ࡱ > 7 @6 bjbjUU O 7| 7| @2 l ( , d ( ( L V i i i ' ' ' ' ' ' ' $ ( * 0 ' i i i i ' ' i ' i ' W% W% @ q #( c W% W% D ' 0 ( W% "+ u "+ W% ( ( INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\images\\hmsc_logo.gif" \* MERGEFORMATINET INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\images\\lathe.gif" \* MERGEFORMATINET Volume 7, No 7 -July, 2002 President - HYPERLINK "mailto:tobadog@swbell.net" Tom MooreVice President - HYPERLINK "mailto:cwest@bcm.tmc.edu " Chuck WestTreasurer - HYPERLINK "mailto:jwperfect@aol.com" John HoffSecretary - HYPERLINK "mailto:jmscott@pernet.net" J HYPERLINK "mailto:jmscott@pernet.net" oe ScottWebmaster -Founder - HYPERLINK "mailto:webmaster@homemetalshopclub.org" Dick Kostelnicek HYPERLINK "mailto:Jgkor@aol.com" John KormanEditors - HYPERLINK "mailto:dwhittaker@pdq.net" David Whittaker HYPERLINK "mailto:JanRwl@AOL.COM" Jan Rowland SIG Coordinator - HYPERLINK "mailto:dlcranston@earthlink.net" Dennis CranstonMembership Information Membership is open to all those interested in machining metal and tinkering with machines. The purpose of the club is to provide a forum for the exchanging of ideas and information. This includes, to a large degree, education in the art of machine tools and practices. There is a severe shortage of written information that a beginning hobbyist can understand and use. This makes an organization such as this even more important. Business Meeting Minutes are sent via email or regular mail to club members. Regular Meeting 1:00 p.m., May 11, 2002 at Collier Library, 6200 Pinemont, Houston, Texas, President Dennis Cranston presiding. There were 32 attendees, including visitor Tom Wright. Nominations/elections were held for 2002/2003 officers. Results follow: President - Tom Moore (by acclimation) Vice-President:- Chuck WestTreasurer - John Hoff (voluntarysecond term)Secretary-Joe ScottWeb-Master - Dick Kostelnicek (voluntary second term)SIG Coordinator - (new position) Dennis Cranston volunteered to serve as temporary special interest group coordinator pending other people to lead theCNC. and Foundry groups. It was decided that each special interest group would provide a presentation for the coming year. Moving Charles Hilton is moving to Connecticut. We hope he continues sending in hisdues. Presentation Ball and ACME Screws as used in Home-Brew Machinery INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\rowland1.jpg" \* MERGEFORMATINET INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\rowland3.jpg" \* MERGEFORMATINET INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\rowland2.jpg" \* MERGEFORMATINET INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\rowland4.jpg" \* MERGEFORMATINET Jan Rowland, HMSC member, gave a slide show of some ingenious and impressive custom-built machinery that he fabricated in his homeshop. Some of his machines are at work in Great Britain. Nice to hear of exporting machinery for a change! Show and Tell INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\gladkowski.jpg" \* MERGEFORMATINET Ed Gladkowski demonstrated an indexing attachment that he designed and built for his lathe's spindle. It is based on the sine bar principle. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\hoff.jpg" \* MERGEFORMATINET John Hoff showed a nice 5-C collet chuck that he made for his lathe. He also showed a slide press for a work-in-progress custom fabrications machine he is building for forming aluminum rod into fiber optic luminaryholders. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\kostelnicek.jpg" \* MERGEFORMATINET Dick Kostelnicek broughta Parkercone gauge used to measure the diameter and cross section of O-rings. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\may.jpg" \* MERGEFORMATINET Alan May showed an inexpensive DRO. that used a plastic digital caliper mounted with super magnets salvaged from a hard drive. He also brought iron-on transfer film used in circuit board etching. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\chartier.jpg" \* MERGEFORMATINET Doug Chartier showed an all stainless flexible gooseneck mount he ebayed, and tailgate hinges with lock rods he is restoring for a 50's Woodie Buick Roadmaster. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\ethridge.jpg" \* MERGEFORMATINET Ray Ethridge showed a fine flywheel that he sand-cast and machined from his own home brew ZA-12 alloy, as well as pictures of the alloy ingredients and his homemade furnace in action. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\williams.jpg" \* MERGEFORMATINET Joe Williams showed a 5C collet adaptor for machining plastic rings for a honey do project, and a set of gear pitch gauges. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\pilcher.jpg" \* MERGEFORMATINET Richard Pilcher spoke on further adventures in replacing a gear on his lathe. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\volz.jpg" \* MERGEFORMATINET Art Volz showed a nomograph book for machine-fabrication from weldments, an antique Bridgeport C head cover, and another of his no weld creations- this one a chuck spinner made from a water faucet handle.Metal Casting Group We discussed Ray Etheridge's homemade ZA-12 alloying from junkyard zinc dicast, aluminum and copper. It looks like an economical way to get ZA-12. The group pour on July 6th at HYPERLINK "http://www.hals.org/map.html" \o "Map to Houston Area Live Steamers at Zube Park" Zube Park (HALS- the train place) was confirmed. We'll be casting some switch components for HYPERLINK "http://www.hals.org/" \o "Houston Area Live Steamers web site" HALS starting around 9:00 a.m. Everyone is invited to observe and comment. From out of the Past Bottom It has three non-swivel casters. What is it ? INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\mystery.jpg" \* MERGEFORMATINET Top Hint:Thinkwindowsticker! Fastener Puzzler by Dick Kostelnicek - HMSC Member Two plates are fastened together by a bolt, spring, washer, and nut. In both figuresthe nut istorqued tillthe bolt tension is 2000 lbs. The spring is not fully compressed. A force F = 1800 lbs is applied to both plates in a direction thattends to separate them. What is the new bolt tension in each figure? The yield strength of the bolt is 3000 lbs. Will failure occur? If abolt yields, where will it likely occur? If the spring represents a compliant gasket between an enginecylinder and itshead, would a metal-to-metal seal be preferable? Send your answers to HYPERLINK "mailto:webmaster@homemetalshopclub.org?subject=Bolt Puzzle" webmaster@homemetalshopclub.org. We'll publish the best and the worst answers in the next newsletter Featured Articles Foot Actuated Welder Controlby J. R. (Joe) Williams - HMSC Member A foot actuated control housing was fabricated from two sections of aluminum channel,1-1/2 x3 x 10 in.long. It uses the potentiometer from a former hand actuated control. Originally the unit was designed to be operated by thumb pressure with the control unit clamped to the torch handle.It didn't take long to decide that a foot operated switch was preferable. After pricing a commercialswitch from Lincoln Electric, I decided to make my own. The electrical connectors are type AN. The large vertical spring is for pedal return. A 1/4 inch roller chain goes underandaround a horizontal roller, and is attached to a section of gear rack that can be seen at the lower left. When the pedal is depressed, the chain moves the rack which rotates the control potentiometer by a small pinion gear. At the same time, amicro switch, located at the end of the rack, initiates the welder's control system. A small spring returns the rack to the OFF position, since you can't push on a chain. The foot switch can be used withstick welding where it simplyturns the power ON and OFF. ForTungsten Inert Gasor TIGwelding; itturns on the power, the high frequency starting voltage, and the shielding gas. It could also control the cooling water if my welding machine was so equipped. I need to add non slip material to the housing's top and bottom surfaces, but this has worked as is for the past 14 years. Horizontal Turning in a Vertical Millby J. R. (Joe) Williams - HMSC Member I motorized my rotary table and bolted it to thevertical mill's table in order to machine a 14-3/8 inch diameter x 1 inch thick PVC flange. The flange is a special spacer for an electronic test unit. The part was too large for my lathe and still too big for the X-Y movement on the CNC mill. The drive is made froma small gear head motor connected to the table's input shaft with two small universal joints and powered via a variable transformer that feeds a diode bridge rectifier. With this setup I can mill and drill the flange providedI dothings in the right sequence. I milled the plywood's top surface before bolting the PVC stock to the table.The plywoodand PVC section wereboth piloted to the center of the table and bolted in place. The work's center was located and the mill's control system set to zero at this location. The next operation was to mill the outer edge and the step on the flange.Then,bolt holes in the flange weredrilled and bolts installed to secure the outer section of the flange to the plywood sub base while the inner cut outwas made. This produceda flat flange with a concentric center hole. The last step was to turn the flange over, bolt it to the plywood and machine a radius on the OD. Unfortunately, the drive hadto be disconnected to use the rotary table's hand wheel for spacing the bolt holes. The table and cutter both rotateclockwise to produce infeedcutter action. With the table rotating into the cutter, there is no problem with backlash or the cutter climbing ontothe work. I used an air powered spray unit with a water soluble oil solution to preventwelding of the PVC chips to the work andcutter. The unit would be able to handle aluminum with no problem but might be a little light for steel. Ed Note: I use this method to turn my truck's disk brake rotorswith a fly cutter since I have only a 10 in. lathe. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\compressor.jpg" \* MERGEFORMATINET Scrap Yard Air CompressorJoe Guidry - Jennings, LA Here's myhome-made air compressor that I builtfrom thingspicked up at a scrap yard. The compressor is form a large truck, air tank froman airplane, motor hadbad bushings, and the base is made from angle iron pieces of unknown origin. Ihad to buy the pressure switch and quick connect air chuck. Everything else wasscrap yard reborn. It will getup to 165 psi. It uses only16 x16 in. of floor space so itfits wellinside myshop. Also,it doesn't make much noise norcondensate.I have two other commercialcompressors. One of them, a Gardner Denver, makesa lot of noise. INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\news\\jul02\\compressor2.jpg" \* MERGEFORMATINET The next meeting will be held on Saturday July 13, 2002 at the Collier Library 6200 Pinemont, Houston, TX at 1:00 p.m. Bring along a work in progress to show. Visit Our Web Site HYPERLINK "http://www.HomeMetalShopClub.org" homemetalshopclub.org INCLUDEPICTURE "C:\\Documents and Settings\\Owner\\My Documents\\Dicks Stuff\\Home Metal Shop Club\\Current Web Site\\images\\collier_map.gif" \* MERGEFORMATINET F G H I f g h p q } ~ + , 5 6 C D k l m n o # $ / 0 ; < c d s t u v 0J 6] j 6U] 0J 6] <CJ aJ j U j UCJ aJ S f g h j l n p | z t t t t $If u $$If 0 N* 0 6 3 4 a b $$If a$ $a$ @6 p q } 7 C 1 ; $If $$If a$ p $$If T \ 2 *A @ @ N*6 3 4 a ; ` $$If a$ p $$If T \ 2 * A @ @ N*6 3 4 a $If # ? L * { $If $a$ ^ p $$If T \ 2 *A @ @ N*6 3 4 a ! ) L V c n ? K L l u & ' ( ) * + z { | } ~ & ' ( ) * 6 - . g js Uj CJ UmH nH u j˷ U j U<CJ aJ jt U jsN U jh( U j U56CJ( \]aJ( 6] 5CJ( \aJ( E* ~ * N H $If 9 $K$L$If T 6 3 4 a $If K$ $ [$ \$ a$ ] $$If T F !* ? )6 3 4 a $If - g N J $$If T 0 !* N*6 3 4 a ] $$If T F P%N* 0 *6 3 4 a $If g h 9 @ o p & [ b b c d e r ! 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