Casting Metals

[Norman]

the spindle is bored the bearing fit nice and tight. I bored a through hole in the spindle for a draw bar when needed on a milling bit. So I have a basic milling machine, well sort of now to make the drive train for this. Even at this early stage of building this the mill has made it's own hole for the spindle head and the hole for the draw bar. Once the drive train is made. I'll build the mill's compound slide, then I'll be able to made most all of the parts for the mill by using the mill to machine it's own parts.
the mill's spindle is in place and now boring the through hole in the spindle for a draw bar to hold to hold a cutting bit

boring through the spindle this will latter be bored to 5/8" for a boring bit. it will be bored to a depth of 1"

using the shaper's power train to power the mill.

Next thing to build is the power train for the mill so off to the man cave.

 

[GearNut]

Your whole endeavor with creating this mill reminds me of this picture:

 

[kicking]

Hello Norm hello all . Its been an while since I have been here . what kind of electric motor is on this mill ? Or are you hand turning ? I see you have been busy . Me too , Are you mainly using wood molding models to pack sand around Norm ? I have to have original gears and stuff to go by , and keep one back for my next pour . P. S . aluminum cans are not that bad if you crush them so they wont take up much room in your pot ; and have an nice pool of molting metal going , to dump the cans in . a lot of grog when first going but that's going to happen . Enjoy that mill --- and let us know how the ram is going ? Latter !

 

[Norman]

The motor powering the mill in the above photos is off the the metal shaper. I've got the mill's transmission built and have the mill making parts for it's self. The motor for both machines is a 1/4 hp 1725 electric motor.
I make the patterns for all of the casting out of wood or med density fiber board. For the aluminum I use what ever I can get my hands on mostly worn out briggs engines.
I need to put up some photos of the mill as I'm getting close to being finished building it.
Norman

 

[Norman]

The mill's transmission is done I've made a face plate and machined the mill's compound.
here is what its looking like.
both sides

the compound slide, the mill will also work like a lathe

the frame of the mill's transmission befor the sheaves, motor, and bearing were installed.

 

[kicking]

The mill's transmission is done I've made a face plate and machined the mill's compound.
here is what its looking like.
both sides

the compound slide, the mill will also work like a lathe

the frame of the mill's transmission befor the sheaves, motor, and bearing were installed.

It has got to be nice not having to run out to get parts . and you could have an small harware store if you wanted to. I might buy some cold rolled steel for some knives and stuff . im not advanced as this mill machine . im going to read up about this stuff , the librairy has some nice books here . enjoy that mill and . the time it took to make your machine will pay off.

 

[Norman]

Got the spindle head bored to 0.625 , drilled and tapped the 5/16" fine thread set screws installed.
Now it's back to pattern making to cast a face mill tool. I'll also make some different tool holders for the spindle head and the compound.
I've been thinking about casting a china engine cylinder head just to see how one would turn out. I plan on filling in the combustion chamber so I can machine it different than stock. Making a cylinder head may be one of the first parts other than tools for the mill and shaper that I'll make
now that I have a way to cast and machine parts.
Its been a lot of work making the machines, was it worth it? Heck yes!
start of the boring to 0.0625 on the spindle head

this is the tool holder with the boring bar.

finished spindle head

this is a shot of the shaper cutting a flat surface on the mandrel for the face mill which will be cast on this 5/8" dia shaft. The flat area will index in the set screws on the spindle head.

 

[Norman]

I'm still making parts for the mill made a fly cutter a while back and today I started making a right angle plate pattern for the mill. I'll shoot some pictures of it soon.
I'm getting close to finishing building the mill only a few more parts to make.
I will then need to build a stand for the mill and shaper probably make it out of angle iron and portable if possible so I can roll it around.

 

[Norman]

I finished the metal mill last night!!!!! I do have one more hand wheel to cast
but all the rest of the mill is done.
I hope to cast the hand wheel today and machine it. Now its done I plan on making some goodies for it and changing a few things. I'm looking at making a power feed for the table hand cranking the cross table will wear you out.

Luckily I didn't break a single tap or drill bit building the shaper or mill.
I did beak some home made mill bits and did some bubo's building the mill
but they can, or were remelted so no one will ever know.
Here is the mill.
first 2 photos is the mill with the tail stand missing it's hand wheel. you can see the right angle plate installed on the permanent table.

this is the permanent table base being milled. It will replace the 1/2" square key stock base that is being used used as a table. The first 2 photos show the permanent table in use.

the tail stand is designed for support for an over head boring tool or for off set machining.

Now that the mill is done I still have things to make like a 4 jaw chuck and a dividing head so more patterns to make, casting to machine, scrap aluminum to gather up and melt. Lot of stuff still to make.
Norman

My lap top crashed about a month ago Ilikeabikea repaired my lap top a few days ago so I'm back in business with messing on the net. So a big thanks to Bob !!!
Norman

 

[Norman]

I used the mill and shaper to fix the sears lathe broken gear here's the photos
cast blanks

building the gear cutting stand

milling the gear using my home made mill

the finished gear

It works fine got my sears lathe back up and running. If I could of bought that gear it was priced at $300.00 it came as a gear machined to a pulley.
I cut off the damaged gear on my pulley machined the gear and now its held on the pulley with bolts that is the reason for the shoulder on the gear.
Guys making and building your own tools is priceless!!!

 

[Thud]

Thats fantastic Norm.
you are in the top 1% of guys who build these machines & actuly use them. (not that building them isn't a good project in itself)
Is that the original gear being used for indexing?
Oh & did you gring your own tooth profile single point cutter? or is that a comercial involute cutter. (you know wich way i am rooting LOL)

I just picked up some propane for firing up my foundry soon I have a few patterns that need to be poured. (custom motor mounts & such)
keep up the great work.
T

 

[Norman]

yes that is the original gear, minus a few teeth. I cut it off of the pulley. I had to get that gear off. the pulley and gear were cast as one piece. That pulley/gear was over $300.00 I almost bought it but held off and when I did try to buy one the lathe shop didn't stock them anymore and I looked all over for one. So I took the $300.00 and started to build the machines to make the gear.
I have probably $400.00 total cost for all the machines mill/shaper/foundry so I think I got a good deal plus I learned a bunch.
I did make the involute tooth cutter.
I'm making another gear so I will have a spare in case the first one tears up.
Now that I've made the mill ,shaper and foundry I know they work good I plan on making more things, what I plan on making I'm not sure but I do plan to give a cylinder head a try and some side covers for the china engine, customized a little may even be able to make a cover that will quiet down the noisy gears. I really think a guy could make a complete engine.
I'm having a lot of fun!!!
Norman

 

[Thud]

Norm said: I really think a guy could make a complete engine.

Do you notice that you look at everything differently now & say to yourself, I could make that.

you can make ANYTHING now Norm. truth be told I have been looking for some old cast iron pipe that could be re-pourposed in making a cylinder sleeve. Once you have some decent core making capacity, your imagination is your only restraint (after time that is LOL)
A head would be a nice project.

Kudos on your progress & keep us posted on your exploits.
I will show some more of my projects in an upcoming build thread.

*****hey look for some steel pipe that would work as well, machine the id. and the od. to the size you need. I've always thought hey I could make that if I had the tools, now I do have a start at the tools.
Norman

 

[Elmo]

Great thread Norm. I have drooled over Gingery machine books and never had the time. I think you have inspired me to start now that I am semi retired. Very good work that you have done.





Elmo
This is the reason for posting on metal casting I hoped to get all you guys inspired to give it a try
you never know what you can do until you give it a try. Most people fix a problem by throwing money at the problem, if you don't have the money,and if you want to change or fix things use your hands and brain, with a little imagination and determination you can do it.
Be prepared to enter the world of being a sand crab once you start making and pouring metal it becomes an addiction but it is a good one, you can even make your better half some really cool things. Plus girls also can get into pouring metal and making the molds etc. One forum I looked at the lady is the master sand crab , she makes some really nice stuff.
Norman

 

[Norman]

I started building the dividing head that is in book 6 of the Dave Gingery's series on building your metal shop from scrap.
So far I've made all the patterns except the dividing wheel disc. I've done the castings for the dividing head frame and have them machined and the bearing are in place on the frames.
I ordered the worm and worm wheel from Mc Master Carr it has a 40 to 1 ratio they are the correct size etc. The plans say they cost about $30.00 including shipping. That was in 1982, boy have they increased in price, close to $100.00 for both.
I'll start casting the rest of the parts soon plus machine the small steel parts that go into the dividing head. I haven't taken any photos, just been lazy about doing that.
If your wondering what this dividing head is for Google "dividing head" then you will know that this thing is for.You will be surprised at what these cost if you are looking to buy one.
Well that's all for now.

 

[Elmo]

Norm watching your thread has cost me 60 something dollars now and who knows how much down the road. I ordered the diy machine shop package from Gingery and it should be in this week. Also I am building a shop again. I have found that the shop with the sky for a roof and the earth for a floor really puts a cramp in making things. I started to buy these books in 2009 but things got in the way. Thanks for this thread and rekindling my interest in this stuff. I have really enjoyed following your progress.

 

[Norman]

Elmo
I bought books 2,3,4,and 6. I will not be building the lathe as I've got 3 lathe now. The first book might be important if you want to build the foundry. I just looked on the net for the info for the green sand and for building a furnace.
Then I set off on using some of the info and my own ideas for building the foundry etc.
I really wanted a metal mill but didn't want to spend the money for one, what you get for the price paid plus the expense for the tooling used on the mill is or can be more expensive than the mill's price. Building your own mill is very inexpensive, you don't have to buy replacement parts if you happen to break it just cast a new part. You can make any tool needed for the mill.
The cold rolled steel will cost around $300.00 to build both the shaper and mill
nuts and bolts around $40.00. If you scrounge the motors that will help keep the price down. Washing machine motors work very well. 1/3 hp at 1725 rpm is what you will want higher hp won't hurt a thing. pulleys can be cast to help keep that expense down. Bearings, if you buy what Dave Gingery specs. for these machine they are not to costly one pillow block bearing is around $12.00. The sleeve bronze bushings are all around $2.50 to $5.00. If you can find used roller bearings that will work too. If you have a metal lathe you will be in business right off if not then either build the lathe or buy one. You will want one that will swing at least 7" dia.
I hope you have fun doing this cause I sure have.

 

[Thud]

Hey Guy's
here is a forum I belong to that is all about the foundry hobby & building theses type of machines. It was my 1st foray into internet idea exchange. its a good site full of friendly helpfull people. Just like here.
BackyardMetalcasting.com - Lionel's Laboratory :: Index
I post there as "Todd"

 

[Norman]

Thud, I go there but haven't joined.
there is a new forum "projects in metal" this forum is new and very friendly people.
here is the start of the dividing head
this is the front of the dividing head there is 3 casting to make the frame of the dividing head. there are 2 bushing 5/8" id by 3/4" od. one bushing on each frame half.

this is the back side of the frame you can see the small foot at the top this is for mounting the dividing head vertical on a mill or drill press.

here is the patterns only one more pattern to make. The last one to make will be the indexing plate. I will need to cast at least 3 plates or more, the plate will be 5" dia. by 3/8" thick not too tough to make I'll either cut the pattern on my dremel table saw or cut a blank and turn it on the lathe.

The worm and worm wheel is on it's way from Georgia should be here by the end of this week and wouldn't you know it its supposed to snow Fri. today we had temps in the 70's. I haven't started to machine all the steel parts yet but they should go quickly as none are very hard to do.
Once this dividing head is made I'll be able to make gears or even a bikes wheel hub and be able to get the spoke holes drilled accurately. This even could be used to make a sprocket.

 

[Thud]

Wow, you are definatly on a Mision there Norm.
I have access to some nice cnc equipment & am really spoiled in that regard. But i did make a few Patterns up to cast. some custome frame clamps & motor mounts for a few projects I have brewing. I post some photo's in a future buld thread.
keep up the good work & keep us posted.