Every tool was used

I’ve been very busy lately outside of the shop on coursework so I haven’t had a lot of time in the shop this week.  I’ve managed to get some time in the shop making 4 more brackets for my friend’s Audi S4 antics:

s4brackets

The brackets are made out of 1018 cold rolled steel.  What I really liked about this project is everyone of my powered machine tools (bandsaw, shaper, lathe, mill, belt sander, bench grinder!) was used.  The method went something like this:

  • Cut to size on the bandsaw
  • Face and machine to thickness on the shaper
  • Square up on the mill
  • Drill the holes and start tapping on the mill (finish up by hand)
  • Cut the large radius in the lathe using a face plate setup (I used a hacksaw first to remove most of the material!)
  • Cut the outside profile on the bandsaw
  • Add the profile radii on the belt sander
  • And of course, sharpening all the tools on the bench grinder and / or belt sander

It was the first job I really put my newly acquired 7″ Ammco Shaper to work.

ammcoshaper

The shaper worked great, and it was really nice to just let the little machine work away while I was drilling on the mill.  Would I trade my mill for a shaper?  No, probably not, but the little shaper is a pretty useful tool.  It did a very good job on finishing the 1018, which can be really gummy at times with poor chip control.  I used a 1/4 HSS turning tool with a small stepper over for roughing and finishing.  Roughing used a depth of cut of about .020″, which I though was fairly respectable given the 1/3 hp motor powering the little shaper.  I’ll be posting some more details on the HSS tool geometry I used soon.

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