Casting and Machining step pulleys
HTML-код
- Опубликовано: 10 авг 2021
- I desperately needed to rebuild the countershaft on my Index 40H milling machine. It turned into an adventure in sand casting and turning v-belt step pulleys.
The specifications for v-belt pulleys I used are here: www.masterdrives.com/engineer...
If you like what I'm doing here and find some value in it, consider supporting my work on Patreon: / jeremymakesthings
I promise I'll still mostly make stuff out of rusty junk and not just buy shiny things with your money. - Хобби
I love what you’re doing. Making most of your own parts and learning from your mistakes. That’s how we get better. I was a machinist in the auto industry for 33 yrs and learned every day.
Just wanna say I really respect the work you do. Thanks for making these videos. I learn more from you than I do from most professional machinists with a $300k shop. You make it all happen with machines like mine.
You’re like all the rest of us, worrying about what it takes to be a machinist, then you figure out the true definition and realize you’ve been one for 20 years. You didn’t have all the fancy tools, but you got the job done!
So glad I found this channel! I have old (1930s) and fairly worn lathe that I have been restoring and improving. I rapidly discovered that restoring a lathe without a second working lathe is not easy!
These videos are so calming. Please don't stop. I need this.
Props to YT algorithm for serving up one of your videos. I am enjoying your work quite thoroughly
Nice work Jeremy. I like the simplified casting setup. Something I could get into! Chirpy is a wizard at all that stuff. Cheers, Craig
"Whip it good...whip it real good!" LOL I got that reference...I'm getting old!
Keep up the good work
I really enjoyed your video. You did an excellent job of casting and machining the pulleys. I did the same pulley casting back in the 1970's when I was trying to build a vertical head for a junk horizontal mill. The pulleys have still not been used and the old mill wound up in the scrapyard.
That sounds way happier . From casting to milling . Great stuff
Fail early. Fail often. Never quit. Great channel.
Good to know about the moisture in the sand! Keeping the old equipment running is totally worth it!!
Sweet.
I have to make a five sheave step pulley for an old drill press.
Your video gave me confidence
Excellent job, when you cast a part and machine it, that's what it's all about, great video, keep'um coming.
I have been watching your videos for a while and you always have a close shot of the part you are working on. Each time you are on the I notice little clues and always think, that's a Wells Index Model 40.
First time I have gotten confirmation.
I have a Wells Index Model 55. I completely rebuilt mine.
From casting to a great useable product, how can you not like that... I have plans to do the same type castings and machining for different uses. Thumbs Up!
Yep, I'm into romanticising old iron. But just like your machines, they're well worn. Casting and turning your own pulleys is a great skill-set - thanks for walking us through the steps! (Love that old Index Mill)
Don’t get me wrong, I really like the machine, it’s a great size for a garage shop. I’ll eventually get it working the way it should.
Don’t get me wrong, I really like the machine, it’s a great size for a garage shop. I’ll eventually get it working the way it should.
It looks and sounds good at top speed, so I think you can count that as a total success. I'd never thought of open casting for this type of shape.
Brought back a memory of my first casting that I made. It was an open one also for a wheel. It did the same Jiffy Pop thing too.
Good job. Very practical skills you are building on there. Keep up the fine work.
Excellent job man, I've been messing around with some casting myself it's alot of trial and error on my part, but alot of fun at the same time, great video, keep'um coming..
Great video. Thanks for taking the time to share.
Really like your projects. Your logan lathe caught my attention. I have a long bed 200 and I added a gearbox from a 820. Also have a 9 inch model 400. Keep up the good work.
Excellent job
When faced with machining parts that overhang the vise I like to pack up a toolmakers vise mounted vertically . Once tightened the toolmakers vise is also clamped to the table constraining the part both vertically and horizontally.
I did watch this a while back, but since then I have started Lost Foam casting, saves making moulds that you will never use again, it has been some trial and error for me, but I have got some good results. 👍
Awesome build there...love the casting stuff. Still haven't gotten around to casting...yet..lol
As for the signing off, that's kinda how I do... "till next time"
Great job and well presented ...
Excellent video! Some learning points, but you learned some new techniques, job done and life of the mill is extended, so I’d say that’s a success.
Nicely done.
Interesting, I like the open casting you did, perhaps not as precise as other methods as you said but it worked. The way it turned is probably the alloy you ended up with, Things like engine parts and wheel hubs tend to be far better for casting but do you really want the spiral razors of death when you turn it....great to see and inspired me to make the ones I need for a belt grinder
Thanks for sharing.
Nice work; thanks for sharing.
Thank you!
A good lesson in hard turning and hard machining... I don't want to do it if I can avoid it. Love it!!! I apply that to just about every job
8)
Pretty awesome feeling though spinning it up at high speed and it sounding so smooth. Very nicely done.
To sign off how about "Thanks for watching, hope you liked/enjoyed the video. Don't forget to subscribe and hit/smash the bell for notification of new videos, Bye for now."
You look just like a guy I use to work with down south keep up the great content I too love to use old Iron
Kelley fleet services.
I feel your pain on the old lathe front. I have a post-war Clausing that doesn't have that many hours on it but is still fairly fiddly.
I cut a CV shaft from a Hummer on mine and was able to push through it at .030, albeit pretty slowly, using HSS.
That was excellent, but I have two problems
1. I'm jealous, as I have better machine tools in my hobby shop, but I am too lazy to do work as nice as yours
2. I'm spending tool much time binge watching your videos in my real job and not getting any work done
Thank you
Maybe I can act as inspiration to help with the first, but that may require you to keep doing the second.
Your old American iron, looks very much like mine. I also have a Logan, a 820 with a quick change gear box. A Wells Index 40H, with a Browne and Sharp #9 taper in the spindle. I have just hit the subscription button. Would be nice to see more mill repair/upgrade videos. Keep up the good work.
I have intentions of some day doing a full rebuild on the mill, but that’s a ways off. The mill and the lathe are such nice small but “real” machine tools for a home shop.
@@JeremyMakesThings I agree completely. I tore my mill down and cleaned it and painted it. Did not restore.
Your whip it good comment got me 😅
Definitely you had lots of dampness in that mold and you can see the gasses coming out of it as you poured.
Bentonite will work better @ about 10% to sand. The local ready mix concrete company sells it pretty cheap, no shipping cost that way. Even better is to make a batch of K-bond sand if you want much nicer finish on the cast surfaces sometime. Simple to make, instructions are on line. Casting is fun. There is a lot more to it when you get going. Check videos by Olfoundryman. Controlling the hydrogen bubbles isn't easy but the fewer the better as they cause brittleness.
"Controlling the hydrogen bubbles isn't easy "
The backyard foundrymen I have seen in Pakistan and India leave the dross on top while pouring and simply hold it back, I'm guessing it does inhibit gassing somehow, but since these guys also use molasses as binder for their sand, anything goes but it seems to work well enough for them.
Try pre-heating the mold with a propane torch, it'll help dry it out and you won't get the steam bubbles.
looking into greensand ive found oil to be a part of a lot of various recipes.
also have you looked into sprue molding instead of puddle?
whip it, whip it good!
Your having fun! Have you looked at Olfoundry man's channel? A pro! Cheers, Matthew
nitrogen pellets mixed in the molten aluminum will get rid of the porosity and pockets... you will need a steel 'swizzle stick' to mix the pellets into the al.
"I suddenly have the urge to whip it good." lol
Well, a problem did come along, so it was inevitable.
@@JeremyMakesThings But in the end, you managed to shape it up and get it straight.
Would you mind sharing your casting equipment. Your crucible is huge, what are you heating that with?
What a great video have You here. Many lessons in one.
The second (or more) time You cast the aluminum, what You did different from first failed cast...?
Thanks A LOT.
I had way too much moisture in sand on the first one, so I dried out the sand a lot. I still don’t the right amount figured out exactly, but it was good enough
@@JeremyMakesThings Is any kind of sand, I have one used to make concret, fine grain, it will works?
Pretty I any sand will work, finner is better, it’s worth running it through a sieve in case there are some stray course pieces. You’ll need to mix in some ground up bentonite clay (kitty litter). There seems to be a good bit of debate on what the best ratio is, so you’ll have to experiment with that.
@@davideliasfloresescalante8840 The ideal sand is crushed and not beach sand. The sharper corners on crushed allow steam to escape easier. Adding some small holes with a piece of straight wire will also help venting (for two part mold.) The ideal moisture content is just enough to make a "solid" piece when squeezed in your hand. Look up K-bond sand on the net. It works nicer.
Torch the cast before you pour the molten aluminium? This was you can get rid of most of the moisture close to the cast
It's been about 42 years since I did any casting so I'm less 100% sure about it, but I was under the impression that molding sand was made with something like boiled linseed oil and not water.... but I could be VERY wrong about that.
On your index mill that collet chuck you have in the spindle what’s it called amd where could I locate some collets for it I’ve got a index 645 with the b&s #9 taper only tooling I have for it is the same little collet chuck that takes small bird egg sized collets
They’re called “double taper” or “universal” collets. They come in a few different sizes, mine are “z” size (1.5” long, 1.16 diameter). The best price I found on them (about $32 each) was from: www.gpcollets.com/products-collets/universal-collets/
@@JeremyMakesThings sounds like we got the same ones thank you for the info and excellent channel content
Any chance your willing to share how many hours it took to do this total repair? I ask because it would have taken me several months. Fabulous results again proving anything is possible if you have the patience and yearning to learn 👍😎👍
I honestly don’t remember. It was maybe a two weeks of mostly working evenings?
hi im thinking of doing some casting did you add anything for de gassing?thx from the UK
I did some salt in the second one, and it definitely came out better.
@@JeremyMakesThings thx ill give that ago
I'm quite surprised your open casting technique worked so well, congrats. I used to pour aluminum bar stock in steel pipes that I ground the inside seam out of with good results. I found, though, the top inch or two needed to be discarded as it was very porous. As I, like you, use a lot of scrap (especially cast iron) for projects, I recently bought an inexpensive portable band saw and it's made a world of difference over angle grinding. Have you considered using one?
I actually just got one (kind of a funny story for another video), and OH MY GOD WHERE HAS THIS THI MG BEEN ALL MY LIFE????
@@JeremyMakesThings I can't wait to see the videos of how you use it. Near the top of my project list is making a table and mount so I can use it as a stationary saw.
"Whip it good." Ok mister Byrne.
👍👍👌👌
Do you make any effort to reclaim the aluminum swarf?
I tried it once, but with so much surface area, there’s too much oxide and too much contamination to make it worth trying to recover again.
Can you tell me the HP and weight of the motor on your 40H? I’m trying to finalize my 40H build. Thanks.
It’s a 1/2hp, and it really damn heavy, I’d guess 80lbs?
The pulleys are made if Zamak. Think Atlas lathes. Your choice of 6061 is far and away much better, but hey, aluminum cost almost as much as gold in 1947.
You are very skilled. You should try making a canoe.
🤔
Was the cat litter you used, new or recycled?
You can get it cheaper used, but I went for fresh.
you just dig out the turds, the piss bricks and bury your hands in there to check if there are any remaining, after that, you make yourself a sammich and some tea, mix the sand with litter and much on your stuff while in the process... the best way of doing it i have come across...
How did you heat the aluminum. I have a source for much of it free but the methods of melting on RUclips are too small scale and complicated.
I made a makeshift foundry out of a pile of bricks and a propane brush burner.
Oh, no, what are you doing step-pulley?
Heh heh. Crack that whip.
arent all bearings Metric? LOL
why mess with aluminum parts? What do you gain by casting aluminum over just buying a piece of ductile iron and machining them? Definitely not time.
I’ve done a few pulleys like this now, each from castings. It might not be faster overall, but it does save a lot of actual machining time at the lathe, since you’re not hogging a 7” diameter piece of stock down to 3 or 4” for the smallest sheave. The big thing it saves though is money. If I bought 6061 round stock for these, it would have been $50+ for each one. Ductile iron would have been substantially more. The scrap aluminum I used was free, I only paid for the cost of the propane ($10 maybe?). Also, unlike the one I made from 6061, the cast aluminum chips break really easily, so it’s easier to machine. And each time I cast one, I get better at casting, so I feel more comfortable casting other parts.
@@JeremyMakesThings Good point! if you're learning how to do something like casting then you are gaining a lot more then just a part. Well Done