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  • Fender brace, 1st milling project

    If Bulldog is still around, he will get a kick out of this one.
    I finally got my turn tables mounted and most of my tooling issues straitened out. The first pic is a drawing of the piece.
    Second pic is making new jaws for the vice to compensate for the base that is worn off square and the excessive jaw lift when its tightened.
    The next pics are just the order of progress. I squared the sides, flattened the face with the fly-cutter then squared the ends.

    Now I'm debating how to continue now that the plates are flat,true and parallel. My plan of attack is to cut the to the widest length and width detentions, then drill and tap the bolt holes.( the bolt holes are not clearly marked on the drawing but I'm sure you can figure out where they are.) Next will be to drill the 1.625" hole with the boring bar, then put it on the rotary table to shape the outside dimensions and last I will cut the slot in the clamps.

    If anyone sees a problem with my plan, please let me know. This is my first project.
    Attached Files
    To all who contribute to this board.
    My sincere thanks , Pete.

    Pureox OA
    Westinghouse 300 amp AC stick
    Miller Syncrowave 250
    Hexacon 250 watt solder iron

  • #2
    This is a more descriptive drawing of the brace. I couldn't find it when I started the first post, then it popped up when I went to check a dimention.
    Oh well.

    To fill you all in, this is part of my headlight project, hears a link to it.
    http://www.millermotorsports.com/mbo...dlight+project
    Attached Files
    To all who contribute to this board.
    My sincere thanks , Pete.

    Pureox OA
    Westinghouse 300 amp AC stick
    Miller Syncrowave 250
    Hexacon 250 watt solder iron

    Comment


    • #3
      Well, I finally finished the braces.They came out real good except for the corner rounding, I'm sure its due to using a cheap Chinese rounding mill. I could see it did not turn true and it felt like only one of the 4 flutes was actually cutting metal.
      The inside radius and all the flat stuff is very smooth but the corner rounded portions feel like snake skin. The first picture shows this very well, although the piece is not complete. The other pics are the finished pieces. I'm not sure what to do about the rough texture of the rounded parts to make them smooth without distorting the shape. Was thinking maybe hand sanding with 320 paper?
      Any suggestions welcomed.

      I just hope when I finish this project, my health will be good enough to still ride. I had to go to the doctor after testing out the riding mower for the neighbor kid that mows our lawn now.

      I have pictures of the whole process of making these if any one is interested in seeing them
      Attached Files
      To all who contribute to this board.
      My sincere thanks , Pete.

      Pureox OA
      Westinghouse 300 amp AC stick
      Miller Syncrowave 250
      Hexacon 250 watt solder iron

      Comment


      • #4
        Nice work, Briar.
        AutoArc 230 (MM 210)
        3035 spoolgun
        Spectrum 625
        Dialarc HF w/Coolmate 4

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        • #5
          Originally posted by bob_e95482 View Post
          Nice work, Briar.
          Thanks, any suggestion on what to do about the snake skin texture on the corner rounded parts?
          To all who contribute to this board.
          My sincere thanks , Pete.

          Pureox OA
          Westinghouse 300 amp AC stick
          Miller Syncrowave 250
          Hexacon 250 watt solder iron

          Comment


          • #6
            Briar, Scotchbrite wheel [#9N] for bench grinder,for the snake skin removal, it does a great job of deburring, sometimes called a convoluted wheel. about 50 bucks but lasts a very long time is is great also for deburring edges, hope this helps, Paul
            More Spark Today Pleasesigpic

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            • #7
              Hey guys,
              Pete,
              The Bulldog is still around... Things here have been real busy. (were still going 7 days a week) I don't have alot of time to respond much any more but I still try to read most of the post.
              Your work looks great! I have been keepinng up with your milling machine saga. Looks like you got things worked out and your definitly moving in the right direction. Good job!
              I'll try to get in here more often.
              See ya,
              Bulldog
              5 Passport Pluses
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              REAL TRUCKS RATTLE
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              • #8
                Pete, Project looks great, I like the textured look, it would be the custom touch for me.
                I would like to see the whole process, so I will be the first to ask for the full photo essay.

                Comment


                • #9
                  Good job..............most that have not machined before have not a clue what it takes to make a part like that. When I made my cnc table, I'm sure glad I had a lathe and mill.
                  Nick
                  Miller 252 Mig
                  Miller Cricket XL
                  Millermatic 150 Mig
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                  2-O/A outfits
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                  www.youtube.com/watch?v=jTu7wicVCmQ
                  Vist my site: www.nixstuff.com
                  and check out some of my ironwork and other stuff

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                  • #10
                    I'd love to see the pics of the whole process. What mill is that?

                    Comment


                    • #11
                      burninbriar, thats great. you shore seem to have the talent for that thing. its got to feel great to be turning out your own part.
                      i have never used a mill but have used a metal lath and i can just imagine the work involved in getting it to come out like that. great work.
                      i really hope you get to ride when you finish it, if it was me i would find a way to ride and deal with the consequences after cant wait to see the finished project. the more pic's the better i say.
                      lish189 welcome to the site, always good to have new people with new idea's.
                      thanks for the help
                      ......or..........
                      hope i helped
                      sigpic
                      feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
                      summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
                      JAMES

                      Comment


                      • #12
                        Originally posted by paulrbrown View Post
                        Briar, Scotchbrite wheel [#9N] for bench grinder,for the snake skin removal, it does a great job of deburring, sometimes called a convoluted wheel. about 50 bucks but lasts a very long time is is great also for deburring edges, hope this helps, Paul
                        Iwas looking in the Enco catalog and they have what seems to be the equivalent to the Scotchbrite wheel, but I think I will look for the real thing. Thanks for the advice.
                        Originally posted by lramberson View Post
                        Pete, Project looks great, I like the textured look, it would be the custom touch for me.
                        I would like to see the whole process, so I will be the first to ask for the full photo essay.
                        Well, here is the rest of the pictures. There is 6 of them so it will have to be in 2 posts.

                        Pic 1 - After flattening and squaring the pieces I drilled and tapped the bolt holes. Then I registered the vice so I could do each operation to both pieces simultaneously, then center-drilled, and drilled a 1/2" hole (not shown) to start the 1 & 5/8" hole.

                        Pic 2 - I put the boring-bar on and enlarged the hole's to 1.625 doing both pieces at the same time with each adjustment. I hung a cutting from the milling machine head so someone might comment on it. Is this very long cutting desirable? I thought it was neat any way.

                        Pic 3 - I cut down the flats for the clamp bolts.

                        Pic 4 - I used a 3/4" roughing mill to bring the pieces down close to the finished shape.

                        Pic 5 - I put on a 3/4" 4 flute mill to clean up the cut and bring it to the finished size.
                        Attached Files
                        To all who contribute to this board.
                        My sincere thanks , Pete.

                        Pureox OA
                        Westinghouse 300 amp AC stick
                        Miller Syncrowave 250
                        Hexacon 250 watt solder iron

                        Comment


                        • #13
                          I did not get a picture of the piece of junk Chinese rounding mill in action, I guess I was too angry at it.
                          The last picture - I used a 1/32" X 3 1/2" slitting saw to cut the slit for the clamp.

                          The last two pics are just repeats of the finished product.
                          Attached Files
                          To all who contribute to this board.
                          My sincere thanks , Pete.

                          Pureox OA
                          Westinghouse 300 amp AC stick
                          Miller Syncrowave 250
                          Hexacon 250 watt solder iron

                          Comment


                          • #14
                            Thanks Pete, nice project! I still like the textured look, I guess that is why I use so much wrinkle/texture paint..LOL
                            If you do any more mill work please post up, very neat stuff.

                            Thanks again for the pictures.

                            Comment


                            • #15
                              it dose look neat like it is, but it could only be in the pic. in person it could look entirely different, or it could just be he knows its not supposed to come out like that so it will always bother him if he leaves it like that.
                              although it would stand as a reminder to him, he cant buy cheap tooling. although i bet the thing wasn't that cheap to buy anyway.some times even the junk is expensive.
                              thanks for the help
                              ......or..........
                              hope i helped
                              sigpic
                              feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
                              summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
                              JAMES

                              Comment

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