I actually got this completed before Christmas but haven’t had a chance to upload till now. So here goes!
Chapter 17.11 –Link BracketsThe next parts up are the Link Brackets. These mount onto the guide yokes and will hold the previously made Expansion Links at the pivot pins.
The link brackets were made from a length of 1/4" x 3/4" 1018 bar. The first thing I did was to shave the 1/4" thickness down to 0.200” per spec.
Only the mounting surface of the brackets are 0.200” wide. The main part of the bracket narrows down to 5/64”. To narrow it, I used a 1/4" carbide end mill. This gave me the required 1/8” radius where the part widened to 0.200”. Since I was going to be doing this four times, I made a removable stop setup from some 123 blocks and a parallel. I could push the bar out to hit the parallel and tighten the clamp down, then slide the parallel out of the way.
Here’s what it looked like with the narrowing maneuver completed.
Next, I cut the narrowed end off the parent stock so I could make the next one.
With four of these nascent bracket blanks I needed to square up the cut end and bring them to a specific length.
Now, using the newly formed base as the datum, I drilled and reamed the 1/8” hole for the pivots exactly 3/4" out, and centered exactly on the part.
And using the DRO set exactly the same, I drilled and tapped the mounting holes in the end of brackets. These holes are centered on the width, but most importantly, they are located the same distance above and below the pivot hole we just drilled. But by using the same settings on the DRO, I am guaranteeing this. Far different processes than Kozo uses, but he wasn’t assuming the reader had a DRO. I believe I can be far more accurate using this procedure than the way he described.
Now for the most complicated operations – cutting the angles on the sides of the brackets. Luckily, this is not that critical, it’s mainly for looks so the accuracy isn’t as important. I calculated the angles to be 15.1
o so I just rounded down to 15
o and used that. It seemed close enough.
For the first side, I made this setup – it’s the bracket with a bunch of packing all set on a 15
o angle block. The actual bracket is sandwiched between a piece of brass and a piece of aluminum and backs up to yet another chunk of aluminum. The piece in the back keeps the part from sliding down the angle block and the brass shim and aluminum packing allow the vise to clamp down on the bracket since it is narrower than the 1/4" wide angle block.
Just to check my setup I removed the aluminum block so I could make sure the angle was coming out in about the right place, and not TOO close to the hole.
With my checking out of the way, I went ahead and cut the side down. I took many small passes since there really isn’t much of the bracket being held in the vise. But it seemed to work pretty well. The additional piece of packing you see sticking out at a jaunty angle on the right was added partway through to hold the back 1/8” aluminum packing in place. It actually isn’t clamped in at all and would jump around terribly during milling. That wedge helped significantly.
Here are all four brackets with one side angled.
For the second side, I changed the angle block to 30
o. I also had to re-arrange all my packing. I did a much better job of it this time
The short parallel sticking out of the vise on the right can be removed after the vise is clamped down on the part. And when that is removed, the angle block can slide over to the right to help get it out of the way so I don’t accidentally take a bite out of it!
And here they are after the second side was angled.
Finally, I made a 9/32” filing button and rounded the ends of the brackets.
Here’s the completed angle brackets:
The next part will be the return crank.
Thanks for stopping by!
Kim