I was given a Metal Lathe., Help me choose projects. Options

[Series9]

So, I was given a lathe that had electrical problems.

I sorted those problems, and I am now looking for some simple projects so I can learn the machine.

My first thought is to turn some clutch pulleys out of brass. Do you have other suggestions?

[veekry9]

The horror technique was used on us in our teen years and effectively shocked us into a safety mode around machine tools.
The instructor was a WW2 vet of military discipline,the values imparted by strict rules of operation.
It is true some people have no business messing with them,at all.Case in point,a new guy tried to off himself twice in a few days.
Untrained,unwary and ignorant of the first premises of self preservation,he was dismissed with a recommendation to a trade school.
A shop coat caught in the lead screw of the lathe,panicked,screamed and was saved by me when I shut the spindle off.
Next day,'forgot'to clamp the barfeeder and had the turret lathe hopping off the floor,he froze. (IMG:style_emoticons/default/blink.gif)
Herbert No9,made in England,30-60's.https://en.wikipedia.org/wiki/Alfred_Herbert_(company)

/

[Mueller]

The horror technique was used on us in our teen years and effectively shocked us into a safety mode around machine tools.
It is true some people have no business messing with them at all.Case in point,a new guy tried to off himself twice in a few days.
Untrained,unwary and ignorant of the first premises of self preservation,he was dismissed with a recommendation to a trade school.
A shop coat caught in the lead screw of the lathe,panicked,screamed and was saved by me when I shut the spindle off.
Next day,'forgot'to clamp the barfeeder and had the turret lathe hopping off the floor,he froze. (IMG:style_emoticons/default/blink.gif)
Herbert No9,made in England,50-60's.https://en.wikipedia.org/wiki/Alfred_Herbert_(company)

We had a cast lathe chuck failure on a machine a little bit bigger than that one a few years ago, the part weighed a few hundred pounds which wasn't the problem , it was too high of an RPM for a cast chuck! Luckily no injuries. The forged steel replacement chuck cost over $15,000.

Joe,

Hurry up and make some chips, show off your work!

[76-914]

So, I was given a lathe that had electrical problems.

I sorted those problems, and I am now looking for some simple projects so I can learn the machine.

My first thought is to turn some clutch pulleys out of brass. Do you have other suggestions?

Arrgh. I hate you. But, as with most gifts, you probably earned it so enjoy. I'm just envious as shit. Did that little red Kennedy KK19 hip box come with it? It's about the same age. Have fun with it, Joe. (IMG:style_emoticons/default/beerchug.gif)

[mbseto]

Machine shop guys always have impressive stories. And there's 101 ways to get zinged. Was in a shop with an impressively large shaper, bed over 30ft. long. Me and a new guy were watching that head slide towards us, curling off .1 thk steel corkscrew. It hit the ground right at our feet and sounded as big as a garage door spring. He bent down to pick it up and I hip-checked him. He was affronted for a moment, but then we watched it slowly turn that same blue as a motorcycle exhaust pipe.

[Series9]

So, I had to replace the front wheel bearings on the right side of my Vanagon today.

The rotor looked pretty crappy, so I took the opportunity to put it in the lathe.

Success! It was the first time I used the power feed and it came out pretty well.

I'm going to want a nicer finish in the future, but definitely good enough for a brake rotor.


My oldest boy (14) seemed unimpressed as I was smiling with the lathe running. I told him he didn't understand the significance of what he was seeing.

(IMG:style_emoticons/default/shades.gif)

[Mueller]

So, I had to replace the front wheel bearings on the right side of my Vanagon today.

The rotor looked pretty crappy, so I took the opportunity to put it in the lathe.

Success! It was the first time I used the power feed and it came out pretty well.

I'm going to want a nicer finish in the future, but definitely good enough for a brake rotor.


My oldest boy (14) seemed unimpressed as I was smiling with the lathe running. I told him he didn't understand the significance of what he was seeing.

(IMG:style_emoticons/default/shades.gif)

There is something therapeutic when turning the handles on a manual lathe or mill when making chips, I don't get the same satisfaction when running the CNC...


Don't laugh.....I might have some VCR tapes of Rudy Kouhoupt that cover lathe operation and tool grinding...if you still have a player and I can find them you can have them for the cost of shipping.

http://bay-com.com/Rudy_Kouhoupt.php
http://bay-com.com/cid/1-1/Machining_lathe...machinists.html

Instructional DVDs to rent:

https://smartflix.com/store/author/23/Rudy-Kouhoupt

[r_towle]

Btw,
I was joking about making something square.

Love this place.

[veekry9]

Now you too can make your own stroker crankshaft!
(IMG:style_emoticons/default/happy11.gif)
Go ahead,make your hay. (IMG:style_emoticons/default/smile.gif)
Note how spic n span his shop is.
A cap for the lathe top should have railings,to keep tee wrenches there.
Long stringy chips are bad,dangerous,and a sign of wrong.
Never mess with those chips while rotating!
Never. (IMG:style_emoticons/default/shades.gif)

[Series9]

I'll be turning that rotor again...... (IMG:style_emoticons/default/laugh.gif)

[MoveQik]

My first thought is to turn some clutch pulleys out of brass. Do you have other suggestions?

Totally lame idea. It'll never work. (IMG:style_emoticons/default/shades.gif)

[MoveQik]

My first thought is to turn some clutch pulleys out of brass.

Like this. (IMG:style_emoticons/default/cool.gif)

I'm sort of a pulley snob. (IMG:style_emoticons/default/biggrin.gif)

[914Bryan]

Lighten a flywheel

[Series9]

Lighten a flywheel

Okay, soon.

Right now I'm thinking, if I lighten a flywheel like I "lightened" that brake rotor, I might damage an engine....

(IMG:style_emoticons/default/first.gif)

[r_towle]

Lol, bet it was fun though.

[toolguy]

Turning a brake rotor on an engine lathe is difficult at best in keeping both sides parallel. The problem is rotors are too damn big to get your cutter to both sides without unmounting the rotor and reversing it. Holding it on a regular chuck for both sides hasn't worked for me without a lot of set-up time with a dial indicator.

Best way is to use a 'faceplate', not a chuck to start.
Bolt the rotor to the faceplate using the flat surface where the car rim mounts. that way you are turning the back of the rotor parallel to the axis the rim spins on. .
Then reverse the rotor, mount the rotor surface you just cut to the faceplate. now turn the opposite side of the rotor. .
Theoretically both sides will be parallel and consistent with the axis of the wheel.

[Buckeye914]

I kinda just skimmed through this post but with that said, I would also suggest investing in quality measurement tools. 1" micrometers and nice 6" calipers from mitituyo or starret can be had for reasonable prices. and like others have said checking the runout of the spindle and chuck assembly is important if you plan on your parts being true. A dial indicator with a magnetic mount should get you running true in no time. And as many others have said safety is most important.

[veekry9]

Several factors in the machining of shafts.
1)The spindle rotates about it's center within 0.00005"/0.00008",under load.(the bearings are good)
2)The spindle is parallel to the bed in both axis.
3)The carriage moves true to the bed.
4)The cross feed saddle is square to the spindle.
5)The clearance gibs are adjusted to minimums.

A tuned instrument is needed to make a correct shaft,adjust the machine to do so.
Speeds and feeds for horsepower are the required knowledge.
Keep a table poster above the lathe for reference,noting the cutting(sfm) (Surface Feet per Minute)speeds.
A turned part in hardened metal can be finished to fine tolerances with these versatile attachments.
http://www.micro-machine-shop.com/tool_post_grinder.htm
http://www.cnccookbook.com/CCLatheTPGrinder.htm
https://www.google.ca/#q=porsche+904+main+shaft
https://www.google.ca/search?q=spherical+tu...RFdCJEQ_AUIBigB
Learn something new every day,continuous learning.
Turning costs money,never turn for free.
(IMG:style_emoticons/default/smile.gif)

(edit:01/14/16)
Quote:post#9
toolguy
....If not set up properly, no matter what you do, your finished project will have taper and be out of square and off center.

Correctomundo.
Pretty basic geometry,the setting up and fettling of the machinetool defines the results possible.
Direct measurement and trial cuts are required,then your efforts will satisfy you and 'customers'.
Nowadays,the price of indexable carbide tooling makes their use standard,tungsten and cobalt hss is perfect for delrin and bronze.
The manual and drawings that came with the machine makes the repair and maintenance of it painless.
The design of the headstock bearing may allow refurbishment,grinding a tighter clearance on a spacer ring.
Make,year,model,ser# and the fx# of the manufacturer is handy.
Never do repair work on the machine while under power,lockout rules apply.
/

[Series9]

Turning a brake rotor on an engine lathe is difficult at best in keeping both sides parallel. The problem is rotors are too damn big to get your cutter to both sides without unmounting the rotor and reversing it. Holding it on a regular chuck for both sides hasn't worked for me without a lot of set-up time with a dial indicator.

Best way is to use a 'faceplate', not a chuck to start.
Bolt the rotor to the faceplate using the flat surface where the car rim mounts. that way you are turning the back of the rotor parallel to the axis the rim spins on. .
Then reverse the rotor, mount the rotor surface you just cut to the faceplate. now turn the opposite side of the rotor. .
Theoretically both sides will be parallel and consistent with the axis of the wheel.

Excellent! These are points I had already decided would be necessary to perform this operation correctly next time.

I ordered another rotor, but I intend to "fix" this one until the three faces are parallel.

I have instruments and holders on order. First, I'm going to make sure the face of the chuck turns true and then proceed from there. I had planned to take the jaws out of the chuck and hold the wheel-face of the rotor against the chuck with the tail stock and a live center.

When I get the instruments, I'll measure the magnitude of my errors and report them for your entertainment. I can tell you the Vanagon is "interesting" to drive right now. (IMG:style_emoticons/default/laugh.gif)

[r_towle]

You might want to consider building a jig or faceplate that has lots of threaded holes in it to accomidate all the cars you work on, then you can reuse the jig for a few years

[worn]

I wouldn't worry too much - the projects have a way of finding you. One of the most useful tools in the shop. For example, I used mine to copy some of your ideas.

I have a few Popular Mechanics year book of projects dated from around 1940. I found them when my Dad passed away last year. They kind of just assume that any guy is gonna have a metal lathe. One article is how to build a complete gasoline engine from scratch - a small motor for a model something.

They also assume that you have a plentiful supply of Model Ts, from which they make an astonishing number of things.

My Dad saved his allowance and bought a Craftsman wood lathe in the 1930s. It is a good as the day it was bought. Plan on a lot of projects (IMG:style_emoticons/default/biggrin.gif)