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

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.

Friday, June 22, 2018

Hobby Filing Machine

So I have a little time this morning before I hit the mowing tractor for one more day. Here is a nice short plan for a small filing machine.

I found it tucked away in a old file. Its titled PM Filing Machine. I uploaded a plan for a PM filing machine before but I don't think this version is it. It was in poor shape but I got it cleaned up nice.

I am sure when I find a day or two in the future, I want to try this. I could see it being a quick way to finish small metal parts accurately. I have a couple of small sets of Mibro files that would be perfect for this project. they have round shanks that would be perfect for a small chuck or collet.

Thursday, June 21, 2018

Small Bending Roll Plan

So 10 posts ago I posted a article on the operation of a small slip roll. I also indicated I would upload some plans. It seems there was a lot of interest in the article, so I figured I should get a plan up. I'll start with the smallest plan I have.

Most people are familiar with "Model Engineer" the British magazine that has been around since 1896 (yes 1896 and still going strong). It contains many metalworking plans and projects covering shop tools, live steam and various other model making topics. One of the plans I have found circulating on the web is an edited version of a plan for a small bending roll from Oct. 1976 Model Engineer. Its a nice plan but the pictures are all dark and not very useful.

I have a large collection of Model Engineer mags. on my shelf. Great deal I got from a retired Brit at a flea market in Thunder Bay, many years ago. On a hunch I checked them, and sure enough I had the two issues the bending roll was published in.

So without further ado here is the original plan from "Model Engineer" magazine. First picture is the cover of the bi-weekly containing Part 1 of the plan for the bending roll.

This is a well designed good quality plan, difficulty leans toward advanced, and a metal lathe is required. I have easier larger plans, but the quality here is hard to beat.

So I got a couple of days to make my property presentable and then it's time to enjoy some summer, but I think it was Arnie who said "aawl be back".


Monday, June 18, 2018

Heavy-Duty Welded Metal Bender

So does a bear EVER shit in the woods? "NEVER" lol. Had one leave a package in the middle of my turn around area, sometime last night. Looks like  he had a late supper on my long grass, sat down in one of my patio chairs and had a relaxing smoke before doing his business and leaving. There was an extra butt in the ashtray on the table, lol.

So its a gloomy stormy day out there today decided to make it a day of rest. Dug up an old file that might be of interest here. This is a plan for a heavy duty metal bender of welded construction. I found this file somewhere on the web years ago, it was originally published in "Science And Mechanics" back in August 1957.

This is a versatile idea capable of some heavy work. If you have the means to weld you can build this.

Click to expand click again for best view.

Notice: I did an edit on this article shortly after posting to get the pages in the correct order.

Saturday, June 2, 2018

From Engine Block To Engine Mill

So been wet and cool last few days, been taking a break from the Cavalier. So thinking about uses for engine parts, my older truck probably has no more than a couple more years left as well, I dug out a few files I have put together on the widely distributed, open source, "Multimachine Mill" pictured below. For those not familiar with this idea, I will do a post including the 80 page build pdf at a later date. However some may find the smaller plan below more suitable for the small shop.

This idea was not original. The idea came from a plan by G. A. Ewen, published in "Machinist's Workshop" in 2002. The above development was done by Pat Delany for the "Open Source Project". Pat also developed a plan for a concrete based lathe, based on ideas from the WWI patent by L. I. Yeomans in 1915, and some of J. V. Romig's ideas, uploaded in a previous post. I have half a dozen files on the development of this lathe for another future post.

So here is George Ewen's project for a very nice, smaller, engine block based, horizontal mill plan. I don't know if this is the original source of this idea, but I have so far not sourced an earlier plan, based on this idea.

The Cavalier's aluminum 4 cylinder block would make a nice lighter (yet still very ridged) machine similar to the one above. My old trucks straight 6, iron block, would be more suited for Pat's Multimachine, at the top of the post.

Wednesday, May 16, 2018

An Indicator, A Vise And A few Quickies

So back to the metalworking shop here is a plan for a nice clamp-on model maker's vise, a cleaned up and clearer scan of a test indicator for the lathe and around the shop. There is another method for cutting keyways in the lathe and a quick little jig for drilling round work.

Keyways are a characteristic common to most shaft, motor, and pulley assemblies in shop built machines of wood or metal construction. Just set screws can come loose and score shafts, keyways and set screws are a better way to go. Above is another idea for cutting keyways in the lathe. If you have a compound slide or have built one from the couple of plans I have posted, you can cut keyways using the above idea in the wood lathe as well. Don't try to hog it off in one pass, feed slowly taking a number of passes to reach the depth required.

If you use this method use a high power low speed drill, like the one below. I purchased this one shortly after "Mastercraft" came out with it. I liked it so much I bought a second one. Lots of power, it draws 7 amps, and the reversible variable speed runs 0-650 rpm. I work them as hard as my Makitas and so far they are holding up well.

Tuesday, May 15, 2018

A Few Easy Metal Lathe Accessories

So here are a few easy lathe accessories for the novice, looking to inexpensively equip his small metal turning lathe and gain some experience at the same time.

Friday, May 11, 2018

A Wood Turners Compound

A compound rest for the wood lathe can be very useful. As mentioned before my used Rockwell/Delta came with one but if they are still available, a new one is quite expensive. With a compound you can turn aluminum, brass and other softer metals on the wood lathe and if you can get your speed low enough even mild steel. Very useful for the hobbyist who would rather avoid the high cost of metal turning equipment.

This one looks solid enough to do light metal work. Switching out the hardwood base for easy to work, mild steel or aluminum, would allow for heavier more accurate work. This plan uses the "no castings" idea from J.V. Romig (the author) for the tool slides in this post Machine Tool Slides.

For straight or stepped wood turning the compound is safer and more accurate but has the limited range of action.

Here's something interesting that even MacGyver would be complimented for knowing. I wasn't aware of this method and I haven't done any research on it (I am not aware of any desalination plants based on this process). Nowadays a tight plastic snap lid and the clay pot is all you would need to survive two weeks in a rubber raft on the open ocean, lol.

Wednesday, May 9, 2018

"Say Good By Hydro-Pedal Power Yes"

Ha Ha wish it was that easy. Pedal power had it's hay day, modern power equipment is unprecedented. If you prefer to live off the grid or the slower bike path is more attractive than the high speed highway, then pedal power may still be very attractive. The early PM Shop Notes had many plans for treadle and pedal powered machines for the shop. Many like the file machine below still make lots of sense for the off grid user, who prefers leg power as opposed to running down his sun or wind charged storage batteries.

Others like the drill press pictured below don't make a lot of sense given the equipment available today. It was first presented in the Model Engineer Magazine and apparently someone actually built it,but to me it seems more like a Rube Goldberg machine, taking a circuitous route to its destination. Still an interesting article though.

Tuesday, May 8, 2018

Early PM Shop Notes Files Preview

So as mentioned before I am working on some early (pre 1930) PM shop notes files in my spare time. For example J. V. Romig, the D. Gingery of his time ( maybe that should be stated the other way around since Romig came first) produced a large number of small hobby shop sized machine plans for publication in Popular Mechanics and Popular Science from 1921 to 1925. That file is now over 75 pages of some of the more interesting plans he produced.

There is another file of short plans and ideas from these early shop notes that I am working on. These all come from the 26 volumes of early shop notes reprinted by Algrove Publishing. Here is a preview of a few short articles from this file.

The first one deals with heat treatment, hardening, and annealing. It is not a well known fact but when heat treatable steel reaches the right temp for hardening it looses it's magnetic qualities. A metal worker who does heat treatment all the time can easily judge by color but someone who only does it occasionally will find this tool very helpful.

This short article is an interesting method of casting brass worm gears. The second article is another plan for cutting circular work. There are lots of plans for this type of fly cutter, I have posted a few. For very thin sheet metal this is probably a better idea since it incorporates a shearing action with less chance of grabbing and damaging the work.

In addition to the many plans Mr. Romig authored, he also produced many articles for publication in the "Popular" magazines of the day. Here is one on making "no casting" machine slides for the hobbyist who would rather avoid setting up a small foundry.

Monday, May 7, 2018

Accuracy In Drilling And Sanding

So here are a couple of articles, a plan and some jigs, to increase your accuracy with the drill press and belt and disk sander. The first is a nice plan from a pre-1930's PM Shop Notes, for a fine feed attachment for your drill press. The fine feed can't be beat for doing accurate drilling in the drill press. You can also do light milling work on your drill press with this attachment. The problem here is that without a draw bar, few import drill presses have spindles accurate enough to keep your chuck and tooling from dropping out and the spindles often have a sloppy fit and light bearings. Ok for their intended purpose, but even light milling can be a step to far.

The second article is a nice collection of quick jigs for doing accurate repeatable work on the disc and belt sander. The article is by R. J. Cristoforo and if you do woodwork, then you have probably come across some of his many books and articles on the subject. This article was published in the 1984 Popular Science Yearbook.