POTD- PROJECT OF THE DAY: What Did You Make In Your Shop Today?

[BGHansen]

Bruce is the man!

Thanks but as I was fond of saying at my former workplace, "If your expectations are low enough, you'll never be disappointed ". I make tons of mistakes and still have lots to learn. You should see some of my attempts at metal spinning.

Bruce

 

[Eyerelief]

Had a interesting little job Sunday. One of my neighbors came over with a jet ski exhaust manifold that was leaking. For clarification, jet skis have a water jacket around the exhaust manifold that circulates water from whatever source the jet ski is floating in.
This was off of a '96 model SeeDoo. It had what resembled freeze plugs welded into unused ports, 4 of them total. These plugs were aluminum, very thin. This one was corroded through. The goal was to try and weld in a new plug.

Getting a grip on it was the hardest part. With no flat surface and not wanting to mar the paint, it was kind a like trying to clamp down a greased bowling ball.

I started by sneaking a 3/8" end mill into the corroded areas to see what I was up against.


The opposite wall was only .200 away! Good thing I went slow. Drilled out the old plug with a 1.25" end mill and machined the top to "reasonably" flat. I removed as little material as possible to give me lots of casting to absorb heat and to stick to. Turned a plug out of 1.5" 6061round bar I had laying around.


After wire wheeling off the nearby paint I "tig'd" (probably not a word) the new plug on.

Now its ready for paint. I don't paint. I hate to paint anything. From the condition of the plug that I took out, I may have three more to do before the summer is out. This could be a problem as I only have so much room in the fridge and he brings over lots of beer when he comes.
My wife says there is a message in his action somewhere...........................

 

[Janderso]

Thanks but as I was fond of saying at my former workplace, "If your expectations are low enough, you'll never be disappointed ". I make tons of mistakes and still have lots to learn. You should see some of my attempts at metal spinning.

Bruce

You should see some of my attempts at making springs on the lathe. The smaller wire comes out great!!

 

[woodchucker]

Almost finished (well, that's a stretch, nothing is ever done in a shop)... installing the VFD.
I used some old switches, and drilled the housing and installed a potentiometer for speed control.
I moved the switch to the belt guard, now I can easily reach without having to reach around things. I had a piece of Steel that came from something else, so I mounted it, and am leaving it full size. I plan to add a jog button later, and a RPM display. I am really happy with the switch position. I also like push buttons (old style) over the touch pad. I found the touch pad didn't always respond to my touch, and these switches do. Power tapping should be easy now. Just gotta build a wire loom holder for the wire. I mounted the vfd up and out of the way. So my only worry is heat up high, but chips should stay out of it.
Then back to finishing the brake on the lathe.. And reconfiguring the spray coolant system. Glad I listened to @rabler and went with 2hp. I can't see this bogging down, when set to low speeds. I think the belt will be the weak point (slipping). I have only used it to test it, but it took a large cut and didn't complain. I think that is much better than before, but it's hard to gauge. Time will tell. I also ordered the extension cable and housing for the touchpad. I figured for $12, buy it now, it might not be available later. If I decide I can use it to program comfortably instead of up on a step stool. Right now it's all programmed for my needs, but adding a jog and other features. This thing can do quite a lot with multi speed settings and times. I think you can make it tap on it's own if you wanted.

 

[Gaffer]

Thanks but as I was fond of saying at my former workplace, "If your expectations are low enough, you'll never be disappointed ". I make tons of mistakes and still have lots to learn. You should see some of my attempts at metal spinning.

Bruce

Your chronology, photos and descriptions in you projects postings are second to none. I always enjoy and look forward to them and I always learn from them. Thanks!

 

[woodchucker]

oops misplaced

 

[AGCB97]

When looking through a file folder on the computer "tools to make" I ran across a picture from an old post from this forum that I had saved. It showed a device for keeping the movable jaw on the band saw straight when clamping short pieces of stock. The Johnson is built slightly different that the pictured one, but a slight modification made it work really well. So, thanks to the person that posted that picture. Here's the one I made.
Aaron

 

[mksj]

Wanted to tweak my knurling skills, so decided to turn/knurl a center punch. Typically I would knurl in one or two passes, but in steel it was always a bit difficult to get the full diamond point. I started out with some 0.5" 01 drill rod and cut it down to 0.45" on either side of the knurl section, then took several slow back and forth knurling passes at 140 RPM, increasing the scissor pressure on each pass. About 5 slow passes and achieved nice full knurls. Will heat treat next.

 

[Inferno]

Wanted to tweak my knurling skills, so decided to turn/knurl a center punch. Typically I would knurl in one or two passes, but in steel it was always a bit difficult to get the full diamond point. I started out with some 0.5" 01 drill rod and cut it down to 0.45" on either side of the knurl section, then took several slow back and forth knurling passes at 140 RPM, increasing the scissor pressure on each pass. About 5 slow passes and achieved nice full knurls. Will heat treat next.
View attachment 443595
View attachment 443599

It's been a while since I did any knurling. I always enjoyed it though.
That punch looks great.

 

[GoceKU]

Yesterday i got a call from my brother, the diesel octavia is at a mechanic to get a new EGR but he seems to blow up the engine. In the last year my brother sunk lots of money in this car full paintjob, new lights, new brakes, suspension, and about 2 years ago i change the engine with a very low mileage one also it got a new turbocharger closely after that. So i went there with my little niva, the guy changed the egr valve and changed the vacum line from the vacuum pump to the booster then decided to take it for a test drive. Drove it up a hill and by his description the engine run away (diesel runaway). He managed to get it shut down in gear but from the marks and the tire, he was doing a one wheel burnout for 1/4 mile and on the other side there was a black stripe from the exhaust. I took the pipe from the intercooler off and about a liter of black engine oil come out. Check the engine oil there was non, so he added old oil and we fire it up it was smoking and knocking the knok changed sound with pressing the clutch, i took it for a test drive it was definitely hurt. Left there, talk to my brother and went back and tow it home because when it cool down it would even start. From paste existence sounds like a bent connecting rod, i immediately got to work took the oil pan off there i could see at least one conrods was sideways. But before buying parts i decided to get the conrods out so i can mesure them. I work all night but wasn't able to lift the head with the turbo by myself so i waited till today to get help with lifting it. Oh man what i've seen one piston is 5-6mm under the deck two centre pistons are melted, melted down to the piston rings. All 4 connecting rods are bent one is very bent. Crank looks Ok but the cylinder bores are scored, one gruve catches my finger nail deeply. This engine has a completely melt down, at this point i know it will need a complete new engine again, no way i'll trust any part of that engine. Now come time to who is going to pay for a new engine and turbocharger. The mechanic straight out said if you want any money you need to sue me, having dealt with people i made few phone calls and found out few people are already suing him but he has nothing in his name so no one can collect. This car may have to seat for a while i already have the abundant 12 valve to work on and about 12 more that constantly break down.