Overarm adapter - 2.375" to 3.5" - trepanning?

tekym

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I have a Van Norman #12 mill and a Bridgeport M head that I'd like to make work together, so that I can add a quill to the VN for easy drilling and boring. I have a mount for the M head that clamps onto a 3.5" diameter overarm bar, and is 5" deep. The VN12 overarm bar is 2.375" diameter. I have a chunk of 3.5" solid rod, and I want to ideally not bore out that center material, but to trepan it out, or use an annular cutter, or something that will separate the center from the outer tube while leaving a usable chunk of material behind (>2" is totally usable for me). My thought is to somehow attach a small HSS cutter onto a section of tube approximately 2.5" or so diameter, and use that to trepan the material, then do the final boring to size after. I have a lathe, but no experience in this sort of thing.

Is there anyone who's done something like this? I see that annular cutters with a cutting depth of at least 2.5" (half of the 5" piece size, just flipped end for end) are extremely expensive, and I don't know if this trepanning idea is workable at that depth either. Looking for ideas just as much as I am someone to maybe do the job for me.
 
I don’t have experience doing this with metal, hav ended up with some wooden plugs left by hole saws though as I’m sure many have.

Are you trying to do this just to save the material, or is there another reason? Maybe some thick walled tubing would work?

If you do end up boring the piece and end up with a pile of chips at least it sounds like a worthy use for it.

John
 
Just trying to save the material. Like I said, I've got a lathe, so if I have to I can just spend several hours drilling and boring out 2 3/8" worth of material, but that's a lot of unnecessary chips if there's a way to save the core for future use in another project.

I've tried to find some thick walled tubing that'd work, but haven't found anything that costs less than about $200, which is more than I want to spend on what is ultimately a very simple part.
 
A couple of issues occur to me.
First, an annular cutter is the way to go if you must save the core. However, that reminds me of a favored saying of college. If he thought one was on the wrong track, he would accuse them of looking up a dead dogs arse and would tell them "Stop that. There's nothing up there that you can use" :grin:
The point is, compare the cost of purchasing a 5" long x core diameter bar of the same material and compare that cost to any save-the-core option. If I had a 2.25 diameter x 2.5" deep annular cutter I (a hobby machinist) would probably charge you more to do the work than the core is worth. Of course, I'm assuming your "solid rod" is not gold or other precious metal and disregarding any "save the Earth" motivation. Recycle the swarf.

Trepanning (single cutter), in general, is a special skill and in the dimensions you mention, it's quite unreasonable, IMO.

Another option is to search out a 2.25 diameter hole saw that can cut 2.5" deep. Hole saws are commonly available as Bi-Metal construction with hardened teeth or even carbide teeth. I suspect such a hole saw (+arbor) could be found for $50-$60. Still probably more cost than the core is worth, but maybe you already have a suitable arbor (and a hole saw?). The problem with hole saws, in general is that you have to FREQUENTLY withdraw them from the material to flush and clear the cuttings. But, rig-up an attachment for your cordless drill to spin the hand wheel on your tailstock so you might be able to get the hole through while avoiding physical and/or psychological therapy. Keep the cut wet to keep the teeth cool. It sound like a mind numbing job, but that's why it's just a hobby.

You didn't mention the size/power/model of your lathe or how large a twist drill you have available. If you have sequence of twist drills up to 2.25" diameter, that would be the cheapest, quickest way to rough out the hole. If you don't have the big twist drills or your lathe doesn't have the power/rigidity needed to use them, then we're back at a mind numbing task of boring a lot of stock, but it can be done.

If you still need to save the core, wire EDM is the way to go. Not usually thought of as an inexpensive process, however the core will be saved, to the max, and the hole will be to finished diameter (no boring required). Do you have a friend with wire EDM?

My recommendation is to save that precious "solid rod" for a yet-to-be-defined future project and get a piece of aluminum, like this, to work with. The sleeve will be used in compression, so aluminum will be perfectly satisfactory and much easier to machine (I assume).

Regardless of the sleeve material, the much smaller over arm (2.375" vs 3.5") may result in a significant reduction in the rigidity of the M head mounting. My concern is hypothetical because I don't know how cantilevered the M head will be on the Van Norman. If the finish produced by the M head turns out to be unsatisfactory, take a look at adding some additional struts or ??? to stiffen the M head mounting.

If your lathe is up to the work, get a piece of aluminum and make chips. :grin:

You're right next to Baltimore? It should be pretty easy to find a piece of aluminum. Go to a few local machine shops and ask if they have a drop that they can part with. You should now know how much it's worth to you. Ask if they have wire EDM and how much $$$ (Ouch!)?
 
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ou're right next to Baltimore? It should be pretty easy to find a piece of aluminum.
Did the OP say what his material is ? I can check my scrap box as he's close to me . No way I would trepan this to save a 2" piece of stock . Time is $$$ . :)
 
Not when it's for a hobby, $$$ is less food on the table with the impending price increases coming.
I agree . I'm saying I wouldn't waste 4 hrs of my time to save a $2 slug of aluminum . Blow a hole thru it with a spade drill and bore it . He has the machines to this .
 
@extropic spelled it out, I would just say NO!

You may get an education and some broken tools by attempting to trepan those chunks, but you will not get usable pieces of material.
 
I agree . I'm saying I wouldn't waste 4 hrs of my time on a $2 slug of aluminum . Blow a hole thru it with a spade drill and bore it . He has the machines to this .
$2, You have to go on ebay and see what a 5" slug of 2" stock is going for.
Or online metals, or metal supermarkets, or mcmaster
 
$2, You have to go on ebay and see what a 5" slug of 2" stock is going for.
Or online metals, or metal supermarkets, or mcmaster

Free shipping on this for 3 1/2" . 2" may be $10 . Either or , is this worth your time trepanning it ? Not to me ! :grin:
 
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