Machining

Articles for beginners are marked with **


Contents

1. Mill Attachments
2. Projects that Illustrate Technique
3. Measurement Instruments and Technique
4. Mill Technique
5. Horizontal/Vertical Band Saw
6. Lathe Attachments
7. Lathe Technique
8. Bench Work
9. Software Tools
10.Shaper
11.Welding
12.Alibre Computer Aided Design Software



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1. Mill Attachments Return to top.

A Light Duty Parallelogram T Nut, version 3 (errata: length is 1.414B + A)

Making Cam Action Clamps for Milling

Mill Vise Soft Jaws, version 6.

Mill Vise Tune-up

An Ultra Simple Ultra Fine Feed for a RF30 Mill/Drill, version 2

A Tap Wrench to fit a RF30 mill/drill.

A Drawbar with Integrated Spindle Lock for a RF30 mill/drill.

A Universal Motor Controller with Indirect RPM Regulation. It powers a table drive for a RF30 mill but has other applications.

An Ettco N. 22 Tapping Head, version 2

The Basics of a Rotary Table with Cross Slide mounted on a Mill Table

Mounting a 3 Jaw Chuck on a Rotary Table with a Face Plate

Centering a Rotary Table Using the Centerline function of a DRO

Making a Few VERY Minor Improvements to my Hold-down Set **

A "C-nut" for a Mill

Making an "Omega-nut" for a Mill **

Making a T-nut" for a Mill **

Variable Frequency Drive Frequency versus Cutter Diameter Spreadsheet (in inches with 60 Hz line frequency)


Variable Frequency Drive Frequency versus Cutter Diameter Spreadsheet (in mm with 50 Hz mains)

A Variable Frequency Drive plus Three Phase Motor on a RF30 Mill/Drill

Want to Go Fast? Put in the Stops **

Basic Digital Read-Out Functionality on a Mill **

A Low Cost and Easily Made Counterbore (by Steve-S'pore as told to R.G. Sparber) **

Softjaw with Pad Separation

A Low Cost Mill Mounted Spotlight **

Replacement Table Feed Motor Drive

An Improved Mill Stop by Brian Lamb as told to R.G. Sparber

A Ring Light for a Mill/Drill

An Electronic Edge Finder - Simple Mechanical and Relatively Complex Electronic for use on a Mill

An Ultra Low Tech, Low Cost Electronic Edge Finder **

A Self Compensating Electronic Edge Finder **

A Noise Canceling Electronic Edge Finder **

Another Edge Finder Tool **

A Small Mill Table Mounted Crane

2. Projects that Illustrate Technique Return to top.

Casting and Machining Parts for the Updated Gingery Metal Shaper

Gingery Drill Press

Moving a small mill in parts. **

A Thrown Together Sheet Metal Finger Brake

An Example of Using a Rotary Table to Machine a Beam for a Steam Engine

Drilling a Hole that is larger in the Middle than At the Ends

Cutting Corners (Making a punch to cut corners in plastic sheet) **

Avoiding Over Constraint **

A Figure Skate Sharpening Machine

3. Measurement Instruments and Technique Return to top.

Repeatability and Accuracy of the Harbor Freight® Caliper; version 3.
Discussion Related to Caliper Accuracy

Precision Machining: the control point and surface.

Total Indicated Runout Explained

Tune In for Better Electronic Edge Finder Accuracy.

Finger type Dial Test Indicators. Theory and practice.

Seeing With a Dial Test Indicator, Torque Wrench, and Excel Spreadsheet

How Accurate is Your Micrometer?

The Intersection of Art and Precision (Using a Caliper)

Scales on my RF30 Mill/Drill

A Possible Means of Measuring a Thread’s Pitch Diameter

Yet Another Way to Hold Thread Wires to a Mic

A Low Cost "Digital" Angle Gage
The Excel Spreadsheet for the "Digital" Angle Gage

The Theory and Practice of a Sine Bar

An Automatic Centerline Scribe **

A Four Ball ID Gage

Improving a Harbor Freight® 6" Digital Caliper

4. Mill Technique Return to top.

Why doesn't my RF30 Mill/Drill Cut Straight?

Endmill Effective Diameter (version 2).

Precision Z-axis Milling on a RF30 Mill./Drill (07/24/2008)

Chasing accuracy on a RF30 mill/drill with Shumatech DRO.

How to cut a block square on a mill.

Why is one parallel always loose in my mill vise? **

Accurate bedding of a part in the mill vise is an essential skill.

A Single Iteration Mill Vise Alignment Procedure.

cutting a helix on a vertical mill

X or Y Axis Zero Set on a Mill, Version 2

Thoughts on Tramming the head of a mill/drill, Version 2

Tramming a Mill/Drill, version 4

Milling Tapered Spokes for a Flywheel designed by Elmer Verburg
John Walker's Spreadsheet for Milling Tapered Spokes for a Flywheel designed by Elmer Verburg

Milling Straight and Arced Paths, version 3

An Alternative to Locking Head Rotation on a Round Column Mill/Drill

Aligning to an Axis

Milling An Angle Bracket **

Drill, Tap, and Counterbore **

A Few Basic Tests to Perform on your Mill **

What to do when you get a New Mill **

Making Soft Jaws for a Bison 3 Jaw Lathe Chuck **

Designing and Milling a Slot **

An Example of Small Scale Production **

Squaring a Bock using Ed Maisey's Method **

Accumulated Error When Squaring a Block **

A Closer Look At Machining a Block Square

Machining a Plate **

A Nice Looking Aluminum Project Box **

A Safe and Accurate Way to Set Zero on a Vertical Mill **

Drilling a Hexagonal Hole **

iPod Touch® Holder for Photography **

Reestablishing Position On a Round Column Mill **

Avoiding Mill Head Repositioning **

Tightening the Y Axis Nut on a RF30 Mill/Drill **

5. Horizontal/Vertical Band Saw Return to top.

Horizontal/Vertical Band Saw Vise Jaw Extender

A 45° Jaw Set for a Horizontal/Vertical Bandsaw

An Improved Horizontal/Vertical Bandsaw Stop **

Cutting it A Bit Closer **

Double V Jaws for a Horizontal/Vertical Bandsaw

Safely Sawing Small Bits **

Bolt Cutting Fixture **

6. Lathe Attachments Return to top.

A Low Cost Longitudinal Axis DRO For my Lathe

A Low Cost Cross Slide DRO For my Lathe
(See "The Home Shop Machinist", March/April 2011, pages 30 - 36 for full details)

Installing a Phase II Quickchange Toolpost on an Atlas Craftsman 12" x 24" lathe **

Comparing a Wimberley Toolholder with a Diamond Tool Holder

A Toolpost Attachment for a High Speed Rotary Tool **

Atlas – Craftsman Lathe Tailstock Lock Modification **

Speed Table for Atlas-Craftsman 12” Lathe **
Excel Spreadsheet for above article **

A Modified Knurling Tool

A Replacement Wrench for my Atlas-Craftsman Lathe **

My New CDCO 5C Collet Chuck

A Spindle Mounted Stop for a 12” Atlas/Craftsman Lathe **

Lathe Cutter Height Gage

A Precision Electronic Cutter Touchdown Detector

A Simple Lathe Pattern Follower **

An Ultra Low Tech, Low Cost Electronic Edge Finder **

The Problem that is solved by the Ultra Low Resistance Electronic Edge Finder **

A Self Compensating Electronic Edge Finder **

A Noise Canceling Electronic Edge Finder **

A Lathe Electcronic Edge Finder (For spindle resistances greater than 3 ohms) **

A Lathe Electcronic Edge Finder (For spindle resistances greater than 0.2 ohms) **

A Lathe Electcronic Edge Finder (For spindle resistances greater than 0.01 ohms) **

Tangential Tool Holder Chip Breaker (experimental) **

7. Lathe Technique Return to top.

True Enough (Lathe Accuracy) **

Using A Taper To set the Compound on a Lathe **

Setting the Compound to Match a Taper, Round 2 **

Suggested Ways to Cut a Taper

Setting the Height of a Lathe Cutter **

Making A Limited Range Jacobs Flex Collet® **

Turning a Precision Washer **

An Easy way to Single Point Thread **

Making a 7/16-10 Acme Left Hand Tap

A Close Look at Single Point Threading**

Reducing Total Indicated Runout on a 3 Jaw Chuck**
Excel Spreadsheet that goes with "Reducing Total Indicated Runout on a 3 Jaw Chuck"**

Making a Knurled Knob for a Socket Head Cap Screw **

Knurling **

Boring Bar Thoughts **

Understanding Nut And Bolt Specifications **

Thread Calculator by Mark Cason
Thread Calculator in LibreOffice format
Thread Calculator in Excel 2007 format

8. Bench Work Return to top.

A Simple Way to Accurately Stamp Text on a Metal Block, Version 3

First Draft of Etching Aluminum Using Laser Printed Artwork

Making it Dead Flat and Square **

Truing Up a Square with a Known True Square **

Hockey Puck V Bench Block **

A Different Kind of Screw Vise

Balancing the Wheels on a Bench Grinder **

Laser Printing to Clean, Smooth Surfaces **

An Improved Tool Support for a Harbor Freight® ToolGrinder

Those Wonderful Spacer Blocks **

A Beveling Tool

Another Bevel Fixture **

Rod Clamp **

Storage of Materials **

The Lowly Bench Block **

Making a Zamak Repair by Lance Eggleston as told to R. G. Sparber

A Drill Size Look-up Table **
A decimal inch Drill Size Look-up Table .jpg file **
A decimal inch Drill Size Look-up Table .xls file **
A decimal inch and metric Drill Size Look-up Table .jpg file **
A decimal inch and metric Drill Size Look-up Table .xls file **
A fractional inch, metric, decimal inch, and thread table by Kevin Steele .jpg file **
A fractional inch, decimal inch, and metric table by Paul .html file **

Rod Clamp (second time around) **

Using a Telescoping Inside Diameter Gage **

A Safety Switch, by John Herrmann**

Absolute versus Incremental Dimensions **

An Inside Diameter Gage, version 1

How to use an Inside Diameter Gage, by Brian L. of Valley Metal Club

A Possible New Inside Diameter Gage

A Stack of Wood on My Drillpress **

What to do with 1-2-3 Blocks **

An End Drilling Guide **

Demagnetizing Tools **

Adjusting a Machinist Square By R. G. Sparber with information from Ron Thompson **

Making Square Holes **

Is it Square? **

Accumulated Error When Squaring a Block **

Making a Dremel Drillpress (or "Feeding the Disease")

Drilling a Hole in a Slot with a Step Drill **

Low Cost Plastic Insulating Washers **

Laser Printing to Powder Coated Sheet Aluminum **

An Experimental Measurement System

Small Tapping Machine Made from Scrap Yard Find By John Nathan

9. Software Tools Return to top.

A program that calculates the best set of 4 gears to achieve a given overall ratio.

Excel® to Walgreens®: Making Small Reference Cards **

Lathe Turning Software Tool For HP-35s **

Lathe Assistant Program for TI-83 Plus **

Ball Turning with Manual Numerical Control Program for TI-83 Plus **

10. Shaper Return to top.

Assessment of My Gingery Shaper’s Accuracy

Sniffing Out Static Error on a Gingery Shaper

The Start of an Idea for a Shaper Vise

How a Lock-down Vise Works, and Doesn’t **

A Lock-down Vise

Gingery Shaper Surface Finish

A Tiny Shear Grind Bit

Gingery Shaper Surface Tests

Rebuilding the Ram Ways on my Gingery Shaper

Ideal Surface Ripple on a Metal Shaper

Metal Shaper Accuracy
Metal Shaper Accuracy Spreadsheet

11. Welding Return to top.

A Replacement Handle for a Harbor Freight® MIG Welder

A $10 Upgrade to my Harbor Freight® 90 Amp Flux Wire Welder

12. Alibre Computer Aided Design Software Return to top.

The Basic Mental Model of Alibre CAD

Two Ways to Skin a Cat: Dan’s Plate

Thinking About the Fillet Tool

Brian's Puzzle

Knurling

The Helical Boss and Helical Cut

Match Drilling

Changing your View

The Triad Tool

Drawing Angle Iron and Square Tubing

Drawing Turned Objects

Placing a Plane at a Compound Angle

Drawing Merged Radii with Alibre PE




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