggestions, or can provide a link showing the right way or a better way to accomplish what I want, your input is welcomed. Had the cylinder turned out exactly right, I would have bored the center hole out to 3/4 inch and proceeded to cut steam passages for the steam chest.

Tuesday, April 29, 2008

Model Steam Engines and Bandsaw Blades


The bandsaw blades I've been waiting for arrived yesterday. They're Lennox Diemaster and they fit and they cut great. The bandsaw goes through half inch steel round in a few seconds, and half inch aluminum like a knife through butter. It even leaves a pretty good finish. It's great. As you can see, the steam engines are coming along nicely. I've still got a few of the simpler parts to finish, but I should have them running by the weekend. The twin cylinder big brother to the two little guys is in the back. I didn't make a left hand and right hand version this time. That way lies madness. One of the new engines already has a new owner, as soon as it's finished. Oddly, some people are fascinated by these things. The Texas quarter in the foreground gives some size reference. I'm thinking about what I'm going to build next. I have several sets of plans, and I'm pretty sure it's going to be a vertical, double acting stationary engine of some sort. I just don't know what sort.