Electrical box cover - 3D printing makes it easy Just a simple projecting showing how handy 3D printing can be. I bet lots of guys are thinking "what would I ever use one for" whereas after having one its like what a pain it would be not having one.I had a cheapo amazon DC controller and wanted to recycle an enclosure I had I printed it in two pieces that were then bolted together. This is only because ideally you want to print stuff with a complete…

The easy way to make PTFE gaskets for model engines Making gaskets for the Triple Expansion Engine seem like a big job, given their number and how holes there were.The solution that worked out really well was to print templates, attach them to the PTFE temporarily with CA glue, punch holes using a leather hole punch then trim the finished gasket with a razor knife.Key to it is that the CA glue sticks slightly to the paper template with currying but after awhile detaches and leaves the…

Add Your Heading Text Here I finaly had some success with lost resin investment casting. This is like lost wax investment casting, however the pattern instead of being was is a special castable 3D printing resin.Been at it for 2 years, each attempt takes so much time and there as so many variables; what resin, what printer exposure settings, what curring process, what metal, what burnout, what investment, what mixture etc etc. Very tedious and lots of blind alleys. But on the weekend, success!The main subject is…

Under bench roll out carts Another project crossed off the list. My shop is split between garage and basement and most of the basement is small stuff where you sit at bench. Forever out of space, I had an idea of making small carts on casters. They sit in unused space under the bench and easily roll out for access. There is one as a file rack (with 3D printed file holders), one for a tool box (holding various unimat and watch lathe accessories) and another for…

20mm Table Saw Arbor In the last year I've added some wood working capability to the shop.  Have a very small area, I ended going with Inca tools and have their table saw, bandsaw and jointer planer. They are small, but Swiss made so of good quality. A challenge is that the arbor is 20mm which (at 10" dia) are impossible to find in Canada so I figured I'd buy some good quality blades and bore them out Freud rant: I need the other Freud, Sigmund First…

Changing the Bearings on an Inca Table Saw Having filled about every bit of space with metal working machines, there was nothing left over for woodworking.  Eventually however, moving the laundry to the second floor freed up a basement room (With kids gone, there were too many empty bedrooms upstairs!)The old laundry room isn't large but if I was going to do working, it had to be working from rough; i.e. table saw, jointer, planer and bandsaw were required as well as a bench.I pine for a…

3D Resin Printer Workstation Resin printing can be messy and the materials are smelly and somewhat hazardous.  Ventilation Unfortunately (because it can be the most difficult aspect to satisfy) working with the resins requires ventilation.  Its stinky, and you are not suppose to breath the fumes.The solution for me was to use a former dry vent (as the kids moved out, I eventually moved the laundry upstairs.  The unit is inexpensive and comes with a fan a light.I welded up some L brackets and used tapcretes to…

A New Crystal for a Dial Indicator A how to video on making a new crystal for a dial indicator or watch.I usually just buy watchmakers crystals for a few dollars from ebay, but they are not available in sizes this large. I ended up making a rotating tail stock pressure plate that worked well, more effort than the indicator warranted but hopefully it sees additional use.This video should be 5 minutes but somehow I drone on for almost 17. And that's with a lot left on…

Threaded Back Plates I recently made some back plates to fit a three and four jaw Burnerd chucks for the Habegger 102.Here a few shots - a more detailed description of the process appears here:   Back Plates - Detailed Description

Crystal Replace for a Swiss Dial Test Indicator Girod indicators are as nice as it gets, every bit the equal of an Interapid.  This one works perfectly except has a badly damaged crystal.  Its a simple repair, although potentially needing some special tools The crystal and bezel on the Girod is a friction fit and just pry's off.  It took a fair bit of force and I was somewhat concerned about something giving way.   Eventually the bezel popped off and all was wellThe first step is to…

Lost Wax Casting from a 3D Printed Pattern My youngest, a Vet practicing in Scotland, was home for the holidays and was keen to try 3D printing.  Eons ago I'd bought all the equipment for investment or lost wax casting but had not got around to using it. This seemed like a great opportunity to do so!  He found a stylized sculpture of a canine, and being a vet, thought that might make a good desktop curiosity/paper weight so we set to work.Lots learned and a lot…

Lufkin Back Plunger Indicator Repair The smart move would have been to toss this puppy....but alas, as the saying goes, "for $50 more, you can fix it yourself.This indicator is fairly solid, but being honest is kind of low end construction.  There is no way I could discover to get to where the bottom jewel is.  It look like riveted constructionThe symptom was that the indicator was sticky and sluggish. The indicator comes apart easily enough.  The upper bezel holding the crystal is a friction fit.  With the…

the Versatility of the Alginment Tool I know, its rather unbecoming to toot ones own horn, however when an idea works out this well I just have to tell someone!The main 'foot' of the alignment differs greatly from the Kingway Alignment tool.  Its a 90 degree arrangement with two positions for the vertical post, 45 degrees apart.  In one position its ideally suited to straddling a V way, in the other it handles box ways More on the Alignment Tool The feet have brass pads so they…

Came complete with BS certificates You can't beat the price of these vises - $100 delivered.  However like so many low end offshore suppliers, the claims and test certificates are just complete BS.  I've been involved in manufacturing in these markets and its different than here; if a manufacture can fill in a bogus test sheet and get away with, that just A OK, so a lot of manufacturing works that way.  Test were done a pristine Starrett grade A inspection plate using a interapid 10ths indicator. The…

This is probably just some sort of psychological indulgence, but its fun, and I have concocted a rationalization.It takes up less space than leaving tools in their boxes, and makes everything quicker and easier to find.Trying to get away junk drawers and have good visibility on my tools.  That and get rid of duplicates.Lots more to be added....printer is running 24/7!

As recently posted, I had this badly broken and bent part for the long case clock needing repair.  This rod connects the pendulum to the escapement the crucial bit that allows for the conversion of the pendulums period to meter rotary motionThe "steel" rod  is wrought iron which is different to work withThe process was:Bend everything straight using localized red heat so as to not fracturesilver solder the fracturing along the parts (three locations)join the two broken pieces via a silver soldered scarf jointEverything worked out well…

With a workshop, there seems no end to interesting adjuncts that can be done so quickly and easily with 3D printing....no printed figurines for this guy!Here are two projects....a drawing liner for my small squares and  drawer liners for carbide burrs.You don't want either of these things banging aroud as it damages them so 3d printing made a quick solution.  The tray for the squares has about 15 thou clearance so the items are easily removed and placed in the trayI've also started printing boxes that fit…

I'm working on a very nice mahogany English long case clock I'm dating as early 19th century, say 1815. I find when hands working on something, vs just observing it as an antique, the connection with the mechanism makes one think about the hands that created; what was life like then, what was making things like then?One thing we do know, the steel wasn't the same! Today's steel production benefits from lots of technological developments over the past 200 years.  I've seen this first hand, Metallurgy is advanced…

Miscellaneous boxes for electronics projects are an ongoing requirement.  They sometimes strike me as expensive but more importantly you can't get exactly what you want. 3D printing solves that.  Front panels come out with all the holes you need and overall its a big time saver.  Not the nested fasteners - print a hex recess and press the nut in for speedy assembly

Lots of fussy work here.  The cladding is .030 Al which is the right thickness to butt up against the steam chests. As there wasn't much width to drill into, and it seem the right call for aesthetics, I went with 0-80 fasteners.The Al was cut out by hand and with my Hegner saw.  Lots of needle filling to get a good fit around the steam flanges. The tedium is there is so much assembly/disassembly.  Starting from the end, I'd get one part fit properly, drill tap and fasten…

Finally! The VFD is installed and all the electrical controls work! The last bit was a modification to the Forward/Stop/Reverse switch.   To wire the VFD I need 3P 3T switch, which the OEM switch could do, however it needed a copper conductor spanning three contacts. I sawed a piece of copper from a small diameter tube so as to have the curved 'seat' for the contact.  This helps provide a solid position when the lever is moved to forward or reverse. It was a fidgety bit of…

Almost ready to run As great as the 10ee drives are,  mine arrived gutted.  All that was left was the two speed back, zip cut from the orginal DC Motor.  The solution is a 240V 5hp 3P motor mater with 2 speed back gear (topic of another story) powered by VFD. All power is wired with 10g and the machines orgial contols are used for On/Off, For/Stop/Rev and speed. Power into the VFD is turned on and off via a couple on contacts with a latch arrange…

Seemed like a bit of blasphemy, adding crappy  3D printed parts to one the icons of "make it as good as is possible" machine tools, however I think it is sound engineering; its out of sight, works and saved a ton of time.The task was to enable all of the machine's original controls with an installed VFD.The device holds a pot that is attached to a shaft via a set screw.  At the other end is  sprocket that is driven by the lathe's original chain mechanism. In the…

making a collet closing nut because of Pregraph's Poor Parts servers Parts availability BS...watch your back I had this U2 grinder, a Deckel clone.  Its no Deckel, but its a made in Tiawan version that is a lot better than the low end offshore clones.It came to me in package and the intent was always to sell it, but the collet closing nut was missing.  I contacted Heinman who contact Pregraph.   The manufacturing would even quote the part.  Unbelievably (at least to my old fashioned notions of…

How to store files?  racks, corrugated bits if cardboard, elastic in a binder, the holy board....best yet, 3D printed file trays.   The very strict file chaperone, never lets one file or rifler touch another.   I designed and made these stackable and trays for small files, they are the best storage yet that I've come up. I'll possibly make some STL files available if there is interest. Previous needle file storage methods included the proverbial wood block with holes (messy, takes up lots of counter space, doesn't…