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SUMMER 1990 rL.I0 Full-size pull-out drawings for an 7 [eal indispensable rotary milling attachment from stock materials An optical centre-finder and centre punch on a budget. A dial test indicator attachment without castings Choosing a chuck Making a plate vice @ Hints and tips Ruild a nowor hackeaw Inelnte maral BOOKSTOLEARN FROM! BOOKSTOTREASURE! Guy Lautard’s “BEDSIDE READERS” Unbeaten for late night thrills and red hot workshop tips! you enjoy metalwork, here are two great books expand your horizons, and give you 2 [tof pleasure. Over 400 pages of experience and infoumation o help you get things done better, faster and more easily in the workshop: workshop érawings &dnstzuctions lor wselul tools ‘accessories and projects: hints. tips and workshop anecdotes in “The Machinist's Bedside Reader”! PRICE 15.70 ine Post & Packing We guarantee you wil nt find any other books ike these -in our BookTit 7 anyone olses Full of usful ideas, hints tips and staries written ia wondertally idiosyncratic syle... ECONOMISE! Buy bath “Reeders” together PRICE £2725 ine Post & Packing (Overseas £9020 su ¢ you FREE copy with BOOK SERVIC Rode, Bath, Somerset BA . . — UK) Phone (0373) 830 181 renee Vik / ACCESS iM bara The Machinist's Bedside Reader” The Muchiaists Second Bedside Reader DATOR Sion oy Phere Pegi ca Pr (Tt 42 Semetere So a oe eu aene etee So eee ain) ria paremearnneaierty ee ee recor yi Ero enen enero Rrra et ater Rrdesccr rected pea esone arety nettomer TT ct CONTENTS 10 12 4 18 9 22 24 28 30 32 33 WELCOME USEFUL PLATE VICE ATTACHMENTS FOR D.T..s FRENCH TRY SQUARES AMILLING HEAD MOD. STOP THAT! QUART INTO A PINT POT A CONVENIENT CRADLE (CZ's HOBBYMAT VARIANT A MINI-WORKSHOP SOFT SOLDERING ENGINEERING OF THE FUTURE USEFUL KEYWAY CUTTER CHOOSING A CHUCK PRECISION OPTICS BENCH VICE VERSATILITY A ROTARY MILLING DEVICE TWIST DRILLS A POWER HACKSAW ELECTRONIC SETTING-UP NEXT ISSUE SCRIBE A LINE HELP US TO HELP YOU Se UE SEND 0p, ‘chnonos tb; Dept Me, 98 Vitoria Street St‘Albans, Mets “oi (0927)32793. Fax-(0727) 28130 ‘Send for your free brochure now Turret Engineering Ltd Pindar Road, Hoddesdon, Hertfordshire EN11 OBZ Pett ee) eee BLACKGATES ENGINEERING The Model Engineers Supplier = sae seanicuureenoueees> ease i ficrRi a0 0-60 vrnion ot Sweet Pea me 8 est00, 2: LULA conrnacrons 1960 BLACKGATES ENGINEERING ume gs PROOPS DISTRIBUTORS LTD (Ex. Tottenham Court Road) HEYBRIDGE ESTATE CASTLE ROAD LONDON NW18TD 071-267 6911 Mon - Fri 9to5 071-267 1718 MATERIALS € ECC pp MG. CARVING. CAST. Si POOKSELLERSs ly Janel Cupar ‘ance, Vibrating Table Hot Melt Vinamald old Melting Alginate, Latex Silicone Rubber Pigments for Silicone & Resin Metal Cleaning & Col Maestro Acrylic PVA C Flexible Drive, Bur Safety Equipment & Hygiene ae Mesoysaa\ys0%™" acing, Berkshire Ri Warren Street, London WIP 5DG, Te CLASSIC The new magazine for Lovers of Steam Steam Classic tells you what you want to know about British Steam locomotive design, history, operation and performance. Emphasising what can still be enjoyed in todays’ lively preservation scene. This magazine is a stimulating mix of past and present. Cover price: £1.50 Published: 2nd Friday of each Month TRACY TOOLS LTD. 2 MAYORS AVENUE, DARTMOUTH, S. DEVON TQ6 9NC. Telephone: (0803) 833134 SET No. 1 MODEL ENG TAP: ( G ) TAPS £15 3 BATAP SET (2 Ta; 0-1-2 345.878-9:10- T-12-14BA TAPS £18 o| 10 PC. HEAVY DUTY DRILL 4 26 TP TAP SET (2 Taps o1 Sac S8 or CED TAPS £15 5 VARIOUS SIZES UP TO 14 ax 26. hq DIES £15 @ £10 SET See ee eee Timon | jos ite tas 10, METRIC COARSE TAP SET (2 Tose sh size), & Metric Die Set TAPS E16 ~ |_47.6". 8 assorted at £10 Lor 18.0, 160, 180, 20.0, 22.0, 240mm DIES £20, Ti METRIC FINE PITCH TAP SET 14.15.18 20.25.» 13mm Pach SeTa16 T2_UNF (OR UNC) TAP SET(2 Taps each sus), & UNF [or UNC) Ow Set TAPS £12 ‘1 A DIES £15 irs 1B UNF [or UNC] Ove Set TAPS £15 c DIES £18 BA TAP SET (igh Spand USA)2 Taps Each Sun DRA SET e20, 'SLITTING SAWS Set of 9, up wo Vie" wide. (approx. 3° o/d= 1" bore £6) Ente SaAia (Sa £18) DRILL CHUCKS [Rohn Precision) a" at &7 ee SESW FIZ With 1 or 2m/¢ FREE ARBOR REAMER SET: an! fa SD SET E20 DBI SET Ne a Ws aT izes) Ground Fins Sere METRIC REAMER SET 0,1 5,20,30,40,50,50,70.800.100,11,.0mm SETEZ0_SpecalOm "ALSO: Selection of Dovotal, Woodruffe, Ballnose, Concase, Spottacers, Broach Centres, Cycle Taps & Dies, Boring Bars, Lett Mand Tap & Dies, Milling Cutters. Reamers, Countersints, Gear Cutters, Siting Saws, Acme Taps. Diehead Chasers, Socket Reamers. These aen available at between 50m & 75% of hst price, (MONDAY TO FRIDAY) OPEN 8 a.m. to 4.00 p.m, (Sat. noon) CLOSED WED. ?Plooae include adequate P&P. Despatch by return, Overseas PEP (Air £12.00) ‘SENO FOR NEW COMPLETE CATALOGUE (STAMP PLEASE), Wo 51S Oris Bowed) £6 _, THENEWASTRA mk vil att GeareD HEAD © J VERTICAL MILLING AND DRILLING MACHINE ks THE MACHINE THaTwinsev THe MOGE! @ TABLE 600 x 150? NO! 730 = 210mm @ SPINDLE TAPER No. 2MT? NO! 3MT OR © A ssreeos Se R8 TAPER | Swive Swivers @ THROAT DEPTH 165mm? NO! 285mm Ths @ NeW RACK @ QUILL STROKE 40mm? NO! 70mm RS / ANOPINION | @ X & Y 390 x 139? NO! 400 x 160mm TOHEAD @ STAR WHEEL ONLY? NO! a \ ALSO HAS GRADUATED @ PLACE YOUR ss wicRo Fine FEED as BETS @ MOTOR ¥sHP? NO! 1HP md ON THE @ WEIGHT 127kg? NO! 270kg e MeTRIC 7 ePrice £1850 No! IMPERIAL : ONLY £1587 ex 371 EARLSFIELD ROAD av LONDON SW18 3DG Phone for your nearest supplier 018745708 Fax: 01 871 2584 Telex: 94012238 URQTG 6 Mode Eoginee READER OFFER mn fu NIBBLER in ‘SHEET METAL CUTTER Cuts: cleaner - faster —longer | asrerunes osc ray (iT) [ suppueD To icon Nv Nv Nv Nv Nv Designed for Electriciar ‘and Ventilating, Reoting and ‘straight lines & curves with a fadias as small as 23mm (1°) Cts Cleanly without Distortion NO MORE JAGGED EDGES, Al Spare Parts available Ex-Stock Professional Ac Version and New Wood Nbler avaiable. soot nesrn y Fy i, 2 OntY QUALIFY COMPONENTS USED FX teveprone orpers “™™ = = 0442. 66551 (24 HOURS) Ne Please supply ROMEIB 11 £32.25 ine. _ Please make chequesPO. payable to ASP Total & or debit my AceessVisa CLIT TTT TTTTITTITIT Expiry Signature NAME ADDRESS. Please send coupon to Model E TUNGSTEN CARBIDE TIPPED TOOLS | 57, ,np moonuns Rag) OS A as Maha A BRITISH Mave BEST RANGE FOR MODEL ENGINEERS Paice NGLUDES VAY & POST one PACKAGE DEAL 40's "£405 £415) Hobbymat steadies £39 pair. inc. VAT + postage 5 FOR LATEST CATALOGUE ' 160 PAGES: + ROTARY TAI PRICES INCLUD: VAT + UK CARRIAGE esis Hous, Alma Steet St Hens. Lancs WAS AR Tel 0748) 53638 MODEL ENGINEERING SUPPLIES & SERVICES LTD. Fax: O744 26264 Hours Mon. Sot &5 30¢m Late Nght ‘TOOL POST GRINDERS Foray lathe from ML? upwards External/Internal ‘models with TEFC motors ” DUPLEX ELECTRIC TOOLS LTD. Old Barn Lane, Kenley, 7 Surrey, CR8 SYY. HANDS _trared and ‘Abourng with SKLL | + NEVERMIND TAME (teri rough oft STIL) DESIGNING anew. just doing COUR SHARE ‘ye FORT TINGS. ‘The Steam Fittings Specialists STEAM ENGINES will East Cowes, .O.W. as long as there are. ‘PO32 6EZ, UK HANDS that CARE we LEMS senitmar || wna ete mcowaremems — Prararaes. || Access Visa accepted ‘our list stil FREE for SAE. RAHAM ze | cxtany ‘OPNMERDAY SRDAYS 0598 SATS 8250 £175.00 THE “DIAMOND” HEAVY-DUTY FRET SAW One of the world’s finest saws The new range of machines with 1SHP motors & Cuts in any direction across table. Orbital action. Rapid blade change. From a 4” max cut to the finest Veneers. British Made, Guaranteed 5 years. SAE. for ilustrated brochure J.D. WOODWARD, Dept. ME, Power Tool Specialists, 6 The Narrows, Hinckley, Leics. LE10 1EH Toi: 0455 613432 DORE WESTBURY MKII VERTICAL MILLER fea serces ats to A228 6” ROTARY TABLE KIT - £59.95 Pees ver “Brays Bench” Model Engineers! Workshoo Johnson Matthey PLC "MATERIALS TECHNOLOGY DIVISION SILVER BRAZING ALLOYS & FLUXES 608% - 617% eR ioo eek 2 Cadmium Bearing Sine a 88 Gada Fr O'Smm wre 1.6mm moa 5mm hod 2 om Ro 3.omm Red Argo Fo Code Bearing 2.0mm Rox Se 20mm Res Siver io 24 (C4) Cadmiam Few 20mm Res Bier 16 Comin Fee 20mm Red SAVER SOLDER PASTE Eney lo No.2 Cody Bearing Grade 258155 1020/0 gam syinge 2 82exe Bes (igo 9am nae £25.85 each General Popore 0% _ 900% 350 game Ener Fl powder 75 20 each S00 jams easy Fo peter fees ‘500 ears Martin 100 poste E100 wach Higher Temps Cobre abo 500 prams Easy Fgaste £8.85 each High Temperature Wide Range ‘00% ~ 800% 800 or ___ ATM Go. LTD. 6 NEW ROAD. DAGENHAM. ESSEX M3 9YS PHONE: 081 592 2629 SUMMER SPECIALS ‘ounPrice MICROBOX DAILL SET, 20 HSS DRILLS 03-18mm £495 ENO-MILL SET 5 HSS END MILLS "IN CASE £1050 PRECISION WARDING FILES, SET- 6 SECOND CUT FILES £6.00 WIGGLER & CENTRE FINDER 5 PCE SET INCASE 10.95 DRILL GRINDING ATT. FOR USE WITH BENCH GRINDER £8.50, HSS ORILL SET — A 19HSSDAILLS 1-10nmn x -5rm 86.95, TINSNIPS - STRAIGHT PATTERN WITH SPRING. Bees, 0-295 2 395 Vis 67/150mm FINE ADJUST VERNER CALIPER £1695 VIS 67/150mm STANOARD VERNIER CALIPER e195 UVE CENTRES No.1 MT £16.95 No OMT £1095, SACOBS No. $4.03) DRILL CHUCK: 816.35 [ARBORS FOR ABOVE NOIMTE2TS No 2MT£295 No SMT. £450 DIAL-A-DRILL HSS DRILL SETS IN PLASTIC CASES SET-A21 HSS DRILLS" -|"* £9.95 SET -8 19HSS DRILLS mm - 10mm » Oem £998 VIS MICROMETERS, WITH CARBIDE TIPPED ANUILS O2Smm E95. 25-5OmmEWS 0: 1 eta 12°1095 20° #2.95 3-4" £25.95 SPRING CALIPERS (Inside ot Outsido) 8 OWVIDERS. Saah Eade wEZOR Pease Se pn) vis Verne iio enue & ACCESSORIES ESS Dra AUTOMATIC CENTRE PUN 8 ts we aso stock wenoxom ones 7 Noemie Ss 1 ER ee eer rte Eamon COMPASS HOUSE TOOLS HIGH STREET - ROTHERFIELD - £. SUSSEX - TN6 3LH Phone 0892 852968 Showroom open Thurs-Sat Summer 1990 Geer] BROTHERS LIMITED SPECIAL OFFERS ON MINIATURE POWER TOOL ACCESSORIES + Set of 4 wood boring drill bits: (3mm, 4mm, 5mm and 6mm) + Pack of 10HS:S. Drill Bits: (2each Imm, 1.2mm, 1.8mm, 2mm and 2.5mm) £3.95 + c/p 40p ‘% Set of 4 Tungsten Carbide Drill Bits: (0.5mm, 0.8mm, 1.3mm and 1.5mm) £2.50 +c/p 40p Set of 4 Carbon Stee! Drill Bits: (1mm, 1.5mm, 2mm and 2.5mm) £1.50 +c/p 40p % Set of 2 Drill/Router Bits: (1mm and 1.2mm) £1.00 + c/p 40p % Diamond Saw Blade for Glass and Metal (Dia. 50mm, Dia. of hole 10mm), £2.00 +c/p 40p % Pack of 8 Assorted Brushes: (incl, Brass, Stee! & Nylon) ...... £3.00 + c/p 40p 4 Pack of 8 Assorted Milling Cutters: incl. Brass, Steel & Nylon) £3.00 + c/p 40p %* “Super Pack” containing at least 30 Different items: (incl. HSS Tungsten Drill Bits, 3 types of brushes, cutters and grinders) £7.50 + c/p 60 SPECIAL OFFER ON “ENGLISH MADE” FILES % Rifler Files . su £1.95 each + ¢/p 50p 6 Assorted Riflers for £10.00 + c/p £1.00 (All different shapes) 10 Assorted Needle Files for £5.00 + ¢/p £1.00 (inel. Round, Flat, Half Round, Triangle etc.) (Please note no specific shapes and sizes offered) &) | i & £1.50 c/p 40p CUTTING MATS UNIQUE SELP-SEALING DOUBLE SIDED CUTTING SURFACE HELPING HANDS # sce mcrae " AibcMOR smc Cr ab CLs Mgr | PROOPS BROTHERS LTD. RETAIL & MAIL ORDER 34 Masons Avenue eran. onty Technology House hells Ciel 34 Saddington Road Fax:01.8615606 ERY Fleckney Bessaer Seaery | Open Friday * Saturday Gioved Monty Only 10.008m-4:00pm TRADE ENQUIRIES WELCOME Practising what he preaches: editor ‘Stan Bray in the workshop at ASP’ 1990 Primrose Valley Modelmakers Holiday Week ‘elcome to Model Engineers Workshop, abrand new magazine specially compiled for all hose who are interested in using model engineering machinery at home to make models, tools and a host of other items! ‘Our subtitles The new, practical hobby .gacine’ and that’s exactiy what we are the accent very firmly on making things rather than merely reading abou them As you wil se as you enjoy this fist tissue, the magazine is packed with practical articles desenbing the Construction of a wide varity af useful tools and machinery improvement ideas ranging from the simple to the more ‘complex. And thisis a policy we intend to follow with future issues as stated, the magazine exists to concentrate primarily on workshops and their use, it will aso contain extensive information on the making of models andi is our intention to cover in depth the multiplicity of tech in thei construction. So wi your ‘workshop solely for the purpose of creating magnificent live steam locomotives, traction engines and other working models, ‘or obtain your enjoyment and satisfaction from the hobby through the manufacture of tools and workshop aids, there will always be something in Model Enginoers Workshop just for you in this fest issue we have attempted to olfer readers as wide a range of subjects to s possible: we hope that we have ‘balonce about right but, naturally, 1S wil © receive. At the mom Setting up a team of brand new veiters who will come Fresh with a new outlook and new ideas, whilst at the same time dealing withthe traditional subjects, PIsot oe eee tet pene isa Prue techies 1 iar eee ey Cor ee ce a etek \ Brrr eta beer NOT Barrer oxen rene ag paneeeineten er rks) Peete nr pet eet pra pees Tt remem) Peete terested et [reer rnd Perera neat can pee ees) pertain ST erties Prone i a pee er eee pone te ts Pe oer Proiierd Pecan erg large part played by electronics with even the smallest of engineering works now having electronically contrelied equipment bee erro ie tor Peri esheets pee ener tren errno eet ere et ater) Pacem myer terk or Pret tad Leet neers ene a foe e can be very useflin the home workshop pene ere One of the nice things about the hobby is that a workshop can be created in many ‘an odd corner; this one Isat the end of egerage. What it’s all about! An evening in the ira pes Perens Po en ey ere ay ran otter ‘concentrate on the traditional model ‘engineering techniques. retin en romans reg ea recy Ca ular rd ree eet! therefore will rely heavity on readers teling ‘us what theyre making and how itis being Pe cre enna) eh rer cn Pet uo rook ary eene er een ary Peat rte ert ao iar ‘copy should be typed with double spacing ‘and, obviously, photographs and drawings rr metre ey ‘ur drawing office so don't worry too much eer) er eee eats Pie eet tested efforts and, while you won't beable to Cd a errs etek kot Pg tee ecion eh Perrone tenianey air me neler both the advanced and the not so advanced nd there will be material too forthe Felecia rears ty Pereira porter rr) ‘cto cater for alllovels of expertise and. Sree os Pekuoieis ds une eeu Unlike its fortnightly parent, Model Prada to tad Ce tar tere eet Pete tultoeutiess sind oe ety Perera ate Pua eda est’ ‘such, we wil be featuring individual set- ey teat Patel tht ogra are oat un en beg might be a special design of storage, an Se ti deduct inners tc ey er rrr Poreea eer terians Parte nd Engineers’ Workshop. As you can see, we Ce Raa pleasure in constructing and use around compet Sree Tate? [something here for model engineers of Pepa ets Cue eutenetet eee oc) {ound to hand in many workshops. The Peeters peel melas ted peas oS eee ens some answers and a free pull-out working Pe er ror in proparation for the next issue isan equally mouth-watering line-up of material pe re land een era ag the home workshop. Mains lighting can be dangerous and the system we offer next car et aad ter aliatad Pee ahead eng Sot pero plenty of room around the machine for the pena re ere eee rere ee tye a rere reiterated erat from it, and we will discuss which type of Perper et) Leno lcd at faetineeren ies Se re riey peerrartinn ke rt Peasants rete ithas been used to mill the flutes ina in | | diameter miling cutter. Add to allo this 2 homemade lathe, 2 gearbox and a special ice, all of which we hope to feature next time, and you wil see that our Autumn issue promises to be even more enjoyable than this! The milling machine (above) will come in | for extensive coverage in future issues ~ | 2s will beautifully aid-out workshops packed with ideas like this. sincerely hope magazine Remember, we need article feedback, letters and tips rom you and if you have anything to offer we would be pleased to hear about it If you don't have anything that you feel is of slic nterest for us to pass on to ot then just write and toll us wh tthe magazine. Your views ar and will help us to maintain the high Standord that Mode! Engineers’ Workshop intends to set At lett, the parts for the vice: dimensions can easily be adapted to suit individual needs. Below, the plate vice viewed from Underneath; main vice jaws automatically close it up as they ‘are tightened There must be many occasions in the productive life of any model engineer ‘when he or she has to grip firmiy items which are ust too thin to trust fo the jaws of tho bench vice. Those thin, ‘plate Tike" components may need to be held firmly for marking-ost, polishing or some ‘essential fling ox other operation and can ‘easily suffer inthe js of the normal ngineers vice which,in any case, provides ‘accommodate the varity of thicknesses ‘we have to deal with. The rer jaw is fixed ft one end ofthe sit whilst the other jaw an locate anywhere along the length of the slot. In use the pate sits on the top of the bench vico with the jaws gripped between the jaws of the bench vice. Having carefully adjusted the height of the jaws. ‘and the distance batwoen them to sult the ‘component to be gripped, the bench vice is thatthe siding jw does not bind except ‘when tightened up inthe bench vice. You tan, 28 a uselul rafinoment, case-harden the working faces of the jaws but this is not ‘essontil to the operation ofthe vice T have found this tool very useful for holding lems of even fess than 0. in, thick, as well as those which are! in. or ‘more but which | peefer not to submit to the bench vice jaws, With a litle ingenuity USEFUL PLATE Holding small parts in order to work on them, particularly where filing is involved, can be a tricky business. There are various ways of ‘overcoming the problems, but usually tools for doing so are complicated things to make. Alan Buttolph solves the problem here very neatly with a small plate vice that slips into the ordinary vice jaws, and tightens on the work as the vice is closed, allowing the pressure applied to delicate work to be controlled easily. The vice is simple to make, and many r jers will be able to construct it from ‘odds and ends found in the workshop. ino suppor other than the usual clamping ection, {have used the simple plate vice shown the photographs for a long time now and has proved invaluable for holding those thin, small and not so small items which we all seem to need to produce at some time, Ithas repaid over and aver again the few hhours needed to make ft All components ‘re of mild steel How it’s made Essentially, it consists of a sloted flat steel plate of reasonable thickness, in the Slot of which are two adjustable jews. The plate provides a firm support and the jaws, the necossary grip for 8 wide range of thicknesses, lengths and breadths. The jaws are together adjustable for height to 2 tightened up to close the plate vice jaws on ‘the component, 3s firmly or delicately a5 required. "The dimensions | have given are suitable for use with a 3 or 4 ins. engineers bench vice but are by na means binding if you {Wish to vary them, eithorlargor or smaller. The construction should be rigid and wel fing, there being litle oF no side-play with the fit of the jaws in the slot. The plate should not be less than jn. thick and after ‘you have cut the sit as carefuly as you can ins advantageous to work the top face as flat as possible. Ordinary bright mild stee! {BMS} plate ts admirable for this purpose. Ensue that the guidebar is squore to the ‘aoe and length ofthe rear jaw. itis secured Firmly to the rear jaw by riveting over the reduced end, Keep the guidebar oiled $0 tho jaw faces can be temporary covered faith brass aluminium, cardboard, ruber, te, ether clipped on or stuck on for thoce special needs which do occur A view from above the plate vice. The jaws close though a siotin the top face ‘and tighten to hold very thin work firmly inposition. Model Engineors! Workshop ares aLWid OS >oorg ue ‘ava a0ind AVE ONIGIIS Mvr avae 7 bail a eRe a REN the turned parts except the clamping screw, | hod one of those ready mode trom uralumin.f sive stool is not available, ‘mild stbel would do; if it could be case hardened so much the better, the camping ‘screw to, could be made from mid steel. | left the slotting of the pivot sorew and did the rostof the turning, The styli - Fig.5 The sy were tuned from the sae in li. siver ste! as the pret screw A lathe {oo with a plan angle of sbout 30 degrees is useful nota screw’ cutting tool The spherical radius was left asa short sation TThvtong, and ed and stoned tots final Shope The 5 degree angle was ext using the compound side, starting at the chuck fend and working back. The one shown in {he photograph ead fo fina shaping. ven the shenk and the radius hod had last polish was cutoff at about Holding onthe {in clamete ameter forthe 8 BA thread ait longer than needed to be and made the stn (50.0070 in clameter Ths gives the ce 9 ‘00d start and should Keep it true. Aral tho turing and treading was done, facod ‘Squate against the datum edge. When | off all the extra length and chamfered wit riled them, I started with a in. dil in. 2 fine Swiss Flo. made three styl, but two ea Modi Engineers Workshon, F1G.6. SHORT ARM. ‘would be enough, one each forthe angled ‘and short arms and they could be lunserewed to use in the long arm. | made the extra one because they are easily lost “The styl should serow into tho a ricaly and, you have strong fingers, no more need be done. If you want to be Certain that they goin ight, small spanner flats can be filed on them to take a 10 BA spanner or a home made key did both this and the sloting of tho pivot screw using @ sprung threod plate, which | use froquently for holding threaded work. Be ‘carefull you do put the fats on:t found that it only neds a fow light strokes with the fle or each side forthe spanner to fit Afinal extra ‘The last component Fig.8. is another ‘extra. If the stylus on the end ofthe dial ‘gouge plunger is unscrewed, it can be replaced with the probe, Fig. 8, or any ther shape needed. have included the Using the attachment to set the fence on a milling table paraltel. The stylus is set in the angle arm for the purpose. BE] 1216" A/G) | TAP BBA es) © 9716" 1, 9716 FiG.2 LONG ARM + 4 | { 4 J vel SL probe because it wil get into places otherwise very dificult to get at: The dimensions are arbitrary, except for the thread, which is 6 BA, and car be made 19 ‘any longth or diameter What | have mainly Used it fori finding the depth of square ‘and acme threads, whore tho stems of ther instruments are usually t00 large. When all the components were finished, hardened those made of silver steel and cll blacked the mild stoel anes, [have 3 large coffe jar half full of quenching oll ‘and the use of the gas stove, good enough {or small jobs. f you do the same, choose a time when food preparation or cooking fs not being done, and ask permission fist, Cl-biacking especially, makes a bit of ‘smoke andl smell ‘As the photographs show, these attachments are well worth making and extend the uslunessof sda ge gy 10 end. concentrically. 6BA, seats eee 1 FiG.s. PROBE 1 Se La t6 SCRAP SECTION ON © ALL 8B.A, HOLES. Here, the short acm is in use to set a bored component TRY SQUARES WITH A. here are thee types of try square shown in the engineering suppliors Catalogues in France, which are of equipment used in that country wrong with the normal type of famikar square, these French types do offer some advantages ‘when marking out, They are called equerre simple, equovre a chopeau, and equerre double onglet Simple translations would b> simple square, square with ahet, and double angle square! All these are of the Same type of construction and 0 have limited the description to the equerre a hapa, Al the squares are made of the same thickness of material and work out to 5mm thick which, aftor finishing, means around 442mm. this material being used for both stock, No matter how largo (and some are as big as 200mm ‘approximately one foot] there are only two fixing screws “The screws are 3mm diameter and, in some cases, the countersunk heads are raduced in size to prevent therm breaking ut of the eds of the material Ung tis Size of screw in such a material thickness ‘wil ell for great care in marking out and ‘riling the tapping sized holes. These holes are also blind, so there isa danger of taps being broken if eateis not taken. Plenty of tapping compound should be used and at the fiat sign of tightness the tap should be withdrawn, The proportions of b 1de to stock follow This photograph shows two sizes of the typical 90 degree square, This little article by R. Wallman illustrates how even common enginoering practices can differ jetail from country to country. Here he describes the popular type of try squares used rench craftsmen and supplies drawings and hints on how to make them. the ratio of the square root of five plus one, divided by two. Care must be taken wl tutting out, 9s distortion is ikely to oc ‘One way t6 of set this Is to partly cut the NC E be to suit the individual: my own squares are ground to a satin finish Readers ‘without faites for this can use a range of smooth surface, # thats the inthe o quotes talon, ‘equerres a 120 degrees, and equerres a 135 ‘degrees are all amongst those sa listed, but {have never yet soen them in use, T do not intend this antici as a treatise juaro construction but offer it meroly for those who like pols and t0 show how scan vary from place to Q EQUERRE DOUBLE ONGLET The angles are 90, 60, 30/and 45° The finished Equerre a Chapea 0 ‘material to shape and leave i for awhile to Slow Stresses to be relloved, shen completo the work afterwards. "The ninety degree square, as the photographs show, fs made by marki bad drling a hole at the comer of angie The metal can then be ext both ways into Us. The work can be miled toa finish it suitable fe 1» available, otherwise it isan excellent exorcise i fling. Constant checking for accuracy is essential “The stock and blade should be dried, ped and ier and then nished afterwards; this wil alow for aey slight errors in marking Out. Final finish can MILLING HEAD MOD FOR THE COMPACT o Whilst Mr Farrugia describes these modifications with the EMCO Compact Five milling attachment in mind, with alterations to the measurements the design would suit almost any milling tachment mounted on around column, euch as the Unimat 2, and ‘other makes as well. Basically, the modification allows accurat measurement of the vertical travel on the head when it is set at an angle and, probably more important still, the head to be moved to change cutters without losing the setting. Good, accurate machining is called for but no castings are needed as the device is made entirely from stock materials. ee pie Pin Sat Ml rece se orl polos oat PiSeerieiceescrate* icles ee Ne ee ee is eC eee Ce ae The modification, which increases accuracy, could be applied to any similar ‘machine important data relative 1 the workpiece fedgo/s since its eat-up will not neal be disturbed. Having the EMCO Compact 5 milling ‘head mouited on the Compact B Lathe {have encountered this situation many 2 time, sometimes fortunately visualised prior to job set-up. while in other instances. Dnly when the operation has already bean intated, with frustrating consequences, ‘A shortcoming ofthe system is that when the miling head is swivelled about the vertical axis and thus displaced from it, the resulting sleeve feed would be only that Incined to the vortico, Josing the actual vertical feed capabilty This ean be easily visualised by referring to diagram A, eliminating the mend of lengthy doseriptions. Thorefore, one can deduco that, 1 feed the cutter edge through a vortical distance x.» complex operation ‘would result, with the actual net movernent tne | having to be achieved through two nets | separate adjustments — one via the inclined vertical 'V' ord the other via the longitudinal axis’, which necessitates ‘geometric calculations with the inherent Becuracy losses. “Th modication effected to do away ‘with this is depicted ints general ‘sssomblod form in diagram B, which shows that, for any actual miling head displacement, full control ofthe weetical displacement is now stil obtainable, thus ‘enabling co-ordinates about a particular {datum tbe maintained, Degree of accuracy “Te accuracy ofthe vertical feed control schleved with this modication fein the ‘rder of © 05mm using the vernier onthe Boek and oFmm only Hsing the ‘Summer 1990 ae "© venwien scat Vine OL HOLES at 45 (reddusted handwbee! collar. However one can easily modi Jewels of accuracy required by altering jeter the leadscrew pitch anid consequently the corresponding hhandwheel collar graduations, or by changing the vernier design. Nevertheless, the 005mm vemier was chosen due to its (900d readability inherent to its wide ‘spacing and also ait has proven itself {Quite adequate for most precision jobs. This modification is of no particular benefit to anybody utilizing a separate riling table capable of vrtical travel adjustments, the whole idea behind this job isto enable the sama result to be obtained without having to complicate the Workplace mounting set-up. thus using ‘only the basic EMCO system flor those ‘who already have if with a normal machine ‘vice directly clamped on the cross-slide yet ‘now achieving four different travel axes, ‘namaly the longitudinal 'L’ {along the lathe bed) and the transverse “T: (across the lathe bed), both in a horizontal plane through the lathes apron and cross-slide assembly: the vertical 'V" and the inlined vertical ''V- both in.a vertical plane through the ming head. ‘Without this modification, the inclined vertical fed IV" is always availble, however only atthe expense of the actual vvetical feed 'V’, which, for accurate ‘dimensioning and other geometric reasons, is indispensable for specific operations. Parts and assembly "To manufacture the whole unit eight rman toms are required, demanding precision in dimensioning ancted in the parts scaled drawings by the symbol vv¥) find the finest finish possible to result in Smooth operation when assembled so that rwould ony require an even appiistion of pressure at al stages ofthe allowable travel Timitsin both directions when feeding or cathrawing the head via the leadsrewe ‘The top and bottom plates arts No.2) and the supporting colar art No.) a have alarge hoe ofthe samo diameter which should run a aising it ove the ‘hiling hood shat in hand thus the ‘ametcrcimension might requite ‘adjustments with respect to the supplied ‘Specifications just to sut the shalt ‘valle, such that would ony requice a tight tightening foro on the respective ‘lamping bolts in order to secure it in position, without giving way 10 Fhisalignment when tightened. The clamping bolts used are standard M6 with ‘an Aller head to facilitate the process — thus using the same Allen key throughout the whole system. “Th purpose of the supporting collar is to enable the whole miling head assernbly, ‘when modified, ta be left loose and be Fotated about the miling column the ‘electric cable perriting) thus enabling ‘cutter changes and ether operations being, ‘executed without losing that particular hhesd setting (diagram B) over the column, datum ‘h The guide shaft The guide shaft part No.4) must slide ft in the threaded block (part No.1) with the maximum alignment possible;care must be exrreinod when boring the 10m smeter hole inthe block, for f the hole ‘axis is misaligned with respect to that of the shaft between the top and bottom plates, then it wil lead to jamming of the ‘system. Sight misalignments ean be ‘compensated for by shimmming the block ‘Standard Emco Compact Five lathe with ‘illing attachment. 20 Model Engineers! Workshop oak ing to make it seat over the milling head block to sult the misalignment, ensuring that When propery seated, twill be adequately tightened ¢o as to retain the effected alignment. “The guide shafts fist threaded snd Jocked to the top plate with an MB nut, thon {ed through the block, threaded again through the bottom plate and locked in the ‘same manner as for the top plate, but with the difference that it cannot now be driven fully home through the bottom plate since alignment of the plates’ shaft holes is ‘essential — so before tightening the bottom plate, pass the whole setup over the fniling heed shaft, align the plates and then tighten and lock with the M8 nut, ensuring that after tightening, both plates will remain aligned and thus run quite foal, but not loosely. Handwheel ‘Next fix the handihee! (pert No.6, eomiplate with tho drive pins. parts No. 7) to the leadscrew (part No. 3} locking the hhandwheel with ani M7 nut. Pass the leadscrew through the top plate, the M7 thread inthe block, and the bottom plat and before inserting the M5 nuts on the leadscrew end ft a steel shim washer to reduce grinding when rotated. ‘Note that two MS nuts ae used here so that withthe first one the leadscrew ‘backlash is adjusted, and the second one. will then lock tho fies. Checking alignment ‘Qn all these components are in place, oil the leadscrew and guide shaft, run the block a few ines up and down between the plates to cheek for any wobbling or misalignment, and if satisfied that all seems ‘wel fx tho biock to the milling head rear face by wo hexagon headed bolts Tnekdentaly the oxginal miling hose block has 1 be first dismantled to enable the facing of is rear side 90 that it can then ‘sccomodiate the leadscrew block without ‘misalignment. and also to provide the recessary two Holes for fixing of the same dloce The ruler The last item is the ruler part No. 5) to be bridged between the top and bottom. plates, providing a read-out against the ‘vernir seale on the side of the leadscrow ‘block To mark the graduations on both the ruler and the block, use a sharp end mill at 45 deg, and do not feed it deep, otherwise the accuracy of reading would be impaired due to the width of the resulting groove: a typical cutter edge feed of 1mm on the vertical axis wil do, ‘When all is assembled, the whole ‘modified miling head can now be inorted ‘and removed from over the ming colurnn by just unlocking the clamping bolts on the top and bottom plates and sliding the head {up oF down while at the samo time slightly rotating the seme to and fro and taking up its weight atthe heavy end (motor assembly sie) Part details and scaled drawings Refer wo figures 1 though 8 All ports, except the guide shaft) are finished by heating ane blackeing in thick Dl The verner and wer gradations, 38 ‘wellas the handafite clr markings ae ‘hon fisheclin wit ping of whe wax orp kor congy ie and rote rom chipping of by applying an Crerpcyresere rene in rere {NF appears aganat a dimension ‘denotes thatthe particular dimension is Non Functional ie. Lean be altered to suit tho machinng process and tools 96 required. @ Gragutes fatter 10 Divisions MATERIAL-ALL MILD STEEL.FINISH, BLACKENED IN OIL. NF-NON FUNCTION DIMENSION. Vwv-PRECISION FINISH ‘Summer 1960 ape 8st Scns ‘When working to set dimensions, stops are invaluable as they a 8 ) ee VASSCREW = 9 both time saving and an aid to accuracy. Pat Twist offers something alittle extra in his version, and whilst they are designed for use on a Myford lathe, they can be adapted to suit machines of other makes without much difficulty. ;thout a saddle stop, boring a smalish blind hole to a fixed depth isa ‘dicey’ operation, (yas | ‘know there are such things a ‘0’ bits, but unless one has the correct size, making one takes longer than boring a hole} The danger is thatthe small boring too! might inadvertantly be fed in a fraction too ‘uch and one it lcky ifthe tip ofthe tool ‘snot snapped off In any event there fsa nasty scratchy noise at the end ofthe hole and the probability thatthe too! has moved. Without a stop the usual way of boring bind holes isto stop the lathe, ocd the ‘ool into the hole until the end of the hole is 2 {olt, or until a pencil mark on the bed ts reached, restart the lathe. put on the cut ‘and fie feed the tool out. With a positive ‘top however, ane can leave the lath running and feed the tool in and out a azen times if nocessary without having to ‘worry about the consequen ‘Messrs Myford have provided on the ‘back ofthe lathe bed a machined surface ‘with 6x in. BSF tapped holes, put there ‘0p ore the eens ‘shown inthe skatch, The two clamping pieces hold then, bar firmly to the back Of the lathe bed by two {in countersunk screws in the already tapped holes, and the thee fingers ae adjustable along the bar. “To use the stop, move the sade along the bed to the required postion, lift up the rearest finger on the headstock side of the ‘saddle and side the finger along the fin. bar until tho knurled stop touches the back loft hand side ofthe side. Five “adjustments can be made by screwing the Knurled headed bolt in oF out and focking t inpostion with the knurled lock put ‘Should one want a stop when moving to the right, use one of the other fingers. When not wanted, loosen the finger locking bolt and allow the finger to drop down, that's al, Wis.2 positive stop, accurate to 001 in, on a dial test indicator every ime, there is fh rrutilation of the Lathe at al, ad the device wil fit all models of the ML? range. ‘A 12n. length of 16 gauge sheet metal about in, wide with ane long side bent ‘over to an angle of 45 deg. rests nicely on the bar clamps and keops the devieo free from swat {A stop for the cross slide isa must on ‘occasions, imagine for a moment eiling the slide Valve ports in a cylinder block with a small size end mil inthe usual way, with the cylinder block held on the vertical slide. “The first cut of a few thousandths of an inch doep is made and the exoss slide handle is turned sevoral turns to finish up» (na calculated reading ofthe micrometor collar ‘With every increase inthe depth of eut this procedure has to be carefully followed {for al throe slots), One mistakan calculation could be disastrous ‘With across slide stop once adjusted it is just a matter of putting on the cut wi ‘the leadscrew handle and fooding the cross. slide in andl out without having ever to look atthe micrometor colar reading oF count The carriage stop showing the adjustable fingers which allow for varying positions to be used. Mode Enonec SADDLE STOP aastane Stor “A CP, earn ont Seam © } S| } oe vera} iersnee mas 4 eta 28 8 seiner Toft 14a! ‘SW GUT TRU PART "A'-BAR CLAMP. My" HS. Lemke RG 970-0 om Yeo ee Hees | ‘Seine van" le \ sawcur theusn PART ."B" FINGER 30011 54° 501% MS, The parts for the cross-slide stop. “The photographs and sketch really ‘explain everything, but here isa briet ‘description of how its made ‘Aa in. length of mid steel to the cross section ofa tee nut, for & strength I macle this part stand up than the cross side which necessitated the saddle shaped iter th itin place e sot, The shaped piece on tho end ‘and siver soldered in position in. BSE fo and tapped Sorcwed studing, length of The part with the open ended slot shown cleeely in both photographs isa piece of anole sitting over the gap in the lathe bed. Riveted to itis a Thx 11x 2m thick piece of mid steel accurately fing the qap berwoen the lathe shears. This ‘assembly fs clamped in place along the bed ‘with a keep plate loosely held in place with the choose headed serew as shown inthe: photograph, “This keep pat the gap in the bed is made to drop through iby turning ta verter ur, the sotted angle can be secur hatin place by Ovo! wi, BS Fea Screws. olso shown Inthe photogs. ‘Adjustable unutled nits and lock rts on the screwed rod either side ofthe Slotted angio enable the movement of the tross side to be accurately controlled. ‘uibe seen tht the screwed od roe (0 mmave slong the slotted angie asthe cut progresses. "he device can be easily made from bits fom the sera box wh no matlaton of the lathe, ls quielyfited and is precise nis action 9 The cross-stide stop in position on the author's Myford Lathe. 2 ‘any people probably wil have looked atthe drawings of the larger traction engine miniatures ‘published in the Made! Engineer from time {otime and decided that some components \were just too large for their equipment and turned to other things. It is my purpose in this article to describe how a former locomotive builder tackled and overcame ‘one of the more fundamental diferonces between traction engines and locomotives. ‘Whilst the general run of traction engines havo similarities with the locomotives —a boiler of the same classic ‘Stephensonian type, evinders, valve gear ‘and various accessories — the details are Certainly dissimilar. Traction engines ‘Alocomotive builder contemplating ‘constructing a traction engine of around 2 in seae is faced with a number of ‘outstandingly differnt problems than those encountered previously. The sheer site, in terms of diameter of some ‘components are a major hurdle t0 those of ‘Us whose lathe isthe ubiquitous 3: in. type: ‘mine is a Mylord Super 7 and what follows isrelevant to tha very many brands of machine of this capaci ‘AX first sight of waction ange drawings, the most outstanding tems are the final dive goat hind wheels and fywhee! Further examination will draw attention to the size and shape ofthe cylinder block. Wheels \Wheals may be fabricated using the well ‘proven methods propounded by the late W,. Hughes whon describing Royal Chester which give very good results, or machining can be eontracted ‘outside ‘Some rims are avaiable requiring no machining, the easiost of al. No ‘tremendous accuracy is called for with these slow-moving components. Stenath, to say the least, is ample; and normally, ‘appearance isthe most important eritria, Flywheels Flywheels, depending upon whether spoked, solid, or dished, ought to be ‘machinable ifthe lathe has 8 gap bed towing the diameter to bo swung. My Super 7 has handled the outside andl fms of 2 9in. dished Fowler flywheel using the foceplate for roughing and bing then finishing on a rutted spigot inthe mandrel Itwould be dishonest not to state that chatter may be expected or that no special tooling is needed, especially fr the rear of ‘the rims, but ican be done, Chatter marks ‘on the fim sides may be dressed off ‘carefully using a fie, cimensions are of less importance then appearance “Thera is much to be gad in dealing with these types of casting by the method ‘oF removing most of the metal at one l INTO A PINT Machining the components for» large scale traction engine such as this can be Uiticult on smal machines. This ardele describes a way around some of the problems. setting then removing from the athe fora Gears, ‘period in order to allow strosses to relieve. For solid or dished flywheels an anneting [process consists of heating the sem machined casting to a black heat and as slow a cooling as can be arranged accelerates the relief process In any event, Final drive gear banks, f cast require a ‘generous allowance upon the periphery 19 allow removal of any porosity, sand Inclusions and the like. An ‘outside! roughing operation to allow finishing in the workshop lathe may again be the answer, ‘with the consolation that someone else has hhad to deal with all the rubbish, ‘Night classes can be used where available to perform these tasks and with forward planning to ensure suitable Workholding equipment, tooling and s0 8 delay of a wosk or wo between ‘operations ean only be beneficial. ‘Another advantage is that with only ‘small amounts of motal to bo removed, ‘driving arrangements on the lathe can be lighter obviating ony risk of distortion ‘caused by heavy clamping. the spigatis _ fort, many ofthese jobs could be ideal in these citcumstances. completed over a sotios of evenings, In this article, CS. Bamford relates his problems in machining the components for a large-scale traction engine on a small lathe, and how he overcame them. Many readers will have had similar problems from time to time and may like to read of another's exploits, When it came to the cylinder block, this was specially cast for the writer in two pieces. Although it is unlikely that all readers will be in a position to get this work carried out, a normal cylinder block could, however, easily be split on a large band-saw. If one is not available in the home workshop (which seems highly probable) a local engineering works would almost certainly be willing to quote for sawing through it, and the work should not be too costly. More adventurous readers will, no doubt, wish to consider the possibility of sawing the casting with a hacksaw —a time consuming but practical idea if plenty of care is taken in the process... pe ea POT Meade! Enginaors! Workshop especially where larger machine tools are Installed; roughing one session and finishing another, or special arrangements ‘might be made for a longer stint. Cylinder problems (Gyinders however are a different proposition. Compared to even 7. in. gauge Toco eyinders they are chunky. oddly ‘shaped lumps of iron, especially for ‘compound engines and, at frst glance, may appear to present insuperable dificult for turning upon the class of Jathe under discussion. The major difference fs the curved flange to seat upon the boiler shell which will prevent offering the bore or bores to the tool inthe normal ‘Alternative resources may be used Where available but eylinders require to be ‘dimensionally accurate and usualy, ‘excepting the bore, there isnot a great deat ‘of surplus material to remove. Ideally, bore ‘nd other surfaces relating to them need: Setting to ensure the utmost rruth and ‘accuracy and are not condusive to repeated Setting and resetting, Cost would preclude Summse1960 urside machining for most of us and, personally, | profor to retain control over Such complex components and offer my Solution to the problem as one way of achieving the required result, Basic paramters to be aimed for aro that bores are to diameter and parallel throughout their length, and to each other if more than ona and correctly spaced in relationship to othor machined areas. Bore tends must be true to axis, especialy the slide bar end and the eurved flange to be Correct in relationship to bore and boiler Centre ines. This isa ital requirement to ensure the eventual ruth of crankshaft Journal to big end relationship. ‘To quarantoe this sort of accuracy | profer to use my Super 7 os a horizontal borer using the cross stide as the boring table. As an aside, and not as a Mylord shareholder, this machine was purchased in AStica in 1965, travolieg to the UK. in 1968. ‘and to Australia in 1972, al in the onginal packing case, Having been well used, but ‘ot abused (ell not often), its stil easly capable of work to toolroom standards. For my cylinders the limiting factor wos ‘the 2; in height of lathe centre above cross slide surface. Obviously, other makes will have diferent dimensions but the principle ‘remains. Thus a surface is required to llow the block to be clamped so that lathe and, bore centre tines coincide, Locating upon the port face to an angle plate oF vertical slide might allow some machining but at best the set-up would be flimsy and some designs have an inclined port face. ’A number of ideas ware examined including using the milling machine but this was rejected on the grounds of insecure holding and lack of faith in my ability to produce a good bore finish by hand! feeding the table. ‘Were the curved surface absent then a locating surface could be machined upon. the base of the blank to a dimension of 21 Jn. from the bore centre and machining ‘ould proceed at one setting. Splitting the castings Thus there was only one solution, 10 remove the curved flange and 19 machine block and ange as soparate enti, tejoining [ator ‘see photo 1)-Potterns were made by 2 colaague, incorporating boting tgs so placed as to ratch the oe slots on lathe and shaper Ample metal was allowed {or machining 1 give agood porosity free “Eile and bats commenced by Gripping in my lrgest machine vieo xed vo the Shaner table Even the ves required ‘magication by substitution of the moving {aw bya stee! Bar For hose without he luxury of a shaper, formation of these large fat surfaces can be achieved using ‘yeutting methods. Cleaning castings Prior to machining east motl the usual seivice, and sound ts to remove sand ‘snd scale using ol les, but in ths Gay and ‘90, the use ofan angle grinder may br prelerted and this used itis especially Celt rermave the hard idges share corners tendo clin the mould and hhardon. Absence ofthis metals kinder to the tool machine, and one's temper. Obviously,» shaper subjects the tool to this cause. Incidentally, | make my own, ‘special’ tioped tools by silver soldering 3 ‘used! commercial tip toa mid ste! blank, subsequently grinding to shape. ‘After te frst pass, examination showed that thin aroas such as the lugs were hard ‘on the edges and this was removed. When Soft metal was exposed, a high speed tool was substituted to ensure a reasonable finish and fat surface, Failure to remove the ‘hat spots wil result in excessive tool wear and an uneven surface, as testing with a ‘ule will quickly show. This is undesirable and must be guarded against. ‘The curved flange, fat surface was “similatly dealt wth: Helding of these wide in. BAAS. was mitod down the centre for depth of in-with {india eater and then Pevelod {onerousy on ts two outede edges Sijacent othe groove. See Diagram 4) ‘Tho pace was then sawn in two and the two halves held topetor ina vic ready for Welding: a eerap piece of i square BMS ‘was used to locate tho two halves tor Welding the Ves formed by the beveling the now Zin. square component was placod for hal is length in 3 four jaw chuck, act rum truly by the |i square serap and turned down unt no evidence ofthe Nat Sides remained. in, longth ofthis tuned potion was pated off and | was now in Dossession of a nea ite ender with an ccurate square hole running down ts Centre. Again. for those nots friar with welding, whore applicable, this technique Can be recommended as being splendly tick and, ofcourse, far superior 10 any sttempts at forming square oles fom ‘ound ones witha fie ‘One of the saw frome ends was placed inthe milling machine and ai. i {oove cut arose tnoar the end, ater Athich the aforementioned eylinder was ‘amped on the outer edge ofthe fame withthe square hole located in elgion to the oroeveln the frame by moans the same piece of in. square material A quick Diast with the weing tod and the two items wate fed tml togeter and ready for the blade tghtener This ast consisted Of a2 n-length of|n. BMS. the same Doce which had done al He ioating) and Inlled for Hal ts thickness fora cistance of init was then placed ina fourjaw chuck and the other end turned fora length of qin. toe digmeter of. (ocuntl the ats just dissppeated, A in BSW. toad wos fun on afr as t would go ater which an in olameter hole wos died nthe ctr of the mited portion. courtersank ti, hal lightly on the milo side 0 as NOT to Motor bracket The obvious means of supporting the ‘mind that, should I fia dashpot, this Ubeacket might also sorve as an anchor point other end of the motor was by using the forthe piston rod. A the time however! soldering @2in. piece of | in ameter tesiliont mounting, Accordingly, bracket was doubtful whether | would be able to BMS. rod in i. than bent the rod ‘inwards ‘Model Engineers’ Workshop | leave a filet of silver solder (the biade ‘would waggle about on this before STAGES FOR MAKING CYLINDER FOR BLADE TENSIONER The parts for the vice it can be used to ut metal at angles other than right- angles. slighty s0 as to form a hook, which would fend 10 make the blade seat fimiy against the milled surface when tightened. After Bending, the rod was cut off to final length Wing nut For this item, | adopted my standard [procedure for making. wing nuts, which is 8 follows Taper turn a 2in.tong piece of in diameter BMS. for a length of | in.oF 0, ‘Clamp squarely under the tooipost and sit Centrally with an in iting saw to the epth of the taper Sew Diagram 8) Strike 37. radius semicircie on a piece of in, BMS. cut out and file to shape- Assemble the two pieces (making sure thot they are {8n 083) fit or the soldat won't penotrato) fhux and silver solder Check that the solder Faas run ight through the joint on both ‘Sides. Shojve the wings by first fling @ SSomicircular depression inthe centre andi then shoping the ends; final shape se febviously dictated by personal taste. Grip, ‘chung pieoe in ‘and tap (BSW inthis caso}. Part off ‘base of taper. Vice The view jaws were made from 4 in Jengths of 2in, of the Frame prop am, contr dil, il Zin. 1 in black mild steel ‘angle. A 11 in. piece of 1 in. diameter BMS. Which hod been axially drilled {in, lometer ‘was then welded ach jaw and the {in diameter hole continued right through. Pieces of in. <1 in. <1in. BMS. we contra and welded to the heads of a couple {f 31in, Ln, dkametor coach bolts with the square bit under the head ‘Those were then usad to bolt the jaws to the runners, the square heads’ being pecessary in order to locate against the hase edge to prevent turning. “The vice serow was reseued from a long sinee discarded woodworkers vico nd after suitable tivation including re scraweuting the throad and turning the end to an included angle of 90 degrees, ‘was matched with a new nu shoulder on the nut and made ta press fit inadin length ot in in BMS. which hod been bered to receive it and filed concentically semicircular with the hove This component was then welded position on the end of the base in the ‘entre of the runners. The conical end of the serew was used to mark a position on the naarer vie jaw which was thon ‘countersunk to recerve & ental position on riled through the Lifting handle {needed to provi a means of ‘weighting the saw frarve and decided thot the weight carrying rod could also serve as convenient lting handle. Accordingly, a pair of Sin picces of ‘were prepored by dling in. diameter holes through them at one end and sloting tho other end to fit over the '’ frame; these ‘were then held in position by cheese heated screws. niall thd planned for just one weight tobe used but found that the saw cut rathor sowy, | added weight of the same dimensions ‘which improved matters considerably. 1 in. diameter plastic ball screwed tothe end od provided a comfortable handle in. square BMS, (One ofthe things which always irritated me when using a certain industrial hacks ‘was the method by which the saw wos Supported betore being re ‘ut This was by a huge ungainly prop ‘which was controled by 8 long fod and ‘operated by the thumb. One had to take the not inconsiderable weight ofthe saw by the emoved) I provided a paved for the i INITIAL STAGCS IN MAKING WING NUT. ' DIAGRAM 6, SECTION THROUGH CL MOTOR BRACKET OMITTED IN THIS VIEW power ‘oven more stractve and stsying to oso he provision of a dashpot a provide back stroke rele! orthe blade Diagrams on this poge describe it. Parts of the dashpot ~a vital piece of the design. ‘Model Engineers’ Workshop ‘lustration above shows how the dashpot provides support to the saw on its return “s270ke. Below, 8 rear view of the completed saw. of an ol eup and piston. As ‘mentioned earlier at tho time of making tho ‘motor support brackat,| entertained Fanciful notions of using it some way to hold such a device but space was 30 restricted that | ket dismissing the idea. Finally, however, the accumulation of thumps crystallised my thoughts and I hit upon the idea of suspending the cylinder fon trunnions in the space beneath the bracket Rummaging around amongst my serap, | produced a piece of 1 in, diameter brass tube which had certainly seen better days ‘but which | thought could be pressed into Service. After removing several dents by Careful planishing on a piece of round bar, | ut the tube to length and skimmed both fends in the lathe. A Ranged base was turned and siver soldered into ene end of after which | turned my attention to the unnion plate. This | made from a 2; in Iongth of 2in. <1. BMS, on each end of ‘which I turned an, long by (in. diameter trunnion before boring its centre out forthe “Hing handle, ress tho knob at the ond of ‘he rod and, tthe same time, attempt 10 teach down and switch on the machine “Bhogether a somewhat daunting feat. “Getermined that my saw should not be so Isatoward to use as this and accordingly