Showing posts with label metalworking plans. Show all posts
Showing posts with label metalworking plans. Show all posts

Sunday, April 22, 2018

Welded Sheet Metal Bending Brake

So to compliment the small light brake I uploaded earlier here is a welded brake that will handle 20 gauge sheet metal up to 36" wide, thicker gauges in shorter widths. It is less complicated than many I have seen without giving up usefulness. An inexpensive stick welder and a method of cutting your stock to size, a drill and grinder are the main tools you will require. Even an inexpensive import in this size goes for $400 +.

This plan came from The Lincoln Foundations book "Arc Welded Projects Volume III" there are more good plans in this volume, heres the cover and brake plan.







Friday, April 20, 2018

Machine Vises

Well looks like this long winter has thrown off even the bears. Timmins is already having a bear problem. Easier to climb into a dumpster than dig through 3 ft. of snow, ha ha.

I found a nice plan for a welded steel vise, so I thought I'd do a write up on vises. Machine bench vises are often subjected to heavy, rough work. I have found over the years that they are not always made the same and going with the cheaper imports often turns into a lost dollar. A statement like that needs some qualification so here goes.

When it comes to imports quality seems to have taken a hit since China became the dominant player. I have two imports that I purchased back in the early 80's. I have them mounted on mobile 3 legged stands and they have been subjected to huge amounts of abuse, rough handling and over tightening. Never a complaint, they are like the day I bought them. Back then the imports were coming mainly from Taiwan.


Since then my shop space has increased and so has the need for more vises. I have 6 vises mounted around the different shops on benches, (yes I know, overkill ha ha). Importers will go with the cheapest suppliers so when China dominated the market, thats where they came from. Unfortunately they do not hold up to my 2 old imports. Over the years I have destroyed three, a 3", a 4" and the latest a 5", a couple of years ago. Here's whats left of it. The rest got melted, back when I tested my furnace. I now have more small bench anvils than I will ever need, lol. As you can tell from the dimples, the iron is too soft, (Poor metallurgical control??).


If money is no problem, heres one that is industrial quality all the way. Wilton makes a full variety of sizes and types, you couldn't break one of these if you wanted to.


So I am to poor to dish out the kind of money Wilton wants, and I would prefer to avoid the imports, so whats the alternative? Weld your own. I have seen many pictures of guys welding their own over the years and some of them are truly outstanding.

Going through my files I found a plan for a welded vise that looks solid, without complication and made from easily obtained materials. In my case, it wouldn't cost a penny, I have everything required. You can easily size it to suit your needs. Here's the plans.






Thursday, April 19, 2018

Plans From My Picture Files

While browsing my picture files I also pulled a few short 1 and 2 page plans gathered from various sources around the web that some may find interesting.

The first is a quick and easy sheet metal brake. Adjustable for a accurate bending line it will handle light sheet metal up to 18" wide. Heavier or strutted bending leaf and clamp bar will allow for thicker gauges.


Next is a nice little knurling tool, ideal for the mini lathe.


If you can get a hold of a hunk of 4" plate steel (salvage yard), you can grind out this nicely sized anvil. At almost 3 times the weight of an RR anvil it's nothing to sneeze at.


For the woodworker comes this nice large and heavy traditional workbench. The Moxon on the front, a traditional end vise and the tool tray make this a great workbench for the woodworker who likes to work with hand tools.


This 2 piece machine vise is a must for the milling and grinding tables.




I came across this on a shop made tools thread on a forum that escapes me now. I like it, the casters are too light for heavy work but for curves and hoops in light flat bar and other material, this is another quick and easy solution.



Tuesday, April 17, 2018

Plans - Welding & Cutting Bench

So from the same book as the last post, "Arc Welding Projects" Volume II, comes this great little plan for a welding and cutting bench. It is small enough that it can be moved around and large enough to work on many project sized assemblies. There are a few accessories that you don't normally find on a small bench. A small vise mounted on the front right corner and a shelf on the bottom stretchers will make it complete for me.

Here are the plans, good resolution, so click twice to expand for best view.



So tomorrow is a snow day, got 30 cm. (12") and 1/6 of a mile of heavy wet snow to clear. They are forecasting 13*C (55*F) for this weekend. So knock on wood, spring might actually be here.


Plans - Truck Mounted Hoist

So while I was browsing the Metalworking Drop Box yesterday I came across plans for a truck mounted hoist. Problem is, it was such a poor scan it was unusable. It was scanned from the Lincoln Foundation book "Arc Welded Projects Volume II". I checked my shelves and sure enough, I had it. These project books are all available on the Lincoln welding site, but sadly shipping to Canada has recently become prohibitive.

I have had use for one of these many times on my yard truck, and I have been on the verge of buying an import on sale more than once. I have always backed off because I have everything I need to build my own, (if I could only get off my butt cheeks, lol ). This plan is better than the imports and if you build it, you control the quality.

So here is the plan, resolution is very good, so expand for best view.




Check out the next post for a nice welding & cutting bench from the same book.


Sunday, April 15, 2018

Boring Head Plan

This is a very nice, fully measured, 5 page plan for a boring head. Carefully built this is a plan the home shop machinist would be proud of. This one has a 3/4" capacity, I purchased a 1/2" a while back and the good ones are not cheap. I found this plan on line over 10 years ago, drawn by Joe Worthy it looks like it was intended for a college training program.

To download this plan click Boring Head Plan. 119 KB - pdf


Wednesday, April 11, 2018

Holtzapffel Type Bender Plan

So there are many different types of metal benders. The Holtzapffel type is one of the older and some would argue, the most versatile type. There used to be many plans available on the web but I see less all the time, at least for free anyway. I was happy to file away all these plans when they were available and my only desire is to put them back into the sharing loop. Many sites no longer exist and this is a way of keeping parts of them alive. If I can stick to the gray areas of the copyrighted stuff I might even avoid getting my hands slapped ha ha.

This plan made its rounds a decade ago and was repackaged a couple of times at least, I haven't built the bender but have looked at the plan, a number of times and all the numbers seem to jive. All the parts and dies are included in this 38 page file.

To download the file click Holtzapffel Type Metal Bender. 3 MB - pdf



Tuesday, April 3, 2018

Small Project Collection

So here is a small project collection from one of my files. They come from various sources Model Engineer mag., Popular Science, a college site and others. Relatively easy to build and very useful in most small shops, wood or metal working.

The first is a knurling tool. Most of us have probably made an aluminum or other material, knob or handle, and would have liked to have knurled it for grip and decoration. This tool will let you do that with out the expense of owning a metal turning lathe.

Click images to expand.



This is probably the most difficult project in this little collection. This only because of the need to shape and bore the heavy 1" plate steel frame. The result is still one of the easier and better punch plans I have seen out there.


This little pin vise was on a school model engine building site. A very useful little tool for the model building hobbyist.



Can't remember if this was a Popular Mechanics or Popular Science plan, ha ha. In any case I have always found it interesting. In ash it will handle aluminum and light steel sheet, but I have always wondered how much more durable it would be in welded heavy steel.


So this is another drill press vise. You can build this one without castings and with care produce a vise that is more accurate than most.


Hope there is some appeal for these, I will share more in the future.

Monday, March 26, 2018

3 Hammer Builds, 1 Plan Set, and 2 Patents

So spent the afternoon clearing the lane way before it turns to 4" of ice. We peaked on our snow fall and we got about a foot less than we normally get, but it was colder than probably the last 10 years. I am almost out of this years allotment of firewood. April usually has at least one good snowfall. One of my summer projects will have to be the second complete rebuild of my snowblower. After 17 winters of snow clearing it deserves what ever attention it gets, lol.

So I opened the door to power hammers last post, and I have amassed many files in my research over the years, so I will share a few more here.

First is a file I put together mostly from info. on the Iforgeiron site. There are 3 builds in this file and a couple small articles. First a similar version of "Rusty" then a well documented Helve hammer and the last an interesting Oliver anvil hammer.

To download the file click Blacksmith Plans And Projects - Power Hammers. 2.4 MB - pdf

This guy will never be called Rusty, few bearings used but the bushings are all oozing grease. 


Very nice Helve hammer, used for working sheet materials.


Oliver The Hammer, very interesting, with a little practice, two hammers one smith is possible, lol.


I mentioned in the last post that I had lots of plan sets from the net. on file, I guess if I said it, I better back it up. "Krusty" is not connected to Jerry Allens 3 creations (Rusty, Dusty, and Super-Rusty). It is a larger nock-off, from what looks like Germany or Eastern Europe. It was originally for sale but it has been widely available on the net for many years. This is a 17 page plan set.

To download the plan set click Krusty Power Hammer. 1.6 MB - pdf


So in my research I looked at a large number of power hammer patents on the US patent site here are a couple of patents some may find interesting.

The first is a portable power hammer, click Patent: Potable Power Hammer to download. 290 KB - pdf


To download the second patent file click Power Hammer 3. 132 KB - pdf


I find patent files an interesting source of ideas. I am not looking to copy a patent but rather to see how different ideas are used to solve the problem at hand.


Saturday, March 17, 2018

Advanced Projects For The Home Foundry And Machine Shop

As mentioned in a previous post most engineering drawing and design books have a "Working Drawings" section featuring many examples of shop or pattern shop ready plans for different items, some still commercially available.

This is usually my favorite section and one of the reasons I have so many of these texts in paper and on disc. So for the sake of sharing I made up a file of some of these projects assembled from my paper texts, maybe I will make one up from the titles I have on disc in the future.

As mentioned in the file most of these are advanced projects, most will require a full range of foundry skills and machining abilities. Not to put anyone off, but to grow your skills and keep the shop from getting mundane, you need to challenge yourself occasionally.

So I hope someone tries some of these, the drill press vises are an easy start. One of my first casting projects, many many years ago, was the # 2 drill press vise in the file. The aluminum jaws where easy to work without machinist machines, as was the case back then. The wood turning lathe,disc sander, and hand tools such as taps, dies, hacksaw, and files did a fine job.

To download the 40 page file click Advanced Projects For The Home Foundry And Machine Shop. 5.4 MB - pdf.







Saturday, February 10, 2018

Rod And Bar Bender

So here is a second project from P. Blandford's "24 Metalworking Projects". This is another fabricating project that is very useful around the shop, takes up little space and can be stored away when not in use. If you make or repair things in your shop sooner or later you will have need to bend some rod or bar stock for some specific purpose. There are many different plans for benders out there, this one is easy to build and will handle basic bending work in 3 standard sizes 3/8",1/2" and 5/8", also works with 1/4 " but bends wouldn't be as tight.





For the novice please note this is for use with solid stock. For tubing, formed dies are required such as in this article  A Few Vintage PM Workshop Jigs.


Saturday, February 3, 2018

And One For The Metalworker - Bench Shear

Percy Blandford wrote a large number of books for Tab Books Inc. unfortunately in my opinion the emphasis was on quantity over quality. There were a few exceptions to this view point, "24 Metalworking Projects" was one of them. There are some nice well thought out and illustrated projects in this small volume.

A bench shear comes in handy for small sheet metal cutting and trimming and will cleanly shear small metal shafting as well. Importers regularly sell 8" and 12" units in the $100 to $200 range. If my 12" is any indication, their quality is borderline.

The following plan carefully made can easily exceed the quality of the imports for less price and more satisfaction.