AOG's take on Elmer's No 2 Twin Vertical Wobbler

[AOG]

It's a new year and I have some new toys to try out. The biggest one is a new milling machine (a Precision Mathews PM-932PDF) to replace my old minimill. The intent of this build log is to get to know my new milling machine by building as much of the Twin Vertical Wobbler on it as possible. I started by squaring up a piece of stock for the sub base.



Then I face milled the top.



I then attempted to tap the holes with the tap in the chuck.



On my old mini mill I did that all the time to make sure that the hole was tapped streight. The new mill with it's geared head just doesn't have the same level of sensitivity as the old mill. I ended up chickening out and finishing the holes by hand.



Next it was time to mark out and drill the holes for the pivot and crank shafts.



Then the holes were reamed to size.



My new mill has A DRO but I decided t mark out the sub base  while I am learning to use it.



I used the DRO to position for the first cut and cross checked it with my laser spotter. The DRO was dead on.



I then drilled the 6-32 clearance holes



Then I picked up the outer base mounting screw marks with my laser



And then drilled them for 4-40 clearance holes.



After trying the 2 methods I think that for non critical holes the mark out and drill to the marks is faster for me.

Here is the final sub base.



Next it was time to start on the vertical piece.

Again I started up by squaring up a piece of stock



Then I faced both sides.



I then payed out and coordinate drill the tap holes for the base.



Then I set up the piece to cut the required slot. Un fortunately I got to aggressive with my DOC and I ruined the piece.



These things happen when your trying to learn a new machine. I started on a new piece and got as far as drilling the mounting holes. I decided to try something different with the tapping. I have recently won a tapping head on the bay and I thought I would give it a try. After a couple of test holes in my ruined part to set the torque I tapped the piece. On the first hole the torque wasn't high enough and I had to finish the hole by hand. On the second hole I set the torque to high and broke the tap. Thankfully the part is aluminum so it is currently bubbling away in some alum. With that I think I'll call it for this post.

Tony

[b.lindsey]

Nice start Tony and a nice looking new mill too from what I can see.  Maybe you will shame me into finishing the #2 I began over a year ago. We have a new crop of Juniors starting on this project now for their Junior design project only there's will be at 2X scale.

Bill

[Roger B]

Learning by doing is always good  I also have 'acquired' a tapping head I need to learn how to use 

Can you add a picture of the mill for those of us who don't recognise it?

[AOG]

Roger the mill is a Precision Mathews PM-932 with power quill feed. I was planning to write up this weekends progress when I get home. I'll toss in a picture of the mill with that post.

Tony

[AOG]

There was not a lot of progress to show from this weekend. I spent most of the time getting back to where I was when I trashed my last piece. Let's pick up with milling the slot.


After that was complete it was time to make the drill jig for the ports. I started by laying it out on a piece of tool steel.



Then I picked up the starting hole with my laser spotter.


Then I coordinate drilled the holes in the jig.



Then I used my transfer punches to mark out the ports for both cylinders using the jig.



I used my spotting laser to pick up the port markings



Then I drilled the intake and the exhaust ports.



Followed by drilling the oil holes for the bearings.



At this point I realized that I forgot to transpose the ports onto the faces so I took care of that



Using the laser I picked up the scribed lines



And then coordinate drilled the exhaust holes and the intake.



That's when I figured out that I didn't have the tap or die for the 3/16 MTP thread called out in the plans. In the end I decided to go with a 3/16 ME  thread instead. I ended up ordering the tap and die set from PM Research. Work on the vertical is complete except for the tapping of the intake (which I will do when tools come in). My next step is to start work on the cylinders. On a final note Roger asked for a picture of the new mill so here it it.



Tony

[cobweb81]

Congratulations on your new toy. Looks like a nice machine, hope it serves you well.

[Roger B]

Thank you for the picture  Indeed it looks a nice machine   

[AOG]

Thanks, it's certainly a step up from my old minimill.

Tony

[philjoe5]

Nice mill Tony.  And good work on the Wobbler.  I'm just starting to research making a simple Wobbler for our Makers Group.  Seems like a good starting project.

Cheers,
Phil

[AOG]

I got some more work done on the engine this weekend. I made both of the cylinders. Both cylinders were made the same way so I am only going to show one. I started by squaring up the cylinder blanks



Then I drilled the pivot holes



Followed by milling off the top corners of the stock



Then I drilled and reamed the bores



Next I put the blank into the 4 jaw using a mandril in the tailstock to help align the blank



Then the top of the blank was turned round



After that it was over to the mill to cut out the guide.



Then I milled the bottom of the cylinders away per the plans



The remains were marked it up for fileing.



Afterwords was some quality time on the die filer.



Since my tap and die came in I threaded a piece of brass for the inlet



Then I drilled it and parted it off



I also took the opportunity to tap the inlet port in the vertical



That's it for this weekend so I will leave you with a family shot



Next time I will start on the pistons and finish the cylinder ports

Tony

[b.lindsey]

You are making some fine progress Tony. Those cylinders look great!!

Bill

[AOG]

Thanks Bill. I think I am finally getting the hang of this new mill. It's amazing what a difference a DRO and a power feed on the table make. It has me seriously considering a DRO for my lathe.

Tony

[Jo]

It has me seriously considering a DRO for my lathe.

You need it Tony  I love having DROs on the two larger lathes.

Jo

[vascon2196]

Great job....nice machine!

[Roger B]

Nice work    Looks like you are getting on well with the new toy