A Couple Of These And A Couple Of Those..

[zapster]

I have to make a couple of these..
17946

And a couple of those..
17947

I'm gonna start with a couple of "Those"..
Here they are after the heads have been installed and welded..
17948

Weld..
1 Pass..
17949

Here is the bushing for the ends..
Hole in head needs to be 4.750 for it to fit..
17950

Next!

...zap!

[zapster]

Here are the end flanges that I need to make fit after I Blanchard ground them but that will have to wait...
17951

We start by boring out the head for the bushing to fit...
17952

More boring..
17953

Done boring..
17954

There is'nt much of the head left now is there? :laugh:

WoW!
Look at the clock..:dizzy:
2:45 PM and time to go home..

I'll continue with this in the A.M.
I get all the fun jobs..

See you then!

...zap!

[curb guy]

come on man ,don't make us wait:cry:

[Me!]

Hay Zap,
Machining question for ya....

Why do you put two "groves" in things when you turn them?
What does it do?

[Bikespot]

Looks simple enough so far.

:cool:

Not sure what those grooves are for.

[Shox Dr]

going home at 14.45, what time do you start 6?

In a perfect job I'd work 2-10 in winter and 6-2 in summer :drinkup: only problem is finding someone who prepaired to do the other shift :laugh:

[zapster]

going home at 14.45, what time do you start 6?

In a perfect job I'd work 2-10 in winter and 6-2 in summer :drinkup: only problem is finding someone who prepaired to do the other shift :laugh:

I usually punch in at 5:45 A.M.

...zap!

[brandon75173]

I usually punch in at 5:45 A.M.

...zap!

Yikes! Not me, I generally start as late as I can and work late. My mind and body seem to work better in the evening hours, I do envy you folks that get going so early. No prayer for me.

Brandon

[zapster]

Hay Zap,
Machining question for ya....

Why do you put two "groves" in things when you turn them?
What does it do?



What your looking at is the steady rest spots..
Tubing like that is not round by a long shot from the factory..

So you turn spots near the chuck after indicating it in as close as you can get it..
Do one side..
Flip it end for end and do the other..
Keep them both the same size so when you use the rest the tube will be inline end for end..

On this job after the heads were welded in there is no need for the rest anymore..
Its not a "tube" anymore and the "crush and distort" factor is eliminated..
Just indicate the chuck end in and then use your indicator and a rubber hammer to get the "far end" running true just like the chuck side..

...zap!

[zapster]

OK now continuing with "Those"
After boring for the bushings we need a step for the flange to mount on..
1/8" deep will suffice..
17974

Time to deal with the Flange..
17975

Flange step..
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Now that that's done we can assemble the unit..
First the weld in bushing..
You need to orientate the bushings in final assy but bushing #1 can go in anywhere..
17977

Weld close-up..
17978

Next!

...zap!

[zapster]

There is only one way to get down inside the tube to weld in the bushing..
The 'ol "Bent Tungestion" trick..
17979

Flange tacked..
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Welded..
17981

Weld..
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Now that the "busy" end of the assy is done to line up the end bushing you need to get the shaft and associated parts out..
17983

Next!

...zap!

[zapster]

Assemble the rear with the bushing first..
17984

Now screw the shaft bushing to the weld in bushing..
17985

Slide it over the shaft..
17986

Set the weld in bushing by tapping the screws with a rubber hammer untill the weld in bushing is seated..
17987

Dis-assemble and weld in the bushing..:D
Well..
I'll show you that tomorrow..

Thats all for today..
I get all the fun jobs..

...zap!

[semeehan17]

those welds are SEXY!!! you are the man zap, thanks for all the time and effort you put into these posts.

[Burnit]

Nice work Zap, what are these and those for?

[Me!]

I think this is the first post I have seen you use MIG in :laugh:

[zapster]

I think this is the first post I have seen you use MIG in :laugh:

:confused:

I don't have a Mig..
I know what you mean..

Sometimes its the material..in this case the flange..
Whatever no big deal..

Not done yet..


...zap!

[chopper5]

nicely done usual:drinkup:

[zapster]

OK..

Now to finish up "Those"...
Weld in the other end bushing..
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After cooling we use the same set up shaft for turning..
Just re assemble and put in the machine..
18024

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Turn to spec. and thats that!
18026


Now on to "These" next!

...zap!

[zapster]

Now "These" are pretty easy..
The heads are not recessed into the tube..
They are "Faced" after welding..
18027

Weld..
18028

Bored and faced..
Its also a good time to see how much porosity is in the weld..
None that I can see..:cool:
18029

Same thing here..
Weld in one end wherever and use the shaft and bushings to align the other end..
18030

18031

Next!

...zap!

[zapster]

End bushing lined up..
18035

Welded and ready for the lathe..
18036

Set up to turn..
18037

And done..
I'll put the key slot in after..

I get all the fun jobs..

...zap!

[zapster]

Damn!!!!
I have to name the pics better I guess..
Here is "These" all done..
18039


Way too many pics I suppose..:dizzy::dizzy:

...zap!

[tresi]

I usually punch in at 5:45 A.M.

...zap!

Great work but life before the crack of noon is highly over rated.

[Patriot Performance]

Well Zap I think that positioner has paid for itself a couple times over now.

Great work as always!

[Engloid]

Looks like a fun job to do.

I start work at 6am. I prefer to get work done as early as possible, so I can enjoy more of the day afterwards. I see 2 scenarios:

9-5:30 work- I sleep till 8, get off at 5, and have only 6.5 hrs till midnight.
6-2:30 work- I sleep till 5, get off work at 2:30, and have 9.5hrs to enjoy for myself.

So the difference is that I have 3 more hours to enjoy if I go to work earlier. I hate mornings, but I would rather work early and have more "life" to enjoy for myself, than to spend that time in the mornings sleeping and letting life pass me by.

[zapster]

Great work but life before the crack of noon is highly over rated.

Thats why I'm usually :sleeping::sleeping: on the couch at 8..
Or between periods of the Hockey game..:sleeping:

...zap!

[Burnit]

Nice work Zap, what are these and those for?


So, what are they for?

[gnm109]

That's a great thread, Mr. Zap! You are an inspiration! Thanks. :drinkup:

[zapster]

So, what are they for?

Guide rollers for more shingles..

We make alot of 'em..

...zap!

[stickkid]

Great work and incredible welds!

[Mandau]

There is only one way to get down inside the tube to weld in the bushing..
The 'ol "Bent Tungestion" trick..
17979



Great experience...:blob3:

[aczeller]

once again, as usual, absolutely remarkable work Zap. quick question tho... how do you get the bent tungsten? i have no clue, and have never seen it doe before now.

Later,
Andy

[zapster]

once again, as usual, absolutely remarkable work Zap. quick question tho... how do you get the bent tungsten? i have no clue, and have never seen it doe before now.

Later,
Andy

Sharpen to a fine point..
Crank the machine up..
Aim at a chunk of copper..
Wait untill the tip is Red hot..
Let off the pedal and gently sink the tip into the copper and push all in one motion..

Presto!

...zap!

[phila.renewal]

I see you still get all the fun jobs.

Nice work. :cool2:

[zapster]

I see you still get all the fun jobs.

Nice work. :cool2:

Whats up? :waving:
Long time no type!

...zap!

[phila.renewal]

Whats up? :waving:
Long time no type!

...zap!

Hey my friend. I'm glad you still remember me.

Not too much up. Just crazy busy. A project I was involved in for the past three years (a tiny little rehab with enough city red tape to stretch from philly to boston) started to "converge" and it's now (almost) done. I ordered some castings today that will become basement window grates (with a little fab and welding; yes! -- I hope it's a fun job) so I was thinking of you guys and thought I'd better get away from the job to check in.

Hope all is well here. Looks like everyone is good.

We needed a stained glass transom and I was going to get in touch with you (IIRC, your better half does some nice custom work), but as the scheduling worked out, just couldn't make it happen (went from "need it soon" to "need it yesterday" in a blink). Maybe next time.

Like a bad penny, I'll keep turning up. :waving:

[David R]

Zap, your welds are gorgeous as usual.

The one does look a little like mig.

Hmmmm Tig like MIG. :laugh:

David :)