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

Been in the basement all day . Sorting and separating things . Got the UC fired up with 50 or so end mills cooking the Kroil off them . Interested party is looking at large end mills .
Don’t forget your severely injured friend who needs something to look forward to during his prolonged recovery from major surgery scheduled for this week.
 
In line with what I posted a few days ago, now that I have cut my 25 pieces of 13"-long square tubes, I need to notch each end of them. So, I reconfigured the 4x6 saw for vertical operation, and clamped a fence along one side to guide the workpieces into the blade. But I wanted these cuts to be at a good right angle to the workpiece, and the crappy stamped table that came with the saw has a miter slot. The slot is the wrong size for every miter gauge I own, and I own a bunch. Rather than buy something, I thought, "I have a mill!"

So, I took a scrap piece of hex stock and machined it into a 6" bar .590" (15mm) x .235" (6mm), just narrow enough not to bind in the slot, but wide enough to minimize slop. Great precision was not needed, but mill practice was, so I tried to get it within a thou. That let me play with a 5/8" end mill and a 2-1/2" insert facing mill that uses five square inserts. I had to index the inserts to find five good corners, but I didn't have to dip into the new sets of inserts I had just bought for it. The end mill cuts were accurate but not as pretty as the face mill--that produced a beautiful machined finish.

Not sure I was totally within a thou but I got pretty close. It was the first real thing I've made with rather than for the new Bridgeport, and fully complies with what I consider to be the Second Law of Hobby Machining: Squaring up stock is the first thing we learn but the last thing we really perfect.

I then drilled holes and power-tapped M5 threads to attach the angle I'm using for the miter fence to the slot bar.

No pics but I'll add something tonight.

Rick "making chips for the sake of making chips" Denney
 
Hello folks,

Here I am at the library again and printing what I hope is the final product. This time with chamfered edges:

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While the printer is at it, I picked up some quality literature (Koneistustekniikat by Keijo Maaranen) to educate myself:

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I already went through the above scenario in my head. Pillar drill casts hair removal and I counter the attack with male pattern baldness. I win :grin:
Ta-dah!

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Now all there is left to do, is to print and drill a few more of these :grin:
 

No pics but I'll add something tonight.

As promised. Again, nothing special here—just the ability to make what’s needed and keep working and not have to wait to buy something.

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Rick “yup, the angle is left over from the DRO kit for the lathe” Denney
 
Don’t forget your severely injured friend who needs something to look forward to during his prolonged recovery from major surgery scheduled for this week.
Your shoulder right? My brother had both shoulder joints replaced, not fun.
 
Your shoulder right? My brother had both shoulder joints replaced, not fun.
Shoulder left (sorry, couldn’t resist :) ): total reverse replacement - my sister keeps asking if it will kake it easier for me to scratch my back; she’s 8 years older and starting to go.
 
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