The Elements Converge for ±.002 in Tolerance

What can be accomplished with just a torch and compressed air? We can think of many things, but bringing a 17-foot-long marine shaft into ±.002 in tolerance was not on our list.

Heat straightening (PDF) utilizes an oxy-acetylene flame that is used to quickly heat a small section of a workpiece. As the metal cools, it contracts more than it expanded when heated, resulting in a changed volume. With skill, any distortions on a shaft can theoretically be straightened out with enough time (and oxy-acetylene). Heat straightening is commonly applied to steel but works on nickel, copper, brass and aluminum additionally.

[Keith Fenner’s] standard process for trueing stock is sensitive enough that even sunlight can introduce irregularities, but at the same time is robust enough to carry out in your driveway. However, even though the only specialty tools you need are a torch, compressed air and work supports, watching [Keith] work makes it clear that heat straightening is as much an art as it is a science. Check out his artistry in the video below the break. Continue reading “The Elements Converge for ±.002 in Tolerance”

Video Series Shows Custom Machined Fly Reel

For those of us who can’t get enough vicarious machining, YouTube is becoming a gold mine. Intricate timepieces, gigantic pump shafts, and more and better machine tools are all projects that seem to pop up in our feed regularly.

With all that to choose from, can a series on building a fly fishing reel actually prove interesting? We think so, and if you enjoyed [Clickspring]’s recently completed pedestal clock, you might just get a kick out of what’s cooking in [JH Reels]’ shop. Comparing any machining videos to [Clickspring]’s probably isn’t very fair, but even with a high bar to hurdle, [JH Reels] comes out looking pretty good. The challenge here is that this is a saltwater fly reel, so extra care with material selection and machining methods ought to make for some interesting viewing. Also of interest is the range of tooling needed to produce the reel. From lathe to mill to waterjet cutter, a lot goes into these parts, and watching them come together is fascinating.

You wouldn’t think a seemingly simple mechanism like a fly reel would be so complicated to build. But there’s a lot more to it than meets the eye, and with a reel that’s clearly destined to be an heirloom piece, [JH Reels]’ attention to detail is impressive. The series currently stands at 10 videos, and we’re keen to see how it turns out.

The first video is posted below to whet your appetite. But if machining and fishing don’t do it for you, maybe you can try drones and fishing instead.

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Add Broken Tool Detection to Your CNC Mill

A tool breaking in the midst of a CNC machining operation is always a disaster. Not only do you have a broken tool (no small expense), but if the program continues to run there is a good chance it’ll end up ruining your part too. In particularly bad cases, it’s even possible to for this to damage the machine itself. However, if the breakage is detected soon enough, the program can be stopped in time to salvage the part and avoid damage to your machine.

Many new machining centers have the ability to automatically detect tool breaks, but this is a feature missing from older machines (and inexpensive modern machines). To address this issue, [Wiley Davis] came up with a process for adding broken tool detection to an older Haas mill. The physical modifications are relatively minor: he simply added a limit switch wired to the existing (but unused) M-Function port on the Haas control board. This port is used to expand the functionality of the machine, but [Wiley] didn’t need it anyway.

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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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For Your Binge-Watching Pleasure: The Clickspring Clock Is Finally Complete

It took as long to make as it takes to gestate a human, but the Clickspring open-frame mechanical clock is finally complete. And the results are spectacular.

If you have even a passing interest in machining, you owe it to yourself to watch the entire 23 episode playlist. The level of craftsmanship that [Chris] displays in every episode, both in terms of the clock build and the production values of his videos is truly something to behold. The clock started as CAD prints glued to brass plates as templates for the scroll saw work that roughed out the frames and gears. Bar stock was turned, parts were threaded and knurled, and gear teeth were cut. Every screw in the clock was custom made and heat-treated to a rich blue that contrasts beautifully with the mirror polish on the brass parts. Each episode has some little tidbit of precision machining that would make the episode worth watching even if you have no interest in clocks. For our money, the best moment comes in episode 10 when the bezel and chapter ring come together with a satisfying click.

We feature a lot of timekeeping projects here, but none can compare to the Clickspring clock. If you’re still not convinced, take a look at some of our earlier coverage, like when we first noticed [Chris]’ channel, or when he fabricated and blued the clock’s hands. We can’t wait for the next Clickspring project, and we know what we’re watching tonight.

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An Introduction to CNC Machine Control

We recently gave you some tips on purchasing your first milling machine, but what we didn’t touch on was CNC (Computer Numerical Control) systems for milling machines (or other machines, like lathes). That’s because CNC is a complex topic, and it’s deserving of its own article. So, today we dive into what CNC is, how it works, and ultimately if it’s right for you as a hobbyist.

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Sometimes Square is Square: Basic Machinist Skills

Is it possible to make an entertaining video about turning a cube of aluminum into a slightly cubier cube? As it turns out, yes it is, and you might even learn something along with the sight gags and inside jokes if you watch [This Old Tony] cover the basics of squaring up stock.

Whether you’re working in wood or metal, starting with faces that are flat, smooth and perpendicular is the key to quality results. [Tony] is primarily a machinist, so he works with a nice billet of aluminum and goes through some of the fundamental skills every metalworker needs to know. When you’re working down to the thousandths of an inch it’s easy to foul up, and tricks such as using a ball bearing between the vise jaws and the stock to prevent canting are critical skills. He covers tramming the mill, selecting which faces to cut and in which order, and ways to check your work on the surface plate and make any corrections if and when things go wrong. Look for cameos by fellow machinist [Abom79] and [Stefan Gotteswinter], including one with [Stefan] in a very compromising position. But a ball in a vise and no [AvE] reference? C’mon!

[Tony] makes a potentially tedious subject pretty entertaining by keeping things light, and we appreciate both the humor and attention to detail. He’s turned out some great videos that we’ve covered before, like making your own springs or a shop-built boring head, and his stuff is really worth checking out.

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