Pretty Fly for a DIY Guy

Milling machines can be pretty intimidating beasts to work with, what with the power to cut metal and all. Mount a fly cutter in the mill and it seems like the risk factor goes up exponentially. The off-balance cutting edge whirling around seemingly out of control, the long cutting strokes, the huge chips and the smoke – it can be scary stuff. Don’t worry, though – you’ll feel more in control with a shop-built fly cutter rather than a commercial tool.

Proving once again that the main reason to have a home machine shop is to make tools for the home machine shop, [This Old Tony] takes us through all the details of the build in the three-part video journey after the break. It’s only three parts because his mill released the Magic Smoke during filming – turned out to be a bad contactor coil – and because his legion of adoring fans begged for more information after the build was finished. But they’re short videos, and well worth watching if you want to pick up some neat tips, like how to face large stock at an angle, and how to deal with recovering that angle after the spindle dies mid-cut. The addendum has a lot of great tips on calculating the proper speed for a fly cutter, too, and alternatives to the fly cutter for facing large surfaces, like using a boring head.

[ThisOldTony] does make things other than tooling in his shop, but you’ll have to go to his channel to find them, because we haven’t covered too many of those projects here. We did cover his impressive CNC machine build, though. All [Tony]’s stuff is worth watching – plenty to learn.

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Ringing in the new year with an Arduino and Calcium Carbide

carbide

It’s the first we’ve heard of it, but a New Year’s Eve tradition in The Netherlands called Carbidschieten sounds like it’s just up our alley. Basically, a small chunk of calcium carbide and a little bit of water is placed in a metal milk churn. The carbide decomposes into acetylene and a flame is held up to a small hole in the milk churn. The resulting explosion sends the lid of the milk churn across a field and much fun is had by all.

[Edwin Eefting],  [Johan Postema], [Elger Postema] are exploding 1000 liters of acetylene this New Years and needed a safe way to detonate their celebration. They came up with an electronic ignition system based on an Arduino that probably makes just as much noise as the explosion itself.

The build is basically an Arduino with a few relays. When a pair of buttons are pressed for longer than a second, the Arduino goes into countdown mode with the requisite alarms and ringing bells. When it’s time to fire the carbide cannon, a power supply is turned on that heats up a glow plug, igniting the acetylene. It’s a great build, and adds an adequate amount of safety for an event involving exploding 1000 liters of acetylene.

You can check out the videos of the countdown timer after the break, or check out the Facebook group here.

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