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  1. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    UPDATE: We set the old furnace to 700 C and squeezed the channels in with beam clamps and sheet steel to protect it from oxidation. Got them red-hot then cooled slowly over 24 hours. Though they were a bit dirty coming out of the furnace, a few seconds with a wire wheel shined them up again...
  2. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    We have done this once before (thought with a slightly different design) and it seemed to hold up. In an earlier revision of this project we used solder paste, I do not remember the composition of the solder but I do remember it flowed at some 300 F. Painting inner channel with paste, clamping...
  3. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    Sounds like a plan. Being that the channels are about 18" long (and thus hard to heat evenly with a torch), I may opt for using our electric furnace to bring the steel up to temp. Of course this would heat the whole thing and not just the spine. What do you think of this? Thanks, Justin
  4. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    Thank you for the input, seems like excellent options for this op. We have plans to try and split the channels in two for another design revision in the future. Bolts, solder, or welding are all viable options. Out of curiosity, why do you specify TIG over MIG or stick? Unfortunately it is a...
  5. WakelessFoil

    OT. Bandsaw blade welding, which way is best?

    If what you're doing works, why change it? Unless you have to weld blades all the time I wouldn't sweat it. We have some large Do-All saws in our shop that both have blade welders on their sides. Neat and quick little gadgets. As others have mentioned, it is recommended to anneal the joint in...
  6. WakelessFoil

    Western electric rotary black telephone will not ring.

    This should work. Some are saying the VOIP box may not generate enough voltage but I have a Western Electric 2500 with a very similar ringer and it rings loud and clear! I am using a Obihai VOIP box with Google Voice. I can open my 2500 and see how it is wired. I vaguely remember having to...
  7. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    Just a small update. I am not too worried about the part collapsing on the blade as there is still a significant amount of meat at the bottom of the part, and we raised the whole works on parallels so the pressure is concentrated at the bottom where there is less leverage. (See diagram)...
  8. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    Thank you guys for the input. We actually started trying this on a large horizontal milling machine with a slitting saw, but the results were less than satisfactory. I think this was due to an error when aligning our two mounted vises. How deep can you typically cut with a slitting saw? What's...
  9. WakelessFoil

    Milling Thin and Deep Channel on Vertical Mill

    I have to mill a 1/8" thick channel in some long 1018 stock. The channel has to be 1 5/8" deep. I am running this on a CNC vertical mill and I have a couple concerns. First, how do you prefer to balance speed, feed, and cut depth? I know there is a sweet spot depending on what the tool and...
  10. WakelessFoil

    Cinci no. 2 plain horiz spindle lock

    I am the machinist that is assisting the OP with this machine. I have the machine in low gear and I am able to get some torque on it, but it still will not budge! We had the nut off before so I know it can move. I just cant remember for sure whether this was a LH or RH thread. My fuzzy memory...
  11. WakelessFoil

    Milling Thin Copper (Warping)

    Just within maybe .010" end to end, would be ideal. We are using a 3-flute HSS Ti coated endmill with plenty of coolant. Thank you all for the replies. I found an easy way to get the bar reasonably straight with the use of a makeshift bender constructed from a table vise. See video below. I...
  12. WakelessFoil

    Milling Thin Copper (Warping)

    We are attempting to mill a "T" profile on 24" long copper bars that are roughly 3/8" thick and 1-1/4" wide. You can see our set up in the attached images. I knew milling copper was a pain from what other machinists have told me. I followed all the suggestions; use a 3-flute cutter, use high...
  13. WakelessFoil

    Inventor wants to help us on his jobs in shop+sign NDA

    I am not that literate when it comes to policy and law. However, I would imagine that it would be a good idea to have him sign a liability waiver. In addition to that I would make a clear effort to make the workspace as "incident-proof" as possible to show that we are not trying to screw him...
  14. WakelessFoil

    Inventor wants to help us on his jobs in shop+sign NDA

    It likely wasn't the best term to use for the guy, I know how the vague term "inventor" can make some who works in this field cringe. He does not refer to himself as a inventor. He is an engineer and businessman who wants to construct a prototype. Refer to my earlier response.
  15. WakelessFoil

    16C to 5C Collet Adapter Not Working with Hydraulic Draw Bar

    Thank you guys for the input, upon further inspection the drawbar does not move an inch, but more like 1/4"! A lot less than I thought. I have both screwed in as far as they will go, and the adapting collar is shortened as much as I could. Still the collet barely closes at all. If I take the...
  16. WakelessFoil

    16C to 5C Collet Adapter Not Working with Hydraulic Draw Bar

    We have a 16C to 5C collet adapter that we are trying to use in our CNC lathe. Despite repeated attempts to adjust the moving part we can not get the 5C to close in the adapter. I suspect that the hydraulic drawbar, that moves only about 1/4 inch, is not retracting enough for this adapter to be...
  17. WakelessFoil

    Inventor wants to help us on his jobs in shop+sign NDA

    I am the machinist/engineer working with the OP on this project. Yes, the term "Inventor" sounds sketchy when such a title is self proclaimed, but that is just what we are calling him. The client is a electrical engineer with a PhD in physics. He owns a contracting company that develops...
  18. WakelessFoil

    Surface Grinder Ripples

    We ran another test today and I filmed part of the cut. We redressed the wheel with a new sharper diamond, used a super accurate dial indicator to confirm cut depth, and drastically increased coolant flow. I think all of this helped but there are still very faint "ghost lines" in the finish...
  19. WakelessFoil

    Surface Grinder Ripples

    Thank you all for the advice and input! I will try to answer all the questions in one post so I'm not spamming the forum. I was taking the shallowest depth of cut I could get, this was a bit hard as the elevation handle is extremely sensitive and only designates .001" increments, no tenths. At...
  20. WakelessFoil

    Surface Grinder Ripples

    Thank you all for the replies! I'll be sure to answer all when I get some free time this weekend. I wanted to quickly post an update. We dressed the wheel, and sped up the side-to-side feedrate. In my head I figured slow meant finer surface finish, but I was wrong. There is still some visible...

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