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  1. #2461
    Join Date
    Aug 2019
    Location
    Revesby - Sydney Australia
    Age
    56
    Posts
    1,185

    Default Scrap metal

    Had half a car of scrap Al. from an old garden shed (channels were steel, but walls & roof were Al. sheet).

    Grabbed some other Alloy extrusion and castings to go with it, found two skateboard trucks. They are diecast Al over steel axles. Tried hacksawing a slit to hammer axles out, but that was taking too long.

    Then I remembered I now have a mill...
    IMG_1139.jpg

  2. #2462
    Join Date
    Mar 2011
    Location
    Southern Flinders Ranges
    Posts
    1,536

    Default

    Nothing particularly challenging or exciting, but..
    Finally found a few moments to make a new tool post stud for my Hercus 9 to fit a chinesium AXA quick change.
    Attached Images Attached Images

  3. #2463
    Join Date
    Dec 2013
    Age
    56
    Posts
    1,416

    Default

    Quote Originally Posted by racingtadpole View Post
    Nothing particularly challenging or exciting, but..
    Finally found a few moments to make a new tool post stud for my Hercus 9 to fit a chinesium AXA quick change.
    You will enjoy that
    Using Tapatalk

  4. #2464
    Join Date
    Feb 2020
    Location
    Albury
    Age
    58
    Posts
    90

    Default Toll height gauge

    I finally got around to finishing my tool height gauge. The concept originated from a link somewhere on this site.
    The bottom part has an M30x1 thread for fine adjustment of gauge height. The M4 bolt through side secures the height adjusted position.
    The dowel pin is an interference fit on the top part and a running fit on the bottom part.
    Drilling the off-centre hole and getting to the correct fit on both parts was an interesting challenge and so was calculating the details for the [non-standard] M30x1 thread.

    IMG_6643.jpgIMG_6645.jpgScreen Shot 2021-02-08 at 12.46.12.pngScreen Shot 2021-02-08 at 12.55.10.png

  5. #2465
    Join Date
    Dec 2013
    Age
    56
    Posts
    1,416

    Default

    Nice work, did you put a brass slug in the M4 hole to stop it damaging the threads?

    Or you could machine off the threads in the adjustment area.
    Using Tapatalk

  6. #2466
    Join Date
    Feb 2020
    Location
    Albury
    Age
    58
    Posts
    90

    Default

    Quote Originally Posted by Dave J View Post
    .... did you put a brass slug in the M4 hole to stop it damaging the threads?
    The answer to your question is No, but ......
    if you have closer look at the drawings you'll see that the M4 bolt is not touching the threaded part at all, it locks on the plain cylindrical surface located well above the thread.

  7. #2467
    Join Date
    Dec 2013
    Age
    56
    Posts
    1,416

    Default

    Ah I see, good thinking
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  8. #2468
    Join Date
    Aug 2019
    Location
    Revesby - Sydney Australia
    Age
    56
    Posts
    1,185

    Default Pulley machining

    Had a walk-in at the man cave. Looking for someone to machine some new pulleys to fit a wider belt:

    IMG_1241.jpg


    For some reason he wanted both grooves enlarged, so for easy access to both I mounted it the lazy way, using threaded rod thru the spindle:
    IMG_1242.jpg


    Thought about mounting some HSS, but being lazy, started machining with my little parting tool:
    IMG_1243.jpg


    That didn't quite reach the bottom. A little step wouldn't have mattered, but it is for a paying customer, so I should tidy it up.
    Was contemplating grinding some HSS when I remembered that they do make a cutter that matches 40degrees!

    Borrowed a VNMG holder:
    IMG_1244.jpg IMG_1245.jpg


    At 500RPM, could machine the whole 15mm depth and get some decent chips. Here is an 8mm wide (but very thin) one:
    IMG_1246.jpg


    Easy job - could have even done it on the Hercus!
    (which would have been quieter, but the chatter and machining marks would be worse)

  9. #2469
    Join Date
    Aug 2019
    Location
    Revesby - Sydney Australia
    Age
    56
    Posts
    1,185

    Default Fridge shelf lock pins!

    Another day, another walk-in (If this workload keeps up, I might need a holiday?).

    3:30PM, man brings me a sample aluminium pin that goes in a teardrop slot to support shelves in a fridge. Needs 24 ASAP.

    They are 9.5mm dia., and 35mm long, so I need over 800mm of round stock. I don't have anything, so have to scrounge around my factory neighbours.

    One has 350mm of 9.5mm "free machining stainless" (303?). One has 800mm of 15mm brass. I start turning down the brass, but soon decide that will take too long. One has a metre of 3/8" brass, but it is bent, scratched, and fire damaged. By now it is nearly 4. Edcon closes at 4?

    I hacksaw the long bent one into Hercus length rods, grab some emery, polish it up, and part off:
    IMG_1247.jpg


    Looks feasible, so I jump onto repetition machining. I try to setup my tool holder block for efficient facing/chamfering and parting:
    IMG_1248.jpg IMG_1249.jpg IMG_1250.jpg
    but swinging between them (and aligning the parting tool) was taking too long. In the end, I just used the parting tool for both facing and parting, and hand held a carbide insert against the corner to chamfer (it is soft brass, after all). 22, 23, 24. Time is now about 6PM. I'm rushing to try and finish these, to save the man another trip tomorrow.


    Now for the little groove. It is about 1mm wide. None of my neighbours had the correct width - closest was a .6mm, and I don't have time for multiple passes?

    If I had time, I would hand-grind some HSS. Thankfully, toolmaker is willing to use D bit grinder to make me one.
    10 minutes later and a broken carbide end mill is recycled, and another 5 to shim it up correctly. Time is now 6:30, and customer has gone.

    I could wait 'till the morning, but turned the lights on a while ago, so might as well finish. 70 thou deep, and its a match:
    IMG_1251.jpg IMG_1252.jpg


    7:10PM, pins are ready:
    IMG_1253.jpg


    Now, I gotta work out how much to charge him. I'm not a very good machinist - definitely not a $50/hr machinist - but it was over 3 hours, and someone to make a cutter, and the stock.

    Hmmm.

  10. #2470
    Join Date
    Dec 2013
    Age
    56
    Posts
    1,416

    Default



    Now, I gotta work out how much to charge him. I'm not a very good machinist - definitely not a $50/hr machinist - but it was over 3 hours, and someone to make a cutter, and the stock.

    Hmmm.
    You have the equipment, the skills and a rush job, you can't undercut yourself to much.
    If you happy charge him $100-$120.

    I've noticed no one likes stating prices.

    I made a 10mm thick adapter plate (supplied material) to fit larger bore quad rims to a smaller hub along with drilling the stud pattern and charged $70 for a local I do work for, took about 2 hours.he is a boiler maker so he did the welding or it would have been more.

    I also bored out and and drilled the stud pattern of 2 other quad rims for the same guy a week later, it was more knock everything off my mill and set up time with clamping down extensions etc and charged $70 also for a 2 hour job as he is a repeat customer.

    He earlier wanted a new petrol motor adapted to a new electric water pump, all material supplied I made the internal external shaft with threads etc and a 100mm pipe sleeve with flanges welded to couple them together and it cost him $350, but I under quoted as I had a good 6-7 hours into it, but that was on me.

    Charge what you think is fair, but don't undercut yourself to much as you have had to buy the machines etc.

    A person packing shelves at the local supermarket casual gets around $28 plus an hour, and has no real skills and hasn't laid out for expensive equipment.
    Using Tapatalk

  11. #2471
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    6,444

    Default

    Hi Nigel, Guys,

    Here in the UK I would be looking at £2 a pin, say £50.00 I think that is about $110 Au.
    Best Regards:
    Baron J.

  12. #2472
    Join Date
    Mar 2011
    Location
    Southern Flinders Ranges
    Posts
    1,536

    Default

    I charge out at $130/hr in 1/2hr increments no exceptions, plus material.

    That was a drop everything rush job, you asked favours, and ran into outside of normal hours territory trying to save the customer a return trip..
    The most valuable thing you can give anyone is your time, you will never get those three hours back, charge appropriately.

    Good, Fast, Cheap. Pick two, the third is mutually exclusive

  13. #2473
    Join Date
    Aug 2019
    Location
    Revesby - Sydney Australia
    Age
    56
    Posts
    1,185

    Default

    Quote Originally Posted by racingtadpole View Post
    I charge out at $130/hr in 1/2hr increments no exceptions, plus material.
    Wow, you must be a much better machinist than me!

    (or be doing unique/tricky work for select customers?)



    Thanks for the price discussion, guys. I ended up charging $120.

    He is just a glorified handyman working on pub fit outs, and I gave him a business card. Suspect he will come back the next time – hopefully with a bit more notice.

    Good, Fast, Cheap. Pick two, the third is mutually exclusive
    Rough, Fast, Unsafe. We manage to do all three!

  14. #2474
    Join Date
    Oct 2010
    Location
    melbourne, laverton
    Posts
    1,910

    Default very nice

    Quote Originally Posted by Tuomas Soikkeli View Post
    Here is my latest build.
    Took about 5 hours + 2 hours for polishing / finishing after paint was dry. Made from 54kg/m rr-track. Lenght 450mm

    Attachment 390046

    Video about making: https://youtu.be/ZxR-sRFAzYw
    good job that looks smick
    far out just with 9"

  15. #2475
    Join Date
    Jun 2007
    Location
    Vic
    Age
    48
    Posts
    544

    Default

    It was on the agenda to make the sine table for a long time but I never got around it until the recent project where I needed to cut the bib for the dovetail. The “fixture” plate is removeable and I am using that on the rotary table too. Admittedly setting up the strip up is taking a bit of time as you would want the edges of the gib to be parallel, I guess I could mill a recess step for the strip to sit on.

    20210223_175747.jpg

    Using the 8mm dowel, once the plate is bolted, I skimmed the top surface and the outer edge.
    20210223_191411.jpg

    Setup the angle
    20210223_192144.jpg

    20210223_201006.jpg

    20210223_210138.jpg

    Using the existing dovetail to support the strip makes it easier. To cut the opposite side I just elevated the strip up with the ruler and that gives the clearance required.
    20210224_180418.jpg

    Setup to cut the second side
    20210224_182113.jpg

    This is by using the sine table to cut.
    20210224_202210.jpg

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