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My Next Project - A Metal Brake
- Thread starter Mark_f
- Start date
I feel like I really made progress today. I got the bending leaf fit up and it works just like it should! I cut out the handles according to the prints ..... more or less.
I rounded the ends on the belt sander as I have done with other parts. I then milled the basic shape. I feel this handle design is a little lacking, so I am making handle extensions to extend the length of the handles by about 6 inches.
the handle extensions are made from an 8" length of 1" square bar stock. I turn down 5.500" of the bar to .875" diameter.
This is the finished handle extension with a fancy grip ( that matches the ones on the clamp handles)
I test fit the bending leaf and everything lined up and fit good ( I so happy 
). I am really impressed with the 2 1/4" high bending leaf. I feel this will work better than the 1/2" as in the prints, but we shall see when the testing begins.
This is a view of the bending leaf in the up position.
This is a test fit of the handle extension. There will be one on each side. This will make bending much easier with my old arthritic hands.
The steel for the fingers will be here tomorrow. I need a way to mill a lot of repeat angles on the ends so I am making a tilt table to put on my mill. it will make this job much easier. I am just going to make a rough version of the tilt table to use for this project and then I will dress it up and make it nice later. I will post the table here as soon as it is welded up.
I rounded the ends on the belt sander as I have done with other parts. I then milled the basic shape. I feel this handle design is a little lacking, so I am making handle extensions to extend the length of the handles by about 6 inches. the handle extensions are made from an 8" length of 1" square bar stock. I turn down 5.500" of the bar to .875" diameter. This is the finished handle extension with a fancy grip ( that matches the ones on the clamp handles) I test fit the bending leaf and everything lined up and fit good ( I so happy ). I am really impressed with the 2 1/4" high bending leaf. I feel this will work better than the 1/2" as in the prints, but we shall see when the testing begins. This is a view of the bending leaf in the up position. This is a test fit of the handle extension. There will be one on each side. This will make bending much easier with my old arthritic hands.The steel for the fingers will be here tomorrow. I need a way to mill a lot of repeat angles on the ends so I am making a tilt table to put on my mill. it will make this job much easier. I am just going to make a rough version of the tilt table to use for this project and then I will dress it up and make it nice later. I will post the table here as soon as it is welded up.
Today I finished making the handle extensions for the brake. I just have to drill and bolt them on.
I had to take a couple hours to start on the tilt table I need to mill the angles on the fingers. I need a good solid set up that will be easy for repeatability because there is a lot of milling and drilling on the fingers. I found some scraps of steel , sawed them up to size, did a little milling and I got a good start on it.
I made two pivot blocks, reamed them for a 5/8" piece of drill rod. I found two scraps of heavy angle iron, I milled square and reamed holes for the drill rod.
I used SHCS to bolt the table made from a scrap of 1/2" plate to the pivot blocks.
I can clamp the "wings" to my mill table. I will make a couple "locks" for the ends of the drill rod to lock it in position. The front will set on a machinist's jack to hold it up. I will "pretty" it up into a precision piece later after I'm done with the brake. That will be another project.
The last few weeks have been really busy. I am working on a lot of things at the same time. I started building the metal brake and am building the tilt table because I need it for the brake fingers. I am also building a 2" X 42" belt sander. A hobby machinist friend of mine wants to make one so we are sharing materials and skills to make one for each of us. I am doing a complete build write up on it also and will post it here when finished. I am also building another tool and cutter grinder as I get the materials and I just got a batch of aluminum I needed for it so I will be getting back to that as soon as the brake is complete. I started making a fence for the drill press today also. It will make drilling the 22 holes in the finger bar for the brake a lot easier. So.......
I am very busy as of late. I am feeling pretty good so I want to get things done before my next surgery as it will lay me up a few weeks 
. I just have to be careful not to get too worn down
. It has been some time since I could have this much fun .
I had to take a couple hours to start on the tilt table I need to mill the angles on the fingers. I need a good solid set up that will be easy for repeatability because there is a lot of milling and drilling on the fingers. I found some scraps of steel , sawed them up to size, did a little milling and I got a good start on it.
I made two pivot blocks, reamed them for a 5/8" piece of drill rod. I found two scraps of heavy angle iron, I milled square and reamed holes for the drill rod. I used SHCS to bolt the table made from a scrap of 1/2" plate to the pivot blocks. I can clamp the "wings" to my mill table. I will make a couple "locks" for the ends of the drill rod to lock it in position. The front will set on a machinist's jack to hold it up. I will "pretty" it up into a precision piece later after I'm done with the brake. That will be another project.The last few weeks have been really busy. I am working on a lot of things at the same time. I started building the metal brake and am building the tilt table because I need it for the brake fingers. I am also building a 2" X 42" belt sander. A hobby machinist friend of mine wants to make one so we are sharing materials and skills to make one for each of us. I am doing a complete build write up on it also and will post it here when finished. I am also building another tool and cutter grinder as I get the materials and I just got a batch of aluminum I needed for it so I will be getting back to that as soon as the brake is complete. I started making a fence for the drill press today also. It will make drilling the 22 holes in the finger bar for the brake a lot easier. So.......
I am very busy as of late. I am feeling pretty good so I want to get things done before my next surgery as it will lay me up a few weeks . I just have to be careful not to get too worn down. It has been some time since I could have this much fun .
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- Joined
- Sep 2, 2013
- Messages
- 5,440
You da man Mark. If you get all that done by the end of April I could really use someone with your abilities and work ethic out at my place to help me get caught up. Just kidding, kinda. You never fail to amaze and inspire me, and I'm sure many others here. Best of luck on your next medical adventure. Mike
WHAT???????? This stuff will all be done before the end of February
(with the exception of the cutter grinder. it is a slow going as I find materials).
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- Joined
- Apr 21, 2015
- Messages
- 894
Forgive my skepticism, but I question your stories about these builds. I'm starting to think you have some sort of molecular-level telekinetic control of the metal.
It's the speed at which you accomplish all of this that makes it seem suspicious.
However you're doing it, don't stop. I'm learning a lot. 
It's the speed at which you accomplish all of this that makes it seem suspicious.
However you're doing it, don't stop. I'm learning a lot. YOU ARE MORE THAN WELCOME TO COME AND WATCH.Forgive my skepticism, but I question your stories about these builds. I'm starting to think you have some sort of molecular-level telekinetic control of the metal.
It's the speed at which you accomplish all of this that makes it seem suspicious.
And so is anyone else
B
Bill Gruby
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He was just funning with ya Mark.
"Billy G"
"Billy G"
I'm not laughing