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The dynamo and the tu-tu

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zeeprogrammer:
Made you look.

But if you're here for the latter subject you'll be disappointed.
You are welcome to add your own appropriately related posts to this thread. I'm sure they will be appreciated.

As for the former subject...well you might still be disappointed.
It's the PMR Dynamo. Well known. Done and posted thousands of times.
But this one is mine and therefore unique (even if I have to add a tu-tu when finished).

I've been sitting on this model for nearly a year. I'd had big plans for it but not having had time to do any machining for so long I decided to simply make it stock. One of the ideas I'd had was to make a small diorama. The top of the dynamo has a real bad parting line and I was thinking of making a tiny catwalk to go across with a ladder coming up. Some HO figures, a few boxes, maybe a wall...you get the picture.

But job, daughters, daughters' animals...LIFE!...has been in the way and I don't know how much time I have available.
I need a hit of oil so I'll just do what I can do.

So to make this more interesting...come one, come all. Post a joke. Take a jab. Sing a song. (Keep it clean.)

So here's a pic of what you get...

A frame casting. Well made except for the parting line on the top.
Shaft and brush end aluminum castings.
A pre-built armature.
Magnets, bushings, couple of bits of metals, brushes, screws.

Now I need to remember how to post pictures. For that matter...to take better pictures. Sorry about that.

zeeprogrammer:
So you may have noticed the frame has already had some machining done.
My first mistake was not taking the family picture first.
(Or was my first mistake joining this forum?)
Additional mistakes to follow.

Here's the base milled...



Boring. First time I've used this tool. At least with any success.
I used the 4-jaw and indicated the sides and top to get as centered as I could.
I was a little concerned about tilt but placing a parallel on the base seemed to show things were close enough.
It came out well.



I had a picture of facing one end but it was so out of focus there was no point.
This one isn't much better.



And this is no good either.
Drilled the holes for the mounting. You can see one scribe line that was off.



Next step is to spot faces the other side of the mounting holes.
I'd hoped I had a countersink but the 1/4" I need has too large a pilot.
The shaft of a 1/4" end-mill is too big to get past the frame.
Guess it's time to sacrifice a 1/4" drill bit and grind it down.

That's it thus far. No idea when the next installment will be.

But at least I got a little dirty.

b.lindsey:
Nice to see you getting dirty Zee :)  Its a great project that you will enjoy I'm sure and you are already off to a good start!!

Bill

fcheslop:
Nice to see you getting back in the saddle you know getting dirty is the only way to go.
Good luck
best wishes
frazer

mklotz:
It's great to see you back, Carl.  I've missed your humor.

Re cutting pads and need for confined spaces cutter...

Go to Lowes or similar and look in their Dremel accessory cabinet.  Try to find something like this...

http://www.micromark.com/1and4-inch-straight-bit-for-dremel-trio,11408.html

or their straight wood router bit or their multi-tooth 1/4" cutter.  Dremel is very proud of their accessories but you might find something similar at HF or the like.  Remember, cutters meant for wood will work just fine on aluminum.

The alternative is to grind down the shaft of a 1/4" mill but that may be beyond your patience and equipment complement.

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