+Wood-N-Metal Workshop ` I knew a job would come up and we could use them. I'm sure more will come up in the future too. Maybe one day we can mount them on the K&T for a job. Thanks again Kent!!
+Abom79 I know that its as cheap as my rc planes an boats an cars came in cheap. I just want some reliable vernier calliper digital cause my days of welding has scratched and shot metal into my eyes so I where glasses ontop I run safty glasses, I was asked to talk at an student corse and show them why safety glasses are a must. But i need digital but its expensive.
Adam, I'd rather watch re-runs of you than Netflix. I know nothing about machining except from you, but it's hypnotic watching hands on talent. Thanks for the quality vids.
Adam, you let us see the cutter 'walking' over the face! That's what I like, honest machining, no excuses like 'Big bad boys did it and ran away' . Thanks for sharing big chap. Joe
Man Adam, you are the king of the big boy machining on YT! Thats the biggest broach plug I've ever seen! It must of made you jump when that roughing mill kicked the plug. Thanks for sharing
I really enjoy your videos, machine work in this country is becoming more and more rare. I noticed you were using coolant on cast iron. I've worked for the company that puts the Cincinnati logo on several different types of machinery for 46 years and coolant on cast iron was always a big no no because it can not only soften the metal but it saturates into the pores which causes difficulties with heat treat. We always had to use air blowing as close to the cutter as possible. It did make for a dirty plant and nose but worked perfectly.
Truly amazing work thanks for posting it! Years ago I used to test hydraulic presses. It made me very happy to see the size of your push-out punch grow with the pressure exerted. The first piece of rod looked a little thin.
My Dad used to term them 'Apprentice marks' ;) Great job all the same. Nice to see those clamps and how you would use them. I was a bit baffled at first.
Adam, Dumont broaches are not cheap! For the price of those 2 broaches, you could have probably bought a house! Great work as always. Thanks for sharing. Dave
We had a nodding donkey,(vertical shaper) which we used for big keyways. It also had rotary table which we used shape big radius on bearing housings. Some money in time and materials to broach those keyways nice if you can recover costs, on small quantity.
Hey Adam , man those are big broaches! I was surprised you are broaching them, at the mill I worked in, the machinist had a couple of keyway cutters for stuff that size. I wanted to see what you were doing, because the keyseat machine wasn't their favourite operation. Enjoyable series this was! Thanks, H
Definitely big boy broaches! I wonder if using 3/4 hold down hardware on those Carver clamps would pull them tight enough to the mill table that they wouldn't push off from each other. They definitely have a pretty aggressive jaw face to them so they should get a bite.
+bcbloc02 I am thinking the 3/4" is what they need for sure. I just couldnt get enough torque on the 1/2" studs. A more low profile workpiece would be a little easier to handle too though. On there demo video they show guys milling plate steel.
I thought those "pecker tracks" looked like some tricked out oil grooves or dimples, so I wouldn't have known what they were unless you called it out, LOL! Glad it was minor and "no harm, no foul", very nice looking broach plugs and I can't wait to see how those shims work out, Whoo-wee!
All-16ths never heard that one before... otoh we have an import Crescent clone at the shop with metric marks on the jaw way.. so its a metric Crescent wrench.. always good for a laugh :)
Hey Adam. Great Vid. Got to get myself a set of those clamps, they're available in Australia from Dawn Tools. Doing the same job at the moment but on a much smaller scale for a motor shaft on my Huron Mill. Take care dude.
Hey Adam, it's another good job. Wonder what feed you used for that roughing-end-mill? I also have a pair of clamps, similar but much smaller, did not use them yet, if/when I ever use it I will add lateral blocking too, not trusting my small-one-bolt unit. Does yours have a downwards force at tightening?
Had to laugh. I am about to buy a Broach for two cutter heads I made for my wood machine. That broach is bigger than the shaft I am working on. :-) I am also building a press so I can push the broach through. Only 20 ton jack am sure the press you use will be slightly bigger. !
+metalhead2508 I understand what you are saying. I think one could consider the cost of the broaches vs time on the shaper. I don't want a argument, just food for thought.
+Jerry Halcomb It's another way to get the job done for sure, but Not on my little shaper. I do wish we had a big massive 36" plus Cincy sitting in the corner for those odd jobs.
Did you finish off sides with HSS end mill? And don't understand how those cap head bolts don't interfere with brooch? Love the part about you showing the pecker tracks! I keep my mistakes in plain sight, just to remind myself of what a boozo I am sometimes!
+Fred Newman The shims were drilled on both ends and we could flip them around and stack them all together evenly, and only have the outer most shim being held in place with the cap head bolts.
Very Abom sized broach plugs. With all that work and time, required to make everything for broaching, I gotta wonder if it would have just been easier/faster forgo broaching, and just cut the coupler keyways in the shaper?
Hello Adam, Does your machine shop ever do or get an analyses of how long the cutting bits and tooling lasts? In inches cut or hours or however they calibrate it? It would seem essential to keep the overhead down and very interesting for those of us buying out of 'thin' pockets. Maybe that info is available? A comparison of quality of cut versus useful life of the tool would be valuable. Those are some huge broach plugs and broaches! If you speed up the hydraulic pump beyond that slow one you were talking about wouldn't heat become a factor at some point? Say if you had a 100 ton hydraulic ram and pump and shot it through in 10 or 15 seconds--what would the downside of that be? I would think you want to protect such an expensive tool in lieu of speed? I am assuming those broaches are of a very hard steel and brittle? Or is just the cutting edge carbide with the body flexible (to the tiniest degree) tool steel? Thanks again for a great channel. PS: How about another challenge where you and Tom true up square blocks in the four jaw at the upcoming Summer Bash? I was watching your 2014 video of doing that thread clamp block for the hydraulic ram end pintle and the thought occurred to me. I hadn't even seen that done centering a square block with a dial indicator. Doug
Nice watching you work. I'm trying to learn this as a hobby. Are there good reference tables for rpm and travel speed for different kinds of material ie mild vs cast iron vs Chromoly?
Any particular reason to use cast iron for those broach plugs, rather than steel? I suppose iron might be a bit easier to machine. I'll also have to remember All/16 wrench.
+Abom79 Oh duh, that's easy enough. Do you need an extra long edge finder or is it not necessary to reach the tangent edge if the piece is level? I absolutely love your channel! The video quality, angles, lighting, audio, etc. are perfect. A viewer couldn't ask for more.
Considering those broaches probably cost a pretty penny and it looks like they were bought specifically for this job is there not a cheaper way to achieve the same end result?
Just curious as to who pays for the extra work and materials to make the broach plugs and the broaches themselves? Does your company keep all the special parts that was made?
Hey Adam, when you were milling the cast iron with the roughing end-mill it looked like it was cutting very easily. Does cast iron machine easier than steel?
Adam: if for some reason the broaches weren't available, is that something you could have done on your shaper? Or if the customer say had more time than money would it have been more economical to do on your shaper, If it's possible?
Abom79 so a layman's question? If you had gone the shaper route you, or I should say your customer wouldn't have had to expend the time and materials on the plug, and the broach, which had to be a fairly expensive item given its uniqueness? Is it because your employer doesn't own a shaper and they didn't want to be dependent upon yours, plus in the future if you've left they have the tooling for someone else to do it with the same accuracy? Usually there's a rationale reason behind decisions. Oh and don't mean to irritate you. Scott
Geez those are massive broaches for cutting the ways for some equally massive keys! Heh heh, if Union Pacific needs any machining help on freshening up the running gear for the Big Boy 4014 steam locomotive (will be the largest operating steam loco in existence when its fully restored), they could see about giving your employer a call! XDD A lot of these parts you work on are as big, if not bigger, than the side and main rods and pistons of the Big Boy! BTW, a Union Pacific 4-8-8-4 Big Boy locomotive's four main pistons are 23.75" and the stroke length they move back in forth in their cylinders are 32". How does making possibly four 23.75" pistons grab you? Don't know the sizes of the piston rods those pistons go on though, since that's info that's not easily found.
When you got to get a job done don't always have time to find a machine, buy it, ship it in, wire it up, clean it and fix any problems. Yes if love to have a big boy shaper, but we don't even have a spot for it. Shop is out of real estate.
Yeah, I know. It's not realistic to get one, but if most machine shops kept the old tools, some jobs are actually quicker. On the real estate, I completely understand that.
Hey Adam glad that you found a use for the clamps, it was very cool to see them in use.
+Wood-N-Metal Workshop ` I knew a job would come up and we could use them. I'm sure more will come up in the future too. Maybe one day we can mount them on the K&T for a job. Thanks again Kent!!
+Abom79 You are very welcome. I would love to see them on the K&T while you make some big passes.
+Abom79 I know that its as cheap as my rc planes an boats an cars came in cheap. I just want some reliable vernier calliper digital cause my days of welding has scratched and shot metal into my eyes so I where glasses ontop I run safty glasses, I was asked to talk at an student corse and show them why safety glasses are a must. But i need digital but its expensive.
Adam, I'd rather watch re-runs of you than Netflix. I know nothing about machining except from you, but it's hypnotic watching hands on talent. Thanks for the quality vids.
Adam, you let us see the cutter 'walking' over the face! That's what I like, honest machining, no excuses like 'Big bad boys did it and ran away' . Thanks for sharing big chap. Joe
Wow those clamps looks awesome. I could really use a couple sets of those. That's a very generous gift from your viewer.
That's the biggest broach I,ve ever seen . Really cool , good job Adam . Thanks again for all the interesting video,s
Man Adam, you are the king of the big boy machining on YT! Thats the biggest broach plug I've ever seen! It must of made you jump when that roughing mill kicked the plug. Thanks for sharing
I have to say those are some snappy looking clamps. Got to find a couple of those bad boys, Great video Adam stay healthy.
"All-Sixteenths" - I love it.
Love your videos, I should remember to like them some more!!
This is my work shop time, I enjoy watching!
I really enjoy your videos, machine work in this country is becoming more and more rare. I noticed you were using coolant on cast iron. I've worked for the company that puts the Cincinnati logo on several different types of machinery for 46 years and coolant on cast iron was always a big no no because it can not only soften the metal but it saturates into the pores which causes difficulties with heat treat. We always had to use air blowing as close to the cutter as possible. It did make for a dirty plant and nose but worked perfectly.
Good lord. All the stuff you do is seriously jumbo size. I love it!
I'm doing an engineering degree at uni and it's so interesting to see practical side of engineering
Truly amazing work thanks for posting it! Years ago I used to test hydraulic presses. It made me very happy to see the size of your push-out punch grow with the pressure exerted. The first piece of rod looked a little thin.
+Mike De La Mater I always use the biggest one I can fit. I made two new ones just for this job, and always face them in the lathe.
What a great video. Everything about it. Plus I have been needing to see broaching. Thanks
My Dad used to term them 'Apprentice marks' ;)
Great job all the same. Nice to see those clamps and how you would use them. I was a bit baffled at first.
Adam, large machining! Excellent video. We hope for your work broaching!!!
Greetings and success!
I like those Carver clamps. I'm going to point those out o my supervisor. They would come in handy at work
Forty five years in shop never seen those clamps before , nice !
wow never seen broaches that big before! good video m8.
Super awesome share Adam , Never seen anything like that before . So huge !! Love it ..
Wow... those clamps are something else. Great vids BTW.
Im always thoroughly impressed by the work that you do. Id hope to do as well as you in the future
Adam,
Dumont broaches are not cheap! For the price of those 2 broaches, you could have probably bought a house! Great work as always. Thanks for sharing.
Dave
+Swarf Rat I was wondering what those things cost?
Some jobs are not totally complete without a few "pecker" tracks! lmao
Love that photo of you and the "Abom" size broaches. Cheers.
We had a nodding donkey,(vertical shaper) which we used for big keyways. It also had rotary table which we used shape big radius on bearing housings. Some money in time and materials to broach those keyways nice if you can recover costs, on small quantity.
+ANDREW MICAS I wish I had one of those big ole slotters.
Ridiculous broaches! Going straight to part 3 now!
Haha..."all 16ths" wrench 🤣
Definitely Abom broaches.
Thanks,
John
greetings adam, thanks for the amazing vids. i really enjoy them.
Hey Adam , man those are big broaches! I was surprised you are broaching them, at the mill I worked in, the machinist had a couple of keyway cutters for stuff that size. I wanted to see what you were doing, because the keyseat machine wasn't their favourite operation. Enjoyable series this was! Thanks, H
That is cool set of clamps
that is for sure an abom job great work. bob
good video Adam!!!
Definitely big boy broaches! I wonder if using 3/4 hold down hardware on those Carver clamps would pull them tight enough to the mill table that they wouldn't push off from each other. They definitely have a pretty aggressive jaw face to them so they should get a bite.
+bcbloc02 I've also wondered if it were conceivable that those clamps could introduce slight flex into the table surface.
+bcbloc02 I am thinking the 3/4" is what they need for sure. I just couldnt get enough torque on the 1/2" studs. A more low profile workpiece would be a little easier to handle too though. On there demo video they show guys milling plate steel.
Love ur videos , that’s a big key way
Hey Adam,Good work
I thought those "pecker tracks" looked like some tricked out oil grooves or dimples, so I wouldn't have known what they were unless you called it out, LOL! Glad it was minor and "no harm, no foul", very nice looking broach plugs and I can't wait to see how those shims work out, Whoo-wee!
Hard to believe a part would come loose after being ABOM tight. It made some pretty markings though.
Hi Adam, The All /16 wrench, That's a good oneI'll have to remember that one >Joe
Adam's also called them nut lathes. I like that one, too.
+Joe Morris It's what I always call them, don't even remember where I got it from.
+Abom79 When I was visiting a friend in London, Ontario, Canada they called them "all size".
Joe Morris, yeah the all 1/16 nukkle busta
nah nah nah, that's what you call a Saskatchewan socket set ! (although I prefer the "thumb dial nut f***er")
Hey Adam,
What did those broaches cost? Man those are big ones.
Talk to you soon,
Tom
+oxtoolco They were giving them away last week. You did't get the flyer? Man, you missed out big time.
+David Kirtley Harbor Freight, right? ;-)
+Keith Ward You saw it too! They were right next to the free digital calipers and flashlights!
All-16ths never heard that one before... otoh we have an import Crescent clone at the shop with metric marks on the jaw way.. so its a metric Crescent wrench.. always good for a laugh :)
+Greg M (pounce) Always love the Metric adjustable wrench jokes
Nice big stuf!
Awesome Possum!
You are human after all!
Every now and again, you fook up... every now and again, I don't :)
Hey Adam. Great Vid. Got to get myself a set of those clamps, they're available in Australia from Dawn Tools. Doing the same job at the moment but on a much smaller scale for a motor shaft on my Huron Mill. Take care dude.
I NEED THIS CLAMPS. So so so so so much.
nice work man
Great video!
Adam Those are some large broaches . Just need some large keys .
GREAT VIDEO !!
Hey Adam, it's another good job. Wonder what feed you used for that roughing-end-mill?
I also have a pair of clamps, similar but much smaller, did not use them yet, if/when I ever use it I will add lateral blocking too, not trusting my small-one-bolt unit. Does yours have a downwards force at tightening?
1:50
Why is it bad to use an adjustable wrench?
Will it slightly round over the corners? Or what?
In dads shop your "all 16ths" was known as a "Metric Fitsall".
COOL ! It is awesome !
Had to laugh. I am about to buy a Broach for two cutter heads I made for my wood machine. That broach is bigger than the shaft I am working on. :-) I am also building a press so I can push the broach through. Only 20 ton jack am sure the press you use will be slightly bigger. !
Hi Adam, why are you not doing this on your Horizontal Mill in your shop? Seems like the right machine for this job.
+mkeyser I'd like to in the future use the horizontal.
would a piece of paper under the clamps have stopped them from sliding?
Adam, did you happen to think of using your shaper to cut the key Ways?
Jerry
+metalhead2508
I understand what you are saying. I think one could consider the cost of the broaches vs time on the shaper. I don't want a argument, just food for thought.
+Jerry Halcomb It's another way to get the job done for sure, but Not on my little shaper. I do wish we had a big massive 36" plus Cincy sitting in the corner for those odd jobs.
+Abom79
Thanks for your answer.
Did you finish off sides with HSS end mill? And don't understand how those cap head bolts don't interfere with brooch? Love the part about you showing the pecker tracks! I keep my mistakes in plain sight, just to remind myself of what a boozo I am sometimes!
+Fred Newman The shims were drilled on both ends and we could flip them around and stack them all together evenly, and only have the outer most shim being held in place with the cap head bolts.
Very Abom sized broach plugs. With all that work and time, required to make everything for broaching, I gotta wonder if it would have just been easier/faster forgo broaching, and just cut the coupler keyways in the shaper?
Hello Adam, Does your machine shop ever do or get an analyses of how long the cutting bits and tooling lasts? In inches cut or hours or however they calibrate it? It would seem essential to keep the overhead down and very interesting for those of us buying out of 'thin' pockets. Maybe that info is available? A comparison of quality of cut versus useful life of the tool would be valuable.
Those are some huge broach plugs and broaches! If you speed up the hydraulic pump beyond that slow one you were talking about wouldn't heat become a factor at some point? Say if you had a 100 ton hydraulic ram and pump and shot it through in 10 or 15 seconds--what would the downside of that be? I would think you want to protect such an expensive tool in lieu of speed? I am assuming those broaches are of a very hard steel and brittle? Or is just the cutting edge carbide with the body flexible (to the tiniest degree) tool steel?
Thanks again for a great channel. PS: How about another challenge where you and Tom true up square blocks in the four jaw at the upcoming Summer Bash? I was watching your 2014 video of doing that thread clamp block for the hydraulic ram end pintle and the thought occurred to me. I hadn't even seen that done centering a square block with a dial indicator. Doug
Nice watching you work. I'm trying to learn this as a hobby. Are there good reference tables for rpm and travel speed for different kinds of material ie mild vs cast iron vs Chromoly?
Any particular reason to use cast iron for those broach plugs, rather than steel? I suppose iron might be a bit easier to machine.
I'll also have to remember All/16 wrench.
How do you manage to concentrate on work with that view of the outside? Love your videos...
+1dnr91 it sucks but sometimes ya just gotta suck it up and get the work done.
How did you find center on that big plug?
+EweTwoughb Used an edge finder and digital readout.
+Abom79 Oh duh, that's easy enough. Do you need an extra long edge finder or is it not necessary to reach the tangent edge if the piece is level?
I absolutely love your channel! The video quality, angles, lighting, audio, etc. are perfect. A viewer couldn't ask for more.
+EweTwoughb I just used a standard 1/2" edge finder. can't stick it way up in the collet though.
Considering those broaches probably cost a pretty penny and it looks like they were bought specifically for this job is there not a cheaper way to achieve the same end result?
Were the giant plugs cut with a 1.5" and 2" keyways part of the tooling just to hold the broaches or were they part of the gear assembly?
Just Curious, what did you think of the clamps? It looked like the teeth marked up the face?
Now I understand why you love the K&T. Chatter = bad, yes?
hi adam from greece !!!
Good Stuff
perfect job for wire edm :D
Just curious as to who pays for the extra work and materials to make the broach plugs and the broaches themselves? Does your company keep all the special parts that was made?
+tsmartin it all goes into the job.
Hey Adam, when you were milling the cast iron with the roughing end-mill it looked like it was cutting very easily. Does cast iron machine easier than steel?
+David Rahn (Dmrahn) Yes I was using a roughing mill. This was actually ductile iron and yes it's easy to machine, but is more messy.
+Abom79 Thanks I've learned a lot from your videos and I always learn something from watching them.
Do you have power feed on that mill?
I used a keyseater for three decades. I could cut up too 2" wide keyways in a coupling like that in about an hour.
+tfp777 I don't have a keyseater to use.
Are these broaching plugs one-offs for this job alone?! If so, that is certainly a cost factor in the whole job, no?
+Robert C. Probably but we are being told they will have more of the same size to machine soon. The cost was put into the job.
Adam: if for some reason the broaches weren't available, is that something you could have done on your shaper? Or if the customer say had more time than money would it have been more economical to do on your shaper, If it's possible?
Absolutely yes, you can machine those on the shaper.
Abom79 so a layman's question? If you had gone the shaper route you, or I should say your customer wouldn't have had to expend the time and materials on the plug, and the broach, which had to be a fairly expensive item given its uniqueness? Is it because your employer doesn't own a shaper and they didn't want to be dependent upon yours, plus in the future if you've left they have the tooling for someone else to do it with the same accuracy? Usually there's a rationale reason behind decisions. Oh and don't mean to irritate you. Scott
Geez those are massive broaches for cutting the ways for some equally massive keys! Heh heh, if Union Pacific needs any machining help on freshening up the running gear for the Big Boy 4014 steam locomotive (will be the largest operating steam loco in existence when its fully restored), they could see about giving your employer a call! XDD A lot of these parts you work on are as big, if not bigger, than the side and main rods and pistons of the Big Boy! BTW, a Union Pacific 4-8-8-4 Big Boy locomotive's four main pistons are 23.75" and the stroke length they move back in forth in their cylinders are 32". How does making possibly four 23.75" pistons grab you? Don't know the sizes of the piston rods those pistons go on though, since that's info that's not easily found.
4-8-8-4 is definitely A-bomb sized.
I Googled it, with no luck. What exactly is this used for? The bars with ridges on them, pins that hold those bars, etc...I'm confused!
Those Carver clamps are the best, almost too much clamping power .
I forgot to tighten a clamp once on a smaller piece the face mill caught it and flung it across the garage. It made me a bit gun shy for a while. LOL
How do you move hunks of metal bigger then this? Do you got like a crane? Or a motor hoist?
+girrrrrrr2 We have overhead bridge cranes to handle the heavy stuff. We also use metal carts to move parts around the shop as needed.
+Abom79 thanks for the reply. I also saw you using it in the next video, lol
Ah those apprentice marks won't hurt anything 😜
0:30 A Butt Plug !!! Ok I'll take one too!
Oh no, Mr. Bozo visit you at 16:28
why do people dislike this ?
I bet a large shaper could take care of those keyways. It would be slow, but less slow than buying those broaches and machining the plugs.
When you got to get a job done don't always have time to find a machine, buy it, ship it in, wire it up, clean it and fix any problems. Yes if love to have a big boy shaper, but we don't even have a spot for it. Shop is out of real estate.
Yeah, I know. It's not realistic to get one, but if most machine shops kept the old tools, some jobs are actually quicker. On the real estate, I completely understand that.
Wire EDM would be even better in a perfect world. New technology still wins.
That mill probably chatters because of the extended spindle nose adapter.
How much to outsource those keys to have them wire EDM'ed?
+operator0 I don't have a clue, I just know we had to get it done.
Nice pecker tracks on the end of that one plug! Looks like an OOPS to me... :>))
It's not boring, it's interesting. I had to say it, sorry.
Big Big Big
👍👌🌿
Abom size broach
Neat
All 16ths. Aka, adjustable hammer.
Thanks for sharing!
Looks like you're getting a little excited at 10:10...those clamps are nice, but they're not THAT nice.
Using a Metric Crescent wrench on the mill? For Shame!