Todays Project - What did you do today?

[PixMan]

(02-02-2014, 11:50 AM)DaveH Wrote: A lot going on to day
Ken, how is the broach held?
And 111 inches of snow that's Nelson, - Lord Horatio Nelson.

DaveH

The broach is held simply by its tapered teeth jamming between the bushing I made and the bore of the gear. Tap it in with a soft faced hammer until it fits into the arbor press, lube it up with some cutting oil and start pressing it through the gear. There's a mating 0.063" (1.6mm) shim that you then put behind the broach and repeat the stroke through it. I think I'd milled the slot in the bushing just a little too deep because I had to make an additional 0.030" (0.762mm) thick shim out of brass to get the keyway to the correct size. Thus, it took three strokes per gear to get the keyways done.

[PixMan]

Today I spent a couple more hours in the shop. I'd hoped to get more done on Neil's project, but progress was made.

I started off with changing the gears on the lathe to be able to single point thread the bolts and axle we'd made. They fit PERFECT and worked great! First up was two M14x1.5 6g threads, one on the long axle (which would later get cross holes for a cotter pin) and the larger bolt for the rear suspension fixing point. Next, change the full profile threading insert to make two M10x1.25 6g threads, and a simple change of a lever handle to change the thread pitch on the lathe.



Using my spindexer on the milling machine, I first spotted the holes with a Ø 1/4" x 90º spot drill at 4 spots 90º apart, then drilled through with a beautiful Titex A1249TFL-1/8IN drill. It looks bright and uncoated in this photo, but it is in fact coated with Titanium Aluminum Oxide. The 135º split point cut like butter! I then had to run a regular No.29, 0.136" (3.45mm) drill though it to match the size to the original part.



The results, though I did use a jeweler's file to clean it up after I took the photo. The mating nut I had on hand spun right on with no hangups.



I also wanted to show a close up of the heads on those bolts which we made yesterday. As stated earlier, a short plunge with a 1" indexable insert ball mill, a touch with a Dremel and a minute or two of polishing to get this result. Note the little chamfers I milled around the hex. Jewelry!



One final shot of the finished parts together with the originals.

[DaveH]

(02-02-2014, 03:54 PM)PixMan Wrote:

(02-02-2014, 11:50 AM)DaveH Wrote: A lot going on to day
Ken, how is the broach held?
And 111 inches of snow that's Nelson, - Lord Horatio Nelson.

DaveH

The broach is held simply by its tapered teeth jamming between the bushing I made and the bore of the gear. Tap it in with a soft faced hammer until it fits into the arbor press, lube it up with some cutting oil and start pressing it through the gear. There's a mating 0.063" (1.6mm) shim that you then put behind the broach and repeat the stroke through it. I think I'd milled the slot in the bushing just a little too deep because I had to make an additional 0.030" (0.762mm) thick shim out of brass to get the keyway to the correct size. Thus, it took three strokes per gear to get the keyways done.

Thanks Ken,

DaveH

[DaveH]

Ken,
Very nice bolts

DaveH

[DaveH]

(02-02-2014, 12:39 PM)TomG Wrote: Dave, you should visit our upper peninsula here in Michigan. I just checked the annual snowfall for Houghton and it's at 228" inches for the year with 46" currently on the ground. The all time record was 390" in 1978.
Tom

I can see why I left

DaveH

[EdK]

Very nice parts Ken. I love the jewelry aspect. Those sure are pretty.

Ed

[PixMan]

(02-02-2014, 05:17 PM)DaveH Wrote: I can see why I left

DaveH

You used to live in Michigan? If so, how did you end up in SA?

[Mayhem]

(02-02-2014, 07:21 PM)PixMan Wrote: You used to live in Michigan? If so, how did you end up in SA?

Perhaps he was banned by Nelly and had to move on

By the way, very nice work on those parts Ken.

[DaveH]

(02-02-2014, 07:21 PM)PixMan Wrote: You used to live in Michigan? If so, how did you end up in SA?

No I did not live in Houghton, Michigan
Not sure about being banned, more like banished.

DaveH

[DaveH]

Just to mention England (cricket) were all out for 111 runs on the last game against Australia. Nelson strikes again. A fitting end one may say.

DaveH