Custom Drill Press Table Eliminates Hassles

Getting a perfect workshop together, with all the right tools, is a dream for many. A lot of us cobble together what we can with a dremel tool, a soldering iron, and whatever work surface happens to be available in the kitchen or spare bedroom. But even when we finally get a permanent garage or shop to work in, there are still some challenges to overcome with our workspaces. [Workshop From Scratch] was having issues with his drill press, and solved them with this custom build.

Rather than modify an existing press, he first welded a table together from scratch using square tube. From there he set about solving those issues. The first was having to make a large number of adjustments up and down when working on larger pieces. For that he added an electrically adjustable worktop which keeps him from having to make constant adjustments of the press itself. The second improvement over the standard press workspace was adding a cooling system for the cutting tools, saving himself money in bits and allowing quicker drilling.

The finished product looks professional thanks to a quality paint job and, of course, having all the right tools in the workshop in the first place to put something like this together. We all have an idea in our heads about the perfect workshop for our own needs, but don’t forget to think outside the box when it comes to building one yourself.

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Converting A Drill Press Into A Milling Machine

Mills are a huge investment, and for hobbyists without the space to install their own personal mill, it can sometimes be a pain to have to find a facility with a mill to complete your project.

What if you could convert your drill press into a mill instead? YouTuber [Small Metalworking Machines] explores this in his video, where he takes a small Central Machinery drill press and adds a few mods. He took some steps to improve the quill, spindle, and bearings — boring down the quill, replacing the bearings, and finally turning and re-threading the spindle it at 1/2-20.

With the adjustments, he was able to add in a cheap drill chuck, which fit in quite nicely with just a slight wobble of 5 thousandths on either side. To introduce some control, he added in a worm gear to engage a gear on the spindle. A pivot point disengages the worm gear, while bearings provide it controlled movement from the worm wheel.

He also added a cheap milling table from eBay, attached to the base of the drill press, all for a total of $120. While it’s not perfect, it’s still significantly less expensive than buying a mill!

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The Home-Made Drill Press Of Your Dreams

We are lucky to live in an age when tools have almost never been so affordable, when if we’d like a drill press on our benches we can pick one up for not a lot from our nearest discount store. If the cheapest tools aren’t very good quality then even the better ones aren’t that much more expensive. It’s evident that [Workshop DIY] has the resources to buy a decent drill press if he wanted one, but we’re fortunate that instead he’s taken the time to build one of his own from scratch (Russian language audio, Anglophones will have to enable YouTube subtitle translation).

The press itself is made entirely from box section steel tube, with what looks like 25mm square used for the base and 50mm for the vertical shaft. Instead of a rack and pinion to raise and lower the tool it has a slider that runs on a set of bearings and is lifted with a bicycle chain. The chuck itself is mounted to a shaft that runs through another set of bearings to the large pulley and motor from a washing machine. The result is a beautifully made drill press that seems to work very effectively. It may lack an adjustable table or selectable speeds, but we certainly couldn’t build it better than he has. Take a look, the video is below the break.

It shouldn’t be surprising what can be made in a well-appointed metalworking shop, perhaps we have been blinded by the convenience of readily available tools. If you’d like to see more, take a look at this DIY engine crane.

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Print A Drill Press For Your Printed Circuit Boards

If you make printed circuit boards the old fashioned way by etching them yourself, you may need to drill a lot of holes; even surface-mount converts still need header pins on occasion. But, drilling these holes by hand often leads to broken drill bits, which always seems to happen with one un-drilled hole and no spare bits left. [Daumemo] came up with a solution: a 3D printed drill press for a Dremel or similar rotary tool.

While you can buy commercial presses designed to fit these tools, there’s a certain satisfaction to building your own, and if you have a well-stocked parts bin you might even finish it before a mail-ordered version could arrive. Certainly you could do it at lower cost. The design is straightforward, and uses printed parts augmented with “reprap vitamins” (i.e. the non-printable, typically metal, components). If you’ve ever built — or repaired — a 3D printer, you may have these pieces already: a couple of LM8UU bearings, some 8 mm steel rod, and a pair of springs seem like the most esoteric parts required, although even these could probably be substituted without much trouble.

Only a few pieces need to be printed: a base is outfitted with a removable table for holding the workpiece, while a lever actuates the frame holding the tool. [Daumemo] chose to print the design in ABS, but found that it flexes a little too much, occasionally requiring some care during use — a stiffer filament such as PLA might yield better results. Overall, though, this seems like a great project for that 3D printer you haven’t used in a while.

Be sure to check out the video of the press in action, after the break.

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Drill Jig Helps Mount WeMos D1 Mini

As far as ESP8266 boards go, the WeMos D1 Mini is a great choice if you’re looking to get started with hackerdom’s microcontroller du jour. It’s small, well supported, and can be had ridiculously cheap. Often going for as little as $3 USD each, we buy the things in bulk just to have spares on hand. But that’s not to say it’s a perfect board. For one, it lacks the customary mounting holes which would allow you to better integrate it into finished products.

This minor annoyance was enough to spring [Martin Raynsford] into action. He noticed there was some open area on the D1 Mini’s PCB where it seemed he could drill through to add his own mount points, but of course popping holes in a modern PCB can be risky business. There’s not a lot of wiggle room between success and heartbreak, and it’s not like the diminutive D1 Mini is that easy to hold down to begin with. So he designed a laser-cut jig to allow him to rapidly add mounting holes to his D1 Mini’s assembly line style.

For those who might be skeptical, [Martin] reports he’s seen no adverse effects from drilling through the board, though does admit it’s possible the close proximity of the metal screw heads to the ESP8266’s antenna may have a detrimental effect. That said, he’s tested them in his projects out to 25 m (82 feet) with no obvious problems. He’s using a 2 mm drill bit to make his hole, and M2 x 6 mm machine screws to hold the boards down.

The jig design is released as a SVG and DXF for anyone with a laser cutter to replicate, but it shouldn’t be too difficult to extrude those designs in the Z dimension for hackers who haven’t yet jumped on the subtractive manufacturing bandwagon.

When a project makes the leap from prototype to in-house production, designing and building jigs become an essential skill. From flashing firmware to doing final checkout, the time and effort spent building a jig early on will pay for itself quickly in production.

A Scratch-Built Drill Press Vise From Scrap

Never underestimate the importance of fixturing when you’re machining parts. No matter what the material, firmly locking it down is the key to good results, and may be the difference between a pleasant afternoon in the shop and a day in the Emergency Room. Flying parts and shattered tooling are no joke, but a lot of times quality commercial solutions are expensive and, well, commercial.  So this scratch-built drill press vise is something the thrifty metalworker may want to consider.

To be sure, [Ollari’s] vise, made as it is almost completely from scrap angle iron, is no substitute for a vise made from precision ground castings. But it’s clear that he has taken great care to keep everything as square and true as possible, and we give him full marks for maximizing his materials. And his tools — nothing more complicated than a MIG welder is used, and most of the fabrication is accomplished with simple hand tools. We like the way he built up sturdy profiles by welding strap stock across the legs of the angle iron used for the jaws, to give them a strong triangular cross-section to handle the clamping force. And using the knurled end of an old socket wrench as the handle was inspired; we’ll certainly be filing that idea away for a rainy day in the shop. Although we might use Acme rather than plain threaded rod.

We always enjoy seeing someone fabricate their own tools, and this one reminds us a bit of the full-size bench vise built up from layers of welded steel we featured a while back. It even looks a little like this 3D-printed vise, too.

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Wireless Charger Gives A Glimpse Into Industrial Design Process

Almost every product on the market has been through the hands of an industrial designer at some point in its development. From the phone in your pocket to the car in your driveway or the vacuum in your closet, the way things look and work is the result of a careful design process. Taking a look inside that process, like with this wireless phone charger concept, is fascinating and can yield really valuable design insights.

We’ve featured lots of [Eric Strebel]’s work before, mainly for the great fabrication tips and tricks he offers, like how to get a fine painted finish or the many uses of Bondo. But this time around, he walks us through a condensed version of his design process for a wireless phone charger and stand. His client had specific requirements, like being able to have the phone held up in landscape or portrait mode, so he started with pen and paper and sketched some ideas. A swiveling cylinder seemed to fit the bill, and after a quick mockup in PVC pipe, he started work on a full-size prototype in urethane foam. There are some great fabrication tips in the video below, mainly centered on dealing with not owning a lathe.

The thing for us with all of [Eric]’s videos, but especially this one, is seeing the design process laid out, from beginning to (almost) the end. He sure makes industrial design look like a cool gig, one that would appeal to the Jacks- and Jills-of-all-trades who hang out around here.

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