Build a DIY Home Machine Shop the Gingery-ish Way
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- Опубликовано: 13 апр 2023
- We're doing it. The Gingery Lathe is on it's way. Kinda... I'm going to change literally every part and who knows if it will ever work right. The thumbnail is a failed previous attempt at the lathe, so the stakes are kinda high here...
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#lathe #gingery 
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![Gunna - back in the a [Official Video]](http://i.ytimg.com/vi/oBrbejOHjLw/mqdefault.jpg)
Editing - top notch. Speechcraft - upper echelon. Sound and volume - right were it's supposed to be. It's a work of love quite obviously.
It was right, or it's where it should be?
@@Iowa599 nitpicking nitpicker nitpicked my handcrafted flattery
Thank you!
I bought the same Gingery book a few years ago. There's another set of books called The Boy Machanic, lots of thing for boys to build. Everything from crossbows to foundry and machine builds. Copyright dates are from 1913 to 1918, as you can imagine it would give parents today a panic attack if their child had one of these books. The copy i grew up with is 1947 edition. Fun stuff.
Interesting, I've never heard of that one. I'll have to check it out
A more modern equivalent would be the book "Whoosh boom splat"
I mean, not all parents. Until recently I was a teacher at a school where I got to do things like help kids turn the transformers from microwaves into giant electromagnets that they used to climb the steel girders in the building while I belayed them. There's a slow resurgence of appropriate dangers in childhood, which is good. More parents and educators are realizing that we've gone too far in rounding off the sharp corners and bubble wrapping everything in children's lives. We don't need to go all the way back to the 1950s when my dad set his kitchen table on fire with his chemistry set using real-ass chemicals he got from the pharmacy, and blew his eyebrows off with a "rocket" he made by filling an old mortar shell his dad had lying around the farm with gasoline and lighting on fire. There's an appropriate middle ground somewhere.
@@evanbarnes9984 great summary - thanks for teaching there is a way to explore without dying to the next generation.
This is legitimately exciting. It's going to be interesting and funny. Can't wait 😁
I hope so!
Paul,
I was directed here by a commentor on one of my videos. He had heard the marvelous shout you gave for me. I am very appreciative of it - thank you greatly.
As I have no doubt mentioned before I am not a fan of the Gingery lathe idea. There is a perfectly good reason that lathes are (usually) made from cast iron. It’s not that iron is cheap, fluid, casts well and easily, although these things certainly help - it’s because when properly formulated iron has excellent vibration damping abilities that help to reduce the resonances that cause tool chatter. Aluminium is very poor in this regard and a lathe made from aluminium will suffer badly from chatter problems. At first, I was struck by a possible problem in using Ezda / Zamac alloys for a lathe - they are heavy and while it might seem counterintuitive, weight is not a good idea as it lowers the frequency response of the lathe - it’s the lower frequencies that cause the majority of chatter problems so extra weight - not good. However, your choice of Ezda might just turn out to be inspired because these alloys have quite good damping ability - particularly the 27 % aluminium alloy but the 11 and 8 % alloys and almost as good.
A couple of points re these alloys though, they lack a strong oxide film on the liquid and have low surface tension and will thus run into the sand mould surface and produce a rough casting on the slightest provocation. Casting temperature is important to help prevent this - I would start at 500 Deg C and go down from there until just above miss fill temperature. Also important is that mould heights are the minimum necessary to provide adequate feeder height - extra height = extra pressure = rougher castings, see my "possibilities" video for an example of this, (shameless plug😊) and of what is possible with these alloys with careful casting. Good basin/sprue and gating technique to produce the calmest possible fill is important too. One thing that many do not appreciate with these alloys is that they can segregate on melting and on standing while liquid, thus the top of the melt can become aluminium rich and the bottom zinc rich. Careful stirring is needed to eliminate this problem - see my video Don’t stir up trouble… (another shameless plug 😊)
Thank you once again for the great shout out - I just wish more people were of the same opinion 😊... . Martin
Hi Martin, its good to hear from you!
Vibration dampening was the main reason I chose za12 for the lathe project. I saw Makercise struggle with chatter problems until he bolted the thing to a concrete slab, so i decided i wanted to toughen up the castings, use a vibration dampening metal, and then i'll bolt it to concrete anyway. Iron would be great, and i've melted cast iron in my furnace set up, but the extra heat was just no fun to deal with. I don't think my sand could handle cast iron anyway.
I've heard about the metal segregating, and i think i've noticed the issue on some of my test castings. From what I read, they segregate in the mold if they don't cool quickly, and the aluminum rich metal will float and freeze on the top, so the shrinkage occurs on the bottom. I had a couple tests that were probably too hot and poured into overheated plaster, so they stayed liquid a long time, and the bottom shrink upwards. I was confused until i learned about the segregation. I saw your stirring video and that's definitely going to be how I stir this stuff. It makes me wonder If i need to feed the lathe bed casting from below, or if i should just forego feeding entirely because its a thin casting of uniform thickness. Campbells book says to not use feeders unless necessary anyway, and gingery's gating method (dump metal in a hole on top) wouldn't feed very well anyway. I'm definitely not doing that haha!
I printed a box that i can use to make a repeatable pouring basin, which unfortunately adds height but it does allow me to fill it from the crucible without dumping the metal from a height. I noticed on some of my recent test castings that the surface finish in the pouring basin is excellent, which the casting itself (4" lower) is VERY sand textured. And you're right on with 500C, that was the best temperature I found. I could have probably improved the gating and gotten it lower but it was tending to freeze otherwise.
And thank YOU for all of the informative videos! you are a major help to those of use who want better castings! ...Paul
@@PaulsGarage I wonder if the base was full of lead held (poured) in with some cross bolts would be a decent dampener? It would certainly add extra weight. I've been keen to try this series for a few years now and have just ordered the 'big' book. Would the lead soften the aluminium at that temp?
Always entertaining and educational Paul! Looking forward to the series.
Thank you!
I have this book, I haven't used it yet. I bought it after I went to school for machining. It's really neat.
Read "The richest man in Babylon"
I once set a field on fire playing with my Gingery charcoal foundry.
It's best not to play with fire when you have undiagnosed Bipolar II disorder.
Every idea is a GREAT idea!
Hey it might have been a great idea with mediocre execution on the safety front, but still a great idea! 🤣
Got these before PDFs were a thing. Never built any. Didn't know you could get then in one book. Now we can watch others learn for us.
It's a huge book, well worth the money in my opinion
I haven’t dived into it too much, but IIRC Concrete can be a thing for lathes (probably the base and rigid part), there was an OSE Wiki Page on “Concrete Lathes” i think.
Subscribed! Definitely going to follow! Back in the 90s, I was making an order for this series with Lindsay publications, the original place to get the series (Lindsay was a friend of Mr Gingery). I was playing with Mr Gingery's pronunciation with the lady, trying to figure it out, and the lady got slightly aggressive correcting me. The next catalog, they specified "That's Gingery, as in sing-ery". (J sound on the first letter)
You got me checking my local Zinc alloy suppliers here in Oz after that last vid. Never thought of using it before.
You might look online to see what improvements other people have made to the lathe. The biggest suggestion was to scrap the design for the lathe bed and build it according to the bed for the mill with a piece of 1/2" cold rolled steel attached for the bed surface. The next suggestion is to solidly mount the lathe on a large block of reinforced concrete to absorb vibration and reduce the harmonic frequency of the lathe (better surface finish and accuracy). The next suggestion is to throw away the jackshaft power train crap made from old bed rails and set it up with a VFD (Variable Frequency Drive). Either one from China, or a heavy duty RC car setup, called an ESC (also from China). Until you need to cut tapers, just use a solid block as a tool post instead of spending the time and effort to build the compound rest. It will give you a much more rigid setup. And last, setup your lathe to be able to replace the leadscrew. It starts with a regular threaded rod (which is crappy), and suggests replacing it later with square threaded ACME leadscrew. The only place I could find one was from McMaster-Carr industrial supply, and it wasn't cheap. I would have been better off getting a cheap ball screw from China and setting the lathe up to use the ELS (Electronic Lead Screw) system by Clough.
There are a lot of places to get good design ideas and methodologies for building lathes and mills. The Myford 10 is the lathe Gingery copied, and he could have done a better job of it, but looking at the accessories for it will give you a long list of projects to build for the rest of your life. Opensourcemachinetools.org has the concrete Multi-Machine by Pat Delaney. It's cheap to build, ginormous compared to the Gingery, and if you pay attention to detail during it's construction it'll be capable of some decent work. There's also the Stepperhead Universal Machine Tool documented at lathes.co.uk in the "lathes" section. Very sweet. The Hommel UWG lathe used in German U-boats of WWII. Super compact and versatile, just a pain to setup. The Hardinge HLV-H Precision Toolroom Lathe is a thing of beauty. It's what the Myford 10 wants to grow up to be someday. Finally, there's all the people that have modded the standard Chinese mini lathe to make it into a capable machine (Like making a silk purse out of a sows' ear).
Interesting, thanks for those links! I'll check those out. I'm definitely interested in improving the lathe. I've already made the bed pattern so I'm sticking with that (it's modified a bit already) but I'll definitely look into the rest
@@PaulsGarage I would look at other mods, some of the shortcuts were to help make it easier to build and cast with decent results. Now that you have mastered 3d printing, you can more easily do like cross hatches on the bottom of the bed for rigidity (probably tapered to make it easier to get out of the sand) but large enough to hide the single shot whiskey bottles from your wife, or some gems, or the keys to your mistresses apartment. It was a skimp on his part to make it easy to cast.
The other thing that would be great is to replace the brass bushing/bearings with actual bearings. Which I don't know if it is possible or whether you have to build the lathe then the mill to be able to get the holes in the headstock correct to take angular contact bearings. Which are expensive, and can't be found at the hardware store, but would be a vast improvement.
@@seano8927Do you think Babbitt bearings would work ok? Have just ordered the full hardcover book and keen to give it a go.
I bought the book a few years ago and have never done anything with it. My thoughts at the time were, it would be some cool projects for when I retire. Well, retirement is less than a year away so maybe I will learn from your mistakes and save making the same ones myself. Being somewhat lazy, I will probably not do all the scraping. I have a friend who can mill it for me and save days of time and tons of effort. Best of luck on the project.
Thanks and you should totally try to build one!
I've seen some folks use the bed design Gingery employed for the milling machine project for the lathe. The milling machine bed doesn't have a solid top; rather, the resulting casting is "hollow" with just the vertical sides and the cast webs in between. Since the steel ways bolts directly onto the casting there is less casting surface to hand scrape. Further, without that massive top surface, for the same amount of metal you can beef up the front and back and the web, which will result in much greater rigidity.
Good idea! My bed pattern is already very beefed up, it probably uses 50% more metal than the original design
Thanks for not being Mr. I'm So Perfect! Appreciate knowing the pitfalls of these projects.
Oh if one things for sure it's that I'm not perfect haha
Looking forward to this!
A few weeks ago an Atlas metal lathe showed up on my local Craigslist for $250 and I just missed out on it. I have no real use for a metal lathe or a good place to put one, and yet... I NEED it 😭
On the bright side, I didn't throw my back out trying to move a metal lathe!
I know the feeling! I don't need this and yet I NEED IT 🤣🤣
I moved a Flight Simulator Console i got at an Auction for 20USD + Standard Office Computer/CRT Monitor in my *1990’s Honda Accord* a year or two back so i feel that issue of actually *having and moving the stuff* lol.
Hi Paul. Great project to sink your teeth into. I agree several changers should be made to the lathe. If modern components were available back when they would have been incorporated into the design. So go forward and build and learn much along the way.
Awesome to see! And thanks for showing all mistakes, it makes us feel like normal humans as well. :)
The biggest mistake of all, I didn't even get to pour the metal for the bed lol. I wanted that to kick off the project. I guess that means the next video will be all about just molding and pouring this one giant part 🤣
@@PaulsGarage I'm all here for it, no worries. :)
@@PaulsGarage yeah don’t rush yourself/be too hard on yourself. Doing plenty of amazing stuff as is, and i am always team quality over quantity/speed!
You should look into using Epoxy sand/gravel mix to cast you lathe bed in stead of metal casting. I'm not sure if it would be cheaper but, it will be easier to do. After all there are plans for a concrete Lathe
This is a fantastic project, but it will take a lot of time. For those of you who do not have said time it's still quite easy to find used engine lathes that are in perfectly usable condition. Look for Atlas, Clausing, or Shurline. Anything made between 1930 and 1980 will be a good buy and almost all parts are still available at reasonable cost. I bought my Atlas 6" for less than $700 with tooling and change gears.
It will take years most likely. Not just for the lathe but I want to go through the shaper mill and add ons. Gonna be content for a loooooong time
Mate made a gingery lathe many years ago, he used Bronze as the metal, but otherwise followed the Gingery plans. Got to see it last year when he pulled it out of storage to make some parts for an old lathe he was doing up. He is currently almost done making the gingery dividing head.
That's awesome! Bronze would look amazing. I'm going to use bronze for some parts on this one but not the whole thing!
@@PaulsGarage apparently he had a big propeller that fell off the back off a ship at the ship yard he worked at...
@@jackdawg4579 sounds like a good metal source 😉 I wonder what bronze it was? Some newer ships use aluminum bronze, that would be fun to cast I to a lathe for sure
How'd his lathe turn out?
@7.05 that's a 100% vote there, all parties in agreement
So far, in 15 years, I have built the charcoal foundry, melted a lot of small engines and made ingots, AND made the plywood mold for the bed. LOL!!!!! Heh..........life got in the way. And still is. My old furnace isnt looking so hot so im ordering a vevor propane furnace. Rather or not I continue on with this remains to be seen I just wanted to melt stuff and do some simple casting but who knows. Time is a huge constraint and now that im older and looking around im like holly crap..........Ive really let this place go to hell over the years lol. And I work a lot, Still. So, if nothing else, I can enjoy watching someone else do it. We'll see.
PS, im not a procrastinator I just have too much stuff going on and ive been working 70 hour weeks. So its like lets see, play in the barn or finish that bedroom. Im tired.
Nice! Another lathe build on youtube! As you ask, I'd like the lathe to have a wider bed that specified by it's original author, or said otherwise, to have an appropriate width according to it's centre height. But I reckon that's gonna require more than you could probably put into it.
This is what most lathes suffer from (due to manufacturers' will of sacrificing rigidity on behalf of their own profit), and which is specially true for these chinese crappy lathes. But well, maybe in a future.
I'm not changing the width of the bed so much but I am increasing thickness of the walls by 50%, using a more rigid metal, and I increased the taller (2" as opposed to 1.5") so it should be significantly stiffer than Gingery's original design. Iron would blow it away though most likely
Very much looking forward to this series!!
Thanks! I'm excited too
Good luck. I'll be watching.
Thanks!
Looking forward to this series!
I don't hardly know diddly about any of this but I am looking forward to the entertaining ride. And the Learnding of course. Curt Van Filipowski did a YT series I watched a while back about making a lathe bed out of concrete. Interesting idea I thought.
Concrete would make a pretty good bed I think. It's heavy, rigid, and should keep vibrations down really well
Really looking forward to this project. I need a rudimentary lathe so it's his or a pieced together Taig
Looking forward to this! I've had the books for years...
Could you add your current foundry setup and supporting info to the play list?
Good idea! I need to do a playlist update I think anyway. The burner is quite a bit different from when I built it and the furnace is about to undergo some radical changes...
Yay! I hope you stick with it this time. And im really looking forward to watching!
Awwwww yis. Welcome back motherlovers! This is what we have been waiting for!
Looking forward to this series! I have quite a few of Dave’s books, but never got the foundry going…Really enjoy your channel and casting content. Thanks for sharing!
Thank you! Reading the foundry book is a good idea, but I'd still skip the charcoal, his sand, gating methods, etc...
Lol, I literally just cracked my copy of this book the other day and got through book one and thought... "you know what would be great? If someone would do a youtube series on this whole process." A day later and here we are... Cheers mate!
Perfect timing! It'll be a while before I get through it, but I plan to go through the lathe, shaper, mill, then "extras". Slow and steady wins the.... machine shop. I guess..
Yay. I'm so looking forward to this series. Thanks Paul for revisiting this project.
I'm glad you are looking forward to it! The next video in that series should post tomorrow (flattening the lathe bed)
I built a wooden lathe a few years ago with an old drill press motor (didnt have a drill press) and a 1/2" bolt then rebuilt it a few times to be a midi-sized lathe before my wife bought me a DC drive Mini. Currently working on building a metal lathe for the few times a year i am needing one but WAY too poor to buy one, even the $800 one. Steel, concrete and easily machinable metals will be your friends.
Do you mean a wood turning lathe or a lathe made of wood? Both sound awesome. I share your aversion to spending $800 on Chinese junk, and I don't have the thousands needed for a decent one. DIY it is!
I can't wait for this!!
Can't wait !
Wow Paul - this is going to be a GREAT series. One of my favorite RUclipsrs diving deep into the things I enjoy to watch, learn and try myself. 👍👍😎👍👍
I sure hope so!
Fantastic!!! Great work my friend and I am along for the ride.
Thank you!
Built a foundry this weekend and have been working with xps foam and a wire cutter for a couple years now. Will hopefully be building along with you, trying lost foam
That's great! If I remember right, makercise used some lost foam in his build, so you're in good company there
*Open Source Machine Shop?!?* Let’s Fucking Goooooooooooooooooooooo
Loved reading the books. Be interesting to see how you get on 😀
I’m ordering the book! Thanks for sharing, planning to build along
Excellent! Thanks for coming along for the ride
Can’t wait to follow along with this. I bought that book when I first seen you mention it. I’ve built a few foundries and honestly got side tracked with other projects. I’ll definitely be following along. I’ll have to fire up my 3D printer for this project too. Looking forward too this series.
That's great! Next video will be a lathe bed video. Not sure if it's a success or not yet, I haven't opened the mold. The suspense is killing me 🤣
Looking forward to it!!
Thanks!
I'm extremely excited about this series. I do not normally leave comments, but I thought I would this time because this will be such an amazing series to learn from for people that are getting into producing their own parts that are getting hard to find for older equipment vehicles and homesteading.
You know I hadn't even thought about people trying to make stuff for homesteading, that's really interesting. Thanks for commenting. I should probably make a separate series documenting how to get into casting your own parts. I've made all these videos, sure, but they are very scattered and not in any -easy to follow- playlist.
I have been a fan of yours for many years, i am really really looking forward to this as I attempt to do this also... maybe i will video it... probably not...
Thank you! If you decide to build along just know videoing it generally makes things take 3-5 times longer in my experience, you'll have to allow for that 👍
New subscriber. I'm coming along for the ride; thank you Paul.
Welcome aboard! And thank you!
Super excited to see this series, I have to admit I'm one of the people who went out and bought from rotometals after your last video and seeing the results you are getting. I've already got an atlas lathe, so I guess I'm a step ahead of you on the zamak lathe process, but I'm sure there will be helpful tips in the series for casting & machining. Plus, it'll be entertaining.
Thank you! An atlas lathe would make it much easier for you to build a gingery lathe, just saying 🤣. I hope the build will be informative anyway
I'm another who ordered the ZA-12 after watching the last video. I've already got a lathe and mill though so it will be used for casting other stuff... probably some form of project car parts.
I'd like the lathe to have a "Steam Punk" look.
I don't know how to describe it but you know it when you see it.
That's a cool idea. It should be halfway there with all the metal pulleys and stuff, but I can probably add some cast-in ornamentation or something
As someone who found you from your first attempt at Gingery, I'm looking forward to this new series.
Thanks for sticking around this long!
How to start a RUclips series you already started years ago 101.
That I'm still following your progress on the lathe makes me as stubborn as you are so you are not alone.
Haha nobody finishes a gingery lathe without some stubbornness I think
Nice work.
I’m with you!
Thanks!
I’m definitely going to be building along. I’ve tried casting the bed a couple times just haven’t got it quite right yet
Excellent! Makercise had to try a couple times, and the reason I don't have a bed in this video is because I didn't get the ramming right either. It's a process for sure. Fortunately the rest of the patterns are much smaller
I've watched Cressel Anderson's version of the build. He is an engineer type and I don't think I could follow along with him. I've been wanting to do this for a while and now I have the beer keg foundry from Brian Oltrogge. I will follow along with you because, I say this with all respect, you are scatter brained and only half finish things. It takes one to know one. Godspeed and let's get after it.
Haha I am indeed scatter brained! Cressels videos were very tight but they left out a lot of details. Of course he followed the books better (though not entirely) so he didn't need to add as much I suppose. I intend this to be a companion series to the books for people who want an update on casting techniques and maybe a better looking lathe. I hope you follow along and good luck with your build!
Do like I did I just asked the boss then used it to pay it off in a year
Great video gingery lathe😊 man
Dang man, I'm gonna do my lathe too! love your projects
That's awesome!
If you can actually finish one of these lathes from ingot to machining a part then you will have learned much more than the guy that buys a cheepie lathe and starts turning stuff.
So here is looking forward to your progress, mistakes, wild rants and tears and eventually the first part produced that has not got something to do with the lathe.
The tears have already started haha 😂. Molding that bed is a challenge. Makercise said he had to mold the bed several times before he could even pour metal lol
Great video, i subbed along for the ride 👍
Awesome, thank you!
Oh, nice.
Rotometals has one of your videos added to that ZA-12 link. :)
Cheers from Argentina I follow Makexercise from the begining glad to see you retake the proyect I my self gather all materials the foam for lost foam and make a foundry on propane and still I havent make a single piece lughts on me cheets mate and good luck I will see all the videos no mather how much it take
I hope you enjoy! I have a long way to catch up to makercise, he stalled at the mill and I don't have the lathe yet 🤣
Suggestion: make the bed out of epxoy-granite instead of a metal casting. You still need some metal parts, but epoxy-granite looks like a much better material for that part and you don't have to figure out how to pull the bed out of a sand mold.
Never tried to use epoxy granite. What is it like?
@@PaulsGarage From my experience it handles like you'd expect a sludge of epoxy and sand to. But well worth it for the damping capabilities. Even bolting a lathe to a granite countertop base provides a noticeable improvement.
@@terminalvalence9871 that's interesting. I'm kinda set on metal cast bed, but I'll keep that in mind. I know makercise bolted his to a cement base and that helped a huge amount with chatter
@@PaulsGarage Metal casting bed is fine, and true to Gingery's plans. Consider making the base in a way that can be filled with Epoxy Granite for dampening. It's a good way to the mimic Cast Iron properties with easier to cast materials.
Beat me to it, but yeah (Epoxy) Granite/Concrete Lathes are a recent/not as well documented, but great thing.
Terminology tidbit: "pot metal" refers to non-specific low melting alloy, usually tin or zinc based, which can be melted in a pot. So ZA-12 would fit within the general category.
That's interesting! Yes it would fit, but I wanted this alloy specifically for it's casting properties. Mixing "pot metal" seems like a terrible idea to me. Some of the old pewter stuff had lead on it and to combine that with zinc Alloys? Yikes
It's about time you finally got back to this! I bought the book 2-3 years ago and still haven't gotten back to it myself, maybe this summer if you inspire me.
I bought the books 15 years ago, and still nothing...
@@henrymiller1820 lol so I have 12 years or so at least to procrastant still, sweet!
Hopefully I'm still going by summer! 🤣
@@PaulsGarage lol yeah know the feeling!
@@henrymiller1820 I think I've had mine for over 20 and just now getting really started. Nice to see I'm not the only procrastinator here. 😁
This is going to be miserable. I love it. Oh , the suffering. Best of luck. I will definitely be watching with guarded anticipation. I wish the best for you and yours in the trying times ahead of you.
Thank you! And get ready for struggle, I've had problems with the bed already
You're right. Im going to use aluminum, but its going to be from automotive case components like differentials and transmission cases. Lots of oils.
At least those were cast to begin with, that gets you half the way there already
you should pronounce gingery the way you didn't want to pronounce it. It has "harsh" letter Gs in both locations. I have watched the video where he introduces himself and you can hear him say his own name - that is definitive. I believe the video was mostly about him playing a fiddle and I have it on DVD somewhere, but I don't think it is on the Internet.
I need to find some of these videos, I had no idea!
Cool cool cool! Yes I have an atlas lathe but I’d still love to make on too!!!
You can always skip the gingery lathe and go straight on to the shaper
It is definitely hard 'g' for both the first and second 'g'. I talked on the phone to his son's wife when I ordered his books in bulk back in 2006, and that's how they pronounce it.
Ok good to know
I know epoxy granite has been suggested, and that's a really good suggestion, but given that your foundry is capable of doing cast iron, might it not be worth casting major wear items like the bed in cast iron?
My grandfather's lathe, which he made with his father and grandfather sometime around the beginning of the 20th century, and which was CRIMINALLY SOLD FOR SCRAP ALONG WITH ALL THE REST OF HIS WORKSHOP TOOLS by my uncle after my grandfather's death, was a cast iron bed which they cast themselves. And it wasn't small. It was 6 feet long. OK, admittedly they were blacksmiths. But there is a very good reason cast iron has traditionally been used for machine tools.
The other option, and one which I was considering before picking up my own lathe and mill at ridiculously low prices, is the aforementioned epoxy granite and using off the shelf ground and hardened bar or round stock for the ways. It's an approach that will almost certainly net you higher precision than the Gingery machines.
Good suggestions for sure. I can melt iron without a problem, but my sand can't take the heat. I also don't want this build to be inaccessible to viewers. Za12 meets halfway being stronger than aluminum (though definitely not as good as iron) and being easier to cast at home than both. Iron sure is tempting though.
nice vid as always
but a quick advice if I'm allowed (don't go through with this if you are looking for a lathe, do it if and only if it's for learning only)
mainly because I made multiple either "by the book" or by modifying and not even one of them worked {but I learned A LOT}
hope that helps and good luck
It's definitely for the learning 👍
Want me to personally teach you how to use your 3D printer to learn sand casting? Click here: paulsmakeracademy.mykajabi.com/joinus
Find the books here: amzn.to/3KztaSR (large tome version)
amzn.to/3zVWgHe (just the lathe book)
keep the videos just rename them as old something something
I built myself an electric foundry a few years back and some good results with it. I also had plenty of bad results which is why I gave up casting several months ago. I know think I either need a more powerful electric foundry, or a propane one. It's probably going to be propane so I can get higher temps. Cast iron? Yeah! Hopefully, the next video will be less rabbit and more doing. Get on with it Paul. (I don't mind the rabbit really)
I intended this one to have some doing and ran out of time to redo the bed lol I tried twice with the ramming. I think I need some pattern refinement...
I bought a set of those books years ago and was all set to start, I was teaching English to a bunch of machine designers and showed the books to them. They thought the foundry was a great hobby idea and recommended truck pistons as melting stock and gave me lots of other good tips. I showed them the lathe book and were appalled at the design, they begged my to abandon the project due to the (in their view) criminally negligent carriage design. They were convinced that anything but the lightest of cuts would cause the lathe to explode, especially when turning anything harder than toffee.
Oh yeah. The whole thing needs to be beefed up, which is one of my design changes. I'm also using a much tougher metal. In Gingery's defense, if he used aluminum, it probably would just bend and not explode 🤣
hmm, I am tempted by UHPC or expoxy granite for my base but the idea of melting an engine block to nuclear temperatures is kind of appealing to.
I can't wait to see this! I have had the books for over 10 years and have not got past book 1 but my stock pile of AL is growing.
I really need to build / buy a furnace. With this winter it has been super tough to do any shop work.
P.S. hello from ND / MN
You know what would warm your workshop up a lot? A propane furnace at full noise 😉!
@@dfross87 true... 😆
hello from WI! I'm surprised how cheap some of those furnaces are now. The materials I used to make mine cost as much as a finished devil forge lol
I rented the Gingery video a long time ago when i wanted to make one and the pronoucation is the sencond one iirc, not that it matters. Love the vids. I'm trying to make a mill right now, though not the Gingery one, my own design. I want to try zumak instead of the random alu crap i find lol.
Wait there's a gingery VIDEO?
5:06 If only i had an XRF Gun…
You and me both!
That Gingery lathe indeed leans toward kinda crappy to say the least. Also, your baby-mama dresses you funny... now the insults are out of the way.
Despite that (both of it), it will be fun to follow along. One thought I had was, if you're doing it for the fun of building as well as good youtube content, it might be a good idea to think about making it so that, after the functional manual lathe part is complete and able to make useful things, you could expand on it to add some CNC control. All the cool RUclips kids are doing it! A whole new series of content that people WILL watch.
In total seriousness and sincerity, a CNC control is a lot easier to pull off nowadays for much less relative money than it useta was. It's also quite handy once you work through the learning curve a little. Maybe purists wouldn't like this, but with CNC it is possible to program out some inaccuracies a machine might have - a not-well-known feature of the field. I'm a machinist by trade so this is coming from a place of at least some valid experience. It takes time and there are a few new things you need to study up on to do a halfway decent CNC retrofit, but so is the manual part and isn't filling time what we mostly find ourselves doing anyway? Also, the result is almost certainly the single one and only Gingery CNC lathe in existence too. I just thought maybe if you're tweaking the design anyway, maybe some consideration of possible CNC control on those tweaks might be worth it.
Anyways, just an idea. I enjoy your videos. Best wishes to you & yours.
You know that is a fascinating idea, I'll have to look into that. It would certainly be cool to have a CNC lathe. I wonder what I would have to change to accommodate that? Would it be a retrofit kind of thing or would it only work if I allowed for it from the start? I could always adjust and remake parts later anyway if I'm making them to begin with.
@@PaulsGarage Speaking of homemade CNC stuff, you might look in on the FloweringElbow and FloweringElbow 4SuperNerds channels if you haven't already seen them.
Electric Foundry. check. Propane Foundry. check. Chineesium Lathe. check. I'm working on the sheet metal brake first, stopped for the snowy months where garage was cold. check. Have all of the books in the series. check. Lets GO!
Let's gooooo! Im not going to do the sheet metal brake. I got a terrible chinesium one, then threw it out and get a better chinesium one so I'm set for brakes. Electric furnace is on its way, too
@@PaulsGarage yep, I didn't decide on the brake to get a great tool. It looked like the easiest of the projects to complete. For what I've spent on materials and time, I probably could have modified a cheep one much easier. However, I did get a welder, grinder, etc... and spent time drilling and taping. I think it's more for the experience and learning... just like the lathe... I already have a little lathe, but want to do the Gingery one for the journey... for the experience not for the end product. =D Although, I still have a few projects I can use the end product to complete when it's finished. Way more expensive to build your own tool.
@@MikelNaUsaCom I agree, it's worth the journey and it's way more fun to build your own. Even if it's more expensive. The brick foundry furnace I build cost as much in materials as a full devil forge set up, but right now my furnace is all screwed up, and I have no fear of tearing Into it and modifying it. A devil forge though, I would feel a little nervous just because I didn't build it.
Hi, Paul. Coincidentally, I'm nearing the beginning of building a modified Gingery lathe. I still need to finish my new furnace build, so I may be lagging behind you on progress. BTW, I've always pronounced Gingery with the soft G sound. There's video series here on RUclips of a guy that built one, but he keeps saying Gingery with a hard G. I always wonder if he eats (hard G) Ginger Snap cookies. Anyway, looking forward to learning from any goofs you make so that I can make my own unique ones.
ETA: Now I've read in the other replies, the hard G is correct? Ah, I'm sticking with my wrong pronounciation.
Makercise? He started with soft G's and switched. I might have to mirror that, or maybe stubbornly refuse to change even when I'm definitely wrong 🤣🤣
@@PaulsGarage Yep, it was him. Had to go look. I notice he does mispronounce gib. He's saying it 'jib' like the sail on a boat.
No, *I do not understand schadenfreude.*
No, seriously - I seem to not have the wiring to get it.
Hope to see you do well with Señor Gingery.
How many pounds of Za 12 do I need to order from Roto Metals for this project? Looking forward to using my new 3 year old Devil forge for this project. Thanks a bunch bro...
Not sure exactly how much you need to finish it just yet, but I bought 32lbs and it seems like that would cover the majority of it. A standard gingery bed is 4lbs of aluminum, my bed is 12 lbs of za12. Headstock is about the same, and the rest of the parts are much smaller.
I actually put my hand up with you
Thank you! I appreciate the show of solidarity!
How much does that bed weigh? It looks like it could be a 20+ pound pour. That's challenging.
I'm not certain exactly. I do know my giant crucible with a bunch of ingots in it is really heavy, but I CAN manage it with my crucible tongs. I decided to test that out BEFORE it was all molten lol
It is actually pronounced with a hard G like in green or google.
Okay. I’m interested. I’m both broke and bored and could use a small shop.
Perfect!
GUYS! IT'S HAPPENING! 🎉
🎉🎉🎉🔥
Bingo, Mazak machines. Smelting aluminium always looked too hard.
I want to do this with you so badly. I have a smelter already (diy) and I have a mpcnc (built my me too) so why not.
Go for it! Just lag behind me a little and I'll make the mistakes for you and tell you how to get around them lol
If you're having vacuum problems with the pattern why not try set screws that can be removed before removing the pattern?
Screws are a good idea. I think my main problem is draft on the underside. I need to do some pattern "adjustments" before I go on I think
not going to build one of these .....just like too see what you do & say!🤣
Sounds good to me!
I can confirm that you can find the PDFs for free
It looks like your lathe is made of wood that's painted silver…
I'm sure that's just a stack of patterns to make the moulds…but what if you made the lathe out of wood?
I'd think it could still manage rough cuts in aluminum, and maybe surface polishing steel…
Bolt those together!
I'm not sure how tough a wooden lathe for metal would be. Maybe if it was milled out of solid hickory or something?
And those aren't wooden patterns, those are castings from the last time I tried to do this 🤣. Starting fresh this time, with modified and better quality castings
Great video. don't want to discourage you or anything but I think that a lathe would be better if made of steel or cast iron I know that melting steel is a very difficult process trust me I tried so a different a solution would be fabricating and welding there's a couple of videos on RUclips of people doing that. steel will be a better material for a lathe and fabricating and welding would be easier and faster than casting
Casting is what I like though. I can do iron with my set up actually but that's no fun, the heat is crazy! Iron is definitely the best for this though. It's way tougher and even better for dampening vibrations
@Paul's Garage I know iron is a pain in the butt to melt and cast.
By all means go with what you like.
I always wanted to make one myself but because I'm too lazy and suck at casting I find that welding will suit me the most. My biggest problem is milling the bed I don't have a mill, so don't know how to do it any ideas ??
@@THEAngryProjects gingery said he tried to design a welded up lathe but the parts kept warping. I think maybe if he normalized them in a heat treat oven it might have helped? Hard to say. And yes for flattening the bed Gingery says to use a surface plate, blue die, and hand scraping. The old hand scraping method takes a long time but you can get a very large surface very flat, even if you don't have a mill or a big enough mill for a huge part, since the size isn't limited. I suppose you're limited by the surface plate size?
@Paul's Garage for warping the key is pre heating the parts and welding in small batches so you don't let the heat build up in one part causing warpage. Also, clamping helps alot.
Hand scraping will work, but it would take ages. I don't have the time nor the patience of it.
On second thought, I have a belt grinder if somehow I managed to modify it to work as a surface grinder. The lathe project would be possible for me.
I'm in! How many KG do you think we need to order?
Excellent! No idea on the amount. The bed and the head stock are the largest castings, I think the bed is the biggest. After I get it and the headstock build I'll weight them and put that on a video to give people an idea. I think all the other parts combined will be lighter than those 2 parts.
@@PaulsGarage Lets guess for now. How much does your Aluminum bed weigh and I'll get say 5-10x that in zinc ingots as an initial order?
For those in Oz, found a supplier of ZA-12 and was quoted as A$6.81kg + GST + Shipping for a "small" 50kg order. Sounds like the ingots are kind of big however (around 10kg). Supplier is HAYES METALS for those that are interested.
@@jmone3559 Cheers bloke.
Dave said his name was pronounced like thing, as in ging-a-ma-thing ( that is more or less a quote)
So the second G is long? What about the first one?
I just recommend this book to my spouse for a birthday gift idea. Is it worth the $75 on Amazon?
Yes definitely. The projects in it can keep you busy for years