Martin Models Die Filer

[Kim]

With all the filing I anticipate doing on my clock project, I’ve been thinking that I need a Die Filer.  So, earlier this week, I did something about it.  I finally picked up the Die Filer casting set from Gary Martin, of Martin Models.

I’m quite excited about the prospect of having a die filer in my shop, and about having a new little project to do!  I got the 3 casting model without the belt pulley since I'm planning to use a V-belt to drive the unit.  I also, as you can see, opted for the square table, rather than the round one.  It felt like I got more table area with the square one, though I doubt it really matters much either way.


After spending the requisite time fondling the castings, I can tell you that they seem to be very high quality, and have plenty of meat on them.  I should be able to hit all the critical dimensions quite easily! 

I decided to start with the table.  And my first step was to make the table flat.

I have a 2.5” insert face mill that I’ve never used before, and I thought this would be the perfect time to break it out and use it.

After an absurd amount of time figuring out a decent way to hold the casting, I finally got around to facing off the table.


It took many passes and a lot of clamp leapfrog, but I eventually got there.  The face mill performed admirably.


Next, I’ll work on the underside of the table.

Thanks for checking up on my new project that I started even before I completed my other one! Nesting projects is a time honored tradition in this hobby, it seems. 

Kim

[Dave Otto]

Hi Kim

Looks like you are off to a good start, it will be fun to follow along and see how everything works out for you.
I recently tore my Keller down for restoration because I have been making a new sheet metal cabinet for it to mount on. It is copied from some photos of an original one that I collected some years back. I figured that I should get it done while I'm still working in the shop at my day job. That R word gets closer every day.
I have all the repair work done and new paint, maybe I will post some photos when it is complete.

Dave

[crueby]

Oh boy, another Kim project to watch!  Buckets o popcorn are ready!   




And is that a brass 1 2 3 block that I  see behind the steel one under the table casting?




I have to agree on the quality of the Martin castings, the ones I have gotten were great!

[Kim]

Thanks Dave and Chris! 

Yes, Dave, you should DEFINITELY share some pictures of it with us!   I always love to see pictures of your work!

Chris, it's a goldenish colored 123 block, not brass though.  For some reason, one set I bought was coated.  Not sure exactly what the coating is, but it gives it a golden look.  In that picture it does look like it could be brass.  But when you see it in person, it's very clearly not brass! 

But that could be a fun project, make a set of 123 blocks in brass! Sounds like a good Christmas present for your favorite model machinist, doesn't it? 

Kim

[crueby]

Thanks Dave and Chris! 

Yes, Dave, you should DEFINITELY share some pictures of it with us!   I always love to see pictures of your work!

Chris, it's a goldenish colored 123 block, not brass though.  For some reason, one set I bought was coated.  Not sure exactly what the coating is, but it gives it a golden look.  In that picture it does look like it could be brass.  But when you see it in person, it's very clearly not brass! 

But that could be a fun project, make a set of 123 blocks in brass! Sounds like a good Christmas present for your favorite model machinist, doesn't it? 

Kim

That would be fun! And make the blocks with holes and threads to match the hold down clamps for more versatility?  Hmmm, how to get the elves to make me a set?!   

[Krypto]

Side quests are the best part of a project.  Sometimes I spend more time on them then the actual main project.

Before your post, I hadn't realized there's another die filer kit besides the one from MLA.

[cnr6400]

 

[wagnmkr]

A very handy tool to have Kim when projects contain the amount of filing that yours do.

I too have the popcorn out and ready.

 

[mklotz]

Many years ago, on a whim, I made a set of half size 123 blocks = 0.5-1.0-1.5.  It was only later that I discovered that they were as useful, if not more so, than their big brothers.  I

[bent]

Need a tool, make a tool.  Love it! 

[Kim]

Thanks for the comments, everyone! 

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.    Ah well, I got there, even if not the optimal way. 

Thanks for stopping by!
Kim

[crueby]

Wow! The Leaning Tower Of Filer!  Never seen a clamping setup that tall.   

[cnr6400]