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Making The Crank. Top Left :- 4-Jaw back on the rotary table / minimill – clocking true (again). Top Right :- Milling the big-end hole & webs. Bottom Left :- Milling reference flats. Bottom Right :- Back to lathe for final turning & valve gear eccentric. Once again I made an error – see top...

Silver steel works - its easier if you harden and temper it - then grind it - always being careful not to "blue" it. Whatever - your choice. Hardened drill blanks work best. Again don't overheat during grinding. I also make them out of old broken (but decent quality) screwdrivers - if you can...

Making The Pinwheel. (Pinion Wheel) Top Left :- Turning blank for pinwheel and crank flange in my small 4-Jaw. Top Right :- 4-Jaw moved to rotary table / minimill – clocking true. Bottom Left :- Drilling and reaming pin holes and clearance scallops. Bottom Right :- Back to lathe for...

I once drilled a Ø20 hole through a 600mm length of stainless (on a Graziano SAG14) - The long series drill being made by turning down the drill shank and attaching it to a length of Ø12mm rod by silver soldering. The idea was to use the drill as standard at the start, add the extension piece...

I didn't use solder at that end instead I am relying on the locktite - I've spun it to 5000rpm and it doesn't come apart. However, if You wanted to solder them I would recommend drilling axial holes down to the now threaded or stubshaft ends - assemble the whole flywheel. Then lay it on its...

Grinding an accurate key is difficult - try this method. Grinding Hexagon Thingumybobs The sharp corners and grinding pattern also help with torque. Regards, Ken

Making The Flywheel. I thought I would post on making the flywheel which is something I did not do on my prior Hypocycloid post and was asked about it - so I documented the making of this one. I made a change from the earlier version in that I changed the design of the spokes from plain rods to...

O.K. here's the partially assembled first try fit up video. It starts with me turning the Ø6 shaft between my fingers which shows it turns freely and then a super slowmo using a cordless drill for more consistency. Regards, Ken

John, Thanks - I have just trial assembled the crank assembly and will post a video - eureka it works (at least so far). I never posted on how I made the decorative columns - so in case anyone is interested, here it is :- Making The Decorative Bits. Whilst the columns and spacers are simply...

I can't believe its 2+ months since I started this project - but I have been rather busy designing for my business - can't have fun all the time. I have in the interim built the cylinder assembly :- Since this is the same as what I posted under my previous hypocycloid, I saw no point in boring...

If you simply clamp a short length part in an ER type collet it will tend to close bell mouthed and does not secure the part well. In order to prevent this it is necessary to support the rear of the the collet vis :- In this example I needed to turn a bearing bush with a shoulder in the middle...

Personally I always generate my own profiles - much easier to then get over wire dimensions - to verify your assumptions of the gear you are measuring or intending to make. Attached my tutorial on making your own gears and hobbs as well as "cheating" profiles and pitch circles. Also gives you a...

Here's a thread on blowlamps some 10 years back :- Blow lamps I also went through starting procedures etc (Page 1) Avoiding "flamethrower" mode and photos (Page 2) Yes the clip is for a soldering iron :- My homemade heavy duty soldering iron - mostly I heat it on a gas ring nowadays. A...

Awake, Here's a link to an informative thread. Building KEN I Rotary broaching tool and Rotary Broach Tool Design Regards, Ken

Awake, Try this link https://www.homemodelenginemachinist.com/threads/rotary-broaching-tool.29474/ You will find a zip file with drawings etc. Now advanced to page 6 - don't see why that should screw up the address ? Regards, Ken

WisJim, These are what I use for very small holes :- The upper one uses a DC motor, Dremmel collets or chuck (5/16" 40 ME thread) - the whole thing floats in that it is free to rotate and slide in the MT3 shank. It uses a Mabuchi motor running off a DC power supply, all the...

I used to use my drawbar mounted ER32 but eventually went to flange mounted so I could pass the stock through. Also to reduce the stick out to reduce part off chatter :- Its actually an adaptor from a smaller lathe on a larger flange - the recessed location bore was turned to final size reverse...

Use a length of M12 threaded rod as your drift - preferably high tensile - screw it fully bottomed out into the drawbar hole. If you can machine the end to get it against the bottom of the drilled hole, even better. This to help not to damage the thread. Spray some penetrating oil where you can...

Awake, As Minh-Thanh's diagram shows - a Triac simply switches on at some point and off again at each transit through zero volts - so it chops the power so that on average the voltage gets less as you dial it down. This is a pretty blunt instrument but works fine on resistive loads like...

The iron core of a motor can only put out so much torque - not a Nm more. The only way to get more power out of a motor is to spin it faster using the VFD's higher frequency. But that won't work unless the motor impedance is changed or the voltage applied is raised to maintain torque. But that...