Supporting > Tooling & Machines
Martin Models Die Filer
Kim:
Thanks for the comments, everyone! :cheers:
I think I've seen pictures of your little 123 blocks somewhere Marv. Have you posted those here before?
Kim
Kim:
The next thing I did on the table was to mount it to the mill table upside down, with the face I’d just trued up facing down. I did my best to make it square with the table (as good as you can with a casting) and found the center, then drilled a 3/8” hole there. Using the center as my reference, I cut the quadrant flat on both sides.
The inside edge is specified at 1.940” from the center, but I made it 2” because that should work better with the base – i.e. hopefully keep the hole closer to the center of the boss on the arm on that casting. Or at least, that’s my hope. There are lots of casting pieces that need to line up. I guess we’ll see whether my calculations are right or not when we get there. The quadrant is left 1/2" wide, but flat on both sides.
Then I did another complex setup, mounting the die filer table on the rotary table, I lined the center of the top of the table with the center of the spindle (and the center of the Rotary table, of coures!)
And with this fancy setup, I milled the outside of the quadrant smooth and even. The plans don’t call for this, but I may end up doing the same kind of hold-down retention that Dave did on his die filer. And for that to work, you need the outside of the quadrant to be uniform. I thought Dave's method was really neat, and I may choose to do that eventually. So I’m at least leaving the option open. ;)
Here’s a link to Dave’s die filer build showing how he made a pivot under the table quadrant. He also uses that brass chunk as a support for his hold-down and back-of-file support. Very clever, I thought. He has a picture of the completed unit later in his build log here.).
And finally, I moved the table over and cut the radius groove that allows the table to tilt.
This was a very satisfying series of operations! This cast iron stuff is pretty fun to play with. I can see how people get addicted to castings :)
Kim
Kim:
Next, I started on the base.
My first step was to make the bottom of the base level so I can use that as one of the references going forward.
This chunk of iron is a little more gnarly to hold than the table was! I worked at it for some time, and this is what I came up with. The feeler gauges are in there to ‘level out’ the draft angles on the casting. My fear with this setup was that as I played musical clamps, the pressure changes would cause minuscule changes in the level of the casting base.
When all was said and done, I got the casting as level as I could get it. This picture shows me checking the level of that center post in all orientations. The larger photo on the left shows the angle down the back side of the casting. The two smaller ones show the angle on either side of the base. It’s tilted a little on both sides, but is pretty near the same. I’m thinking this is from the draft angle of the casting?
And, as it turns out, I was right to be worried about my clamping. I didn’t have any problems with the casting moving, but as I would take one clamp off, that corner would raise up a few thou. This was my concern, and it proved to be true. I was able to adjust for it a bit, though, and got very close.
I did a little sanding of the bottom side of the casting on a flat surface, and that seemed to work to remove the little discrepancies that I had. In the end, the casting does sit quite level on a flat surface, and I’m pleased. I think this is the most difficult clamping step, and I’m glad it's behind me!
Though there are still some squirly setups to come, I'm sure!
Looking back on it now, I should have just moved the clamps a little to the left or right rather than taking them off. :facepalm2: Ah well, I got there, even if not the optimal way. :embarassed:
Thanks for stopping by!
Kim
crueby:
Wow! The Leaning Tower Of Filer! Never seen a clamping setup that tall. :NotWorthy:
cnr6400:
:ThumbsUp: :ThumbsUp: :ThumbsUp: :popcorn: :popcorn: :popcorn:
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