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

Saturday, December 8, 2018

Old Becomes New Again

There are many who pass off the old PM plans as being obsolete, but for being obsolete, it is surprising how often they show up again as new ideas or as new versions of an old idea. In many cases you are not aware of the previous versions in the old PM or PS magazines. I have been victim to this a few times and it's both, a boost, and a let down, that someone else thought of the idea first.

Following is an example of this conundrum. Back in the late thirties PM published a plan for a useful horizontal disc sander, it's easy to see how this could be very useful, especially for sharpening edge tools, with a few jigs to control the angles.

Below is the plan for the disc sander along with a plan for a beast of a belt sander. I got this from a Popular Mechanics Press book titled "Forty Power Tools You Can Make". It was published in 1941 and the plans are all taken from previous PM magazines. I have posted most of the plans before, in the Shop Notes posts.

Dave Gingery does a recreation of this disc sander in his first book in the "Metal Working Shop From Scrap" series, "The Charcoal Foundry". Dave recognized the versatility of this disc sander for pattern making and tool sharpening and built one almost exactly the same as the old plan in PM. This may have been a product of Dave's very creative mind, but as I like to say "Their's nothing new under the sun" old becomes new again, just a little different.

Don't forget to read Dave's nice little write up on the disc sander and it's uses.

Novice Machinist 4 - Two Vises

So here are a couple of more advanced projects for the novice machinist. The first, a model makers vise, is very handy for doing small work on the workbench. It is all made from cold finished steel (crs).

The second vise is a nice woodworking vice. If you have been looking for a nice aluminum casting project, this might be it. Many years ago when I built my first melting furnace, a drill press vise was one of the first projects I did. This plan is a little more advanced but I would not consider it difficult. The patterns are relatively straight foreword, note the draft lines in the drawing. Draft is generous in the deep section to ease pattern withdrawal from the mold, without damage.

Both of these plans will produce very useful shop accessories that are becoming quite expensive in the retail market, and you will have the satisfaction of having made them yourself.

Novice Machinist 3 - More Small Tools

So here are 5 more small tool plans from "Metal Projects Book 3". These projects are excellent, useful, projects for the beginning hobby machinist. If you own one of the inexpensive import lathes and/or mills, or even better have built your own, these will get you started with set-ups and procedures. Materials are mostly crs (cfs), tool steel, and aluminum, materials that are easy to source and work with.

Tuesday, November 20, 2018

How To Make A Treadle-Operated Wood-Turning Lathe # 6

So continuing with ITP's Workshop Equipment series, here is # 6 "How To Make A Treadle-operated Wood-turning Lathe". This is a metalworking project and involves welding but it's used for woodworking (that will piss-off a few, ha, ha).

This lathe is welded up from mild steel sections and incorporates salvaged parts for the flywheel and drive assembly, mainly a brake drum and bicycle drive parts. There are woodturners who prefer to use a treadle lathe even in the presence of power, it's a personal preference. Mainly, treadle lathes are machines from the past when electrical power was something that shot out of the sky in lightning bolts. If your off grid, like to save on your energy bill, or just enjoy the slower control of a treadle lathe this is one of the more advanced versions of the treadle lathe out there.

To download "How To Make A Treadle-operated Wood-turning Lathe" go to my Books - Free Downloads page. # 67 - 3 MB - pdf.

Looking for a good read? If you like reading politics, and how it is failing us, you might like this.

Interested in reading a good book on the state of the union by a prize winning author? "America, The Farewell Tour" by Christopher Hedges is a good place to start. It has become clear to most that America is on the backside of the slope. The question is how fast and steep will the ride down the slope get? Mr. Hedges is certain we will find that out within the next 20 years (damn, I might live to see it, ha, ha). The author puts the blame squarely on the heads of big business and the 1%. They have destroyed the economic well being of 95% of us, and they are destroying our planet at a unprecedented rate, to satisfy their insatiable appetite, for the power of ultimate wealth. It's a given the Republicans are their puppets and the Democrats have been bought off long time ago. Bernie Sanders was a bright light in the last American election but the Democratic party and their controllers the 1% weren't going to let that happen. The result, Trump. The masses figured he couldn't hurt them worst than Clinton and the Democratic Party had already done (letting the 1% destroy the working class in America to maximize their profits). So what about the 1%, no problem they had both bases covered. God help us, oops, the Republicans own him, were in trouble. 

Tuesday, November 13, 2018

How To Make A Metal-Bending Machine # 10

So from Intermediate Technology Publications comes another of their Workshop Equipment titles. This one "How To Make A Metal-Bending Machine # 10" is the last of the paper copies I have. Like the other two, it cleaned up nice and is complete.

The first half of the manual shows you how to build the bender. The second half of the manual shows you how to build a steel wheel for a agricultural cart. Now your probably thinking "What is wrong with this "Bozo"? What am I going to do with an ox cart?" ha, ha, lol .

But of course you can bend up countless other shapes, for many different projects, with this bender.

To download this manual go to my Books - Free Downloads page. # 66 - 3 MB - pdf 

Saturday, November 10, 2018

An Easy Guillotine Tool

Guillotine tools are very useful helpers for the smith who works alone. A good one will cut your time in shaping and cut-off operations depending on your selection of dies. Dies are easy to make, so it's a simple matter to have a good selection on hand to suit the type of work you are doing.

I have seen many ideas for making guillotines around the web over the years, some are more complicated to make than others. Many have probably seen the one I am posting today before, it has made it's rounds on the web. It is one of the easiest I have seen to build, a few workshop scraps and some welding is all you need. A small price for the huge help this tool can be.

The plan was originally published in ABANA's "Hammer's Blow" newsletter. I got this copy from the "Saltfork Craftsman" newsletter of August 2005.

Atmospheric Forge & Heat Treat Oven

So I spent yesterday morning running errands and settling in for winter. I was almost home when the blizzard started, It blew hard all night and is supposed to continue all day today. Nothing else to do but cook up some tasty treats (winter's coming on, like the bears, a little insulation will help, lol) , fire up the wood stove, and settle in in front of the computer, for the week end. Life is good ha, ha.

Near the top of my build list is a forge, soon I hope. I have lots of plans for forges, and some ideas of my own. One plan that I have always found attractive was published by David J. Gingery Publishing back in the 90's. It was built and the manual written up by William T. Goodman and Robert W. Holmee. It has a very nice appearance but I would make some changes to the shape and refractory of the firing chamber. The refractory in the plan is a little thin in my opinion and there are more efficient materials that can be used today.

It took me a while to find this book, I think I eventually found it on a torrent site. The scan is not great (I cleaned up the two pages below), but it is complete. So if you would like a proven plan for a nice and very convenient forge or just want some good ideas for building one, this should do it.

To download go to my Books - Free Downloads page. # 65 - 4 MB - pdf

Wednesday, November 7, 2018

How To Make A Hand-Operated Holepunch

So as mentioned before I will be uploading a few more "Workshop Equipment" series titles, published by Intermediate Technology Publications.

Today you can download "# 7 How To Make A Hand-Operated Holepunch". As I mentioned before I have taken a bit of time to assemble this file, and you will not find a cleaner version of this title on the internet.

I would consider this project one of the more advanced in the 10 volume series. If you have not done a lot of metalworking before, it is important to go slow and verify your work continually before welding up your assemblies. The finished hole punch will be a great time saver for anyone who requires a lot of holes in sheet metal. It will punch holes up to 25mm or 31/32" in 16 guage  material.

Probably the hardest part of the project will be, making up accurate punch dies. Above 9/32 to 31/32, lacking a suitable supplier, you will have to make your own. Instructions are in the manual.

For holes 9/32 or smaller a cheap alternative is to adapt the punch dies from a hand hole punch, done easily enough.This inexpensive set cost only $34, 10 years ago. It works, but it is a slow process. Installing the dies in your new holepunch would greatly speed things up.

So If you would like to download this nice plan manual, go to my Books - Free Downloads page. # 64 - 4.4 MB - pdf.

Saturday, November 3, 2018

Half Scale Stutz Bearcat Sidewalker

So from the "Junior Mechanics Handbook" is the plan for a half scale, Stutz Bearcat, sidewalker, that I mentioned in a previous post. This is a challenging and interesting project for the all around workshop diy'er. It incorporates aspects of both woodworking and metalworking. If your looking to really impress some young folk with an awesome project, this one will certainly do it.

At 11 pages the project plan is quite complete, and leaves little to the imagination. I have learned over time to clean up and stitch pages together, as long as I can fit the page flat to the scanner glass. Over-size books that lift at the scanner edges, produce deep shadow and are harder to clean up, without effecting the scan content. Stitching pages together allows me to upload more pages in a smaller space. Resolution is good if you expand images to there max., I have no trouble clearly reading the images without my glasses, and believe me, I need my glasses for most of the reading I do nowadays. My pixel height is normally 1200 with the width, a ratio of the original.

Wednesday, October 31, 2018

How To Make A Pipe-Bending Machine

So I have mentioned "The Workshop Equipment Series" before, published by Intermediate Technology Publications. There are 10 manuals in the series covering a variety of workshop equipment, mostly metalworking. I have three paper titles and over the years have found 8 of the 10 titles on line. I am still missing # 8 and # 9. The problem with the downloaded titles is the poor quality of the scans, missing pages, and poor page alignments.

So I decided to do my own scan of one of my paper copies, "# 5 How To Make A Pipe-Bending Machine". I can safely say that this is the best quality scan, of one of these titles, that you will find on the internet.

The plans in this series were all well developed, materials are common steel sections, and similar materials. One requirement of most of these projects is a basic ability to do welding in your shop.

So if you would like to download this plan, to build a piece of essential shop equipment, go to my
Books - Free Downloads page. # 63 - 3 MB - pdf

Tuesday, October 30, 2018

Modelmaker's Arbor Press

So here is another small project from ARCO publishing's "Junior Mechanics Handbook". Don't let the word "Junior" make you think these projects are for just the young novice. There are a good number of projects in this book that the seasoned home tinkerer would be challenged with.

So for the modelmaker machinist here is a useful small arbor press for the shop. You can make this up from small off-cut materials found around the shop.

So below is my mini arbor press. I built this over 20 years ago out of scrap and salvaged materials in my storage boxes. As you can see from the rust I haven't used it much lately (Yes I know, I should paint it to slow down the rust, lol). The last time I used it was to press the bearings into place on the wheels for my double belt grinder project.


So back to this book and a nice collection of projects. Below is the contents page, As can be seen there is a good variety of projects. I would scan and upload the whole book but the electronics projects are dated given todays tech. I recognize that there are hobbyists who still like to dabble in the older electronics tech. but you are becoming few with todays advances. I will upload more projects in the future, like the Stutz Bearcat project below. A project that would be a healthy challenge for the builder, and make some young owner very proud.

Thursday, September 27, 2018

Die Cast Molding Machine

So for something a little different from the recent content, here is a nice little plan for a die cast molding machine. I found this in the middle of a 200 page Word file I made up back in 2005 titled "Shopbuilt Machines". At that time if I wasn't working overtime at a local copper and zinc smelter, I was at home trying to convert the whole, home shop tech. internet, into Word files. I never did succeed, the faster I made up Word files the faster the amount of info. available increased, lol. If you had a site up back then, I probably have parts of it recorded in Word doc. Lately I have been converting some of them to pdf.

I can't remember where I found the more recent accompanying write up for this plan, but the original drawings and idea were from a 1937 magazine, I seem to remember it from somewhere. I know Popular Mechanics published a similar plan that I seem to remember including in a previous post.

This is an excellent little machine for the model making hobbyist who is not afraid of, and has the means to melt low temp. metals. Small metal parts, for all types of model construction, can be produced. The most challenging part is making the dies, but if you have the hobby machines to make metal models of engines, cars, trains, or planes, you can make the dies.

In the article the author had the melting temp. for Zamak at 1800*F, probably just a typo, I changed it to 800*F. Here are the details for Zamak from Google. This metal is ideal for this kind of work.

"These alloys are commonly referred to as Zamak alloys, which is an acronym for zinc, aluminum, magnesium and copper. Zinc alloys have a melting range of about 380-390°C (~ 725°F) although higher levels of aluminum can increase the melting point to as high as 480°C (~ 900°F)."

Here is the article, max out the "expand" for best view.

More Information:

Zamak is a popular die casting metal. It is available in casting ingots as Zamak 2, and 3 among many others. If you pursue this neat little die casting machine, the author refers to Zamak 2 in the article. It has the highest strength and hardness of the Zamak family of metals and has good die casting characteristics. Melting temp. is actually 725*F. Here is a info. sheet on Zamak 2.

Friday, September 21, 2018

Tips And Jigs From "Projects Two"

So we had a very noisy and wet storm roll in yesterday, the Canada Geese must have sensed it and left before it rolled in.

So here are a few tips and jigs from "The Home Shop Machinist" magazine's "Projects Two". I have volumes one to eight. It has been years since I checked they may have many more out by now. This magazine and their popular sites is devoted to the hobby home machinist. In addition to machinist projects and information they also cover some casting and foundry equipment projects.

Here is a collection of three, one page tips and jigs, from the second volume in the series. The V block is a very simple and quick way to make a useful accessory for the drill press. Have you ever cursed a slot screw driver that keeps slipping out and damaging the screw head? Here is a grinding jig to properly grind the blade of a slot screwdriver. Cutting curves in heavier plate can be difficult, here is a drill guide to make it easier. Ever notice how drilling or turning aluminum is always a sticky process on the cutting edges, here is a tip for reworking a turning tool to produce nicer finishes on aluminum. Expand for best view.