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Two things you can count on (hopefully!) T-nut is spelt tee nut Myford super seven is spelt Myford Super Seven 7

Number Page Title 1 10 Hello and welcome 1 1 1 12 14 18 A useful plate vice Attachments for dial test indicators Try squares with a difference

Content Stan Bray Alan Buttolph makes a plate vice that slips into the ordinary vice jaws R J Loader describes attachments that will aid setting-up accuracy R Wallman illustrates how common engineering practices can differ from country to country and describes try squares used by French craftsmen Mr Farrugia describes modifications for the Emco Compact 5 Peter jones describes a use for pickled onions and brass and copper Pat Twist describes stops used on a Myford but adaptable for other lathes

Comment how it's made making the components, the slots, the arms, the styli, a final extra.

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Milling head mod for the Compact 5

degree of accuracy, parts and assembly, the guide shaft, handwheel, checking alignment, the ruler, part detailed and scaled drawings.

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Quick tip Stop that

cross slide stop, saddle stop. traction engines, wheels, flywheels, gears, cylinder problems, splitting the castings, cleaning the castings, boring the cylinder, the cylinder flange, joining the cylinder parts, checking the fit, taking initial measurements, a special boring bar, conclusion. a space problem, in use. a perfect fit, hidden extras. irons, joints, applications, blowlamps, types of solder, fluxes.

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A quart into a pint pot

C S Bamford relates his problems machining the components for a large scale traction engine on a small scale lathe and how he overcame them

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Quick tip A cradle for the Amoloco milling machine attachment The Hobbymat variant A hidden workshop Soft soldering Quick tip Engineering of the future A useful keyway cutter Rotary table plan

Plastic clothes line as a small brush K Spredborough tells how he coped with his on a Myford lathe Peter Jones takes a thorough and critical look at a wood lathe Les May describes his An in-depth survey of what is involved Recording your thoughts The Editor visits a trio of exhibitions A compact add-on feature for your lathe T Daish the body, pivot support, the ram, pivot arm, handle and cutter, smaller cutters.

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Choosing a chuck

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Home made precision optics

Bluey describes his optical centre-punch and centre-finder

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Bench vice versatility A rotary milling device Using and caring for twist drills

How to get the best from yours A simple device by Tony Daish How to use and look after

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A power hacksaw

This one by John Brittain is made form stock materials

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Electronic setting up device

By Edgar Powell

three jaw self-centring, lack of accuracy, living with the faults, four-jaw independent chuck, four-jaw selfcentring chuck, drilling chucks, buying a chuck. the optical centre punch, the support body, the insert, polishing, the centrefinder, the body, assembly, using the centre finder. hammering on the vice, excessive force, removable jaws, making soft jaws, other attachments. making a start, now for the table, in use. drill nomenclature, the business-end, gauges. base construction, 'H' frame, saw frame, crank and connecting rod, motor bracket, blade fittings, wing nut, vice, lifting handle, frame prop, dashpot, stop switch. and fuse tester, construction, manufacture of the probe, the acoustic edge finder/tester, extension piece for the probe, the pen probe attachment for the acoustic device, method of use. metric threads, quenching oils, the Pittsburgh Lock, blow holes in castings.

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In our next issue Scribe a line Questionnaire On the editor's bench In our next issue Stan Bray the mainframe, the tilting block, the pulleys, the pulley spindle, the blade tensioner, the bottom bracket, the table, the centre plug, blade guides, mounting the machine, the motor, the guards, finishing the machine, obtaining the materials. the threading tool, theory of operation, using the tool, construction, taper turning, conclusion.

Make a three wheel bandsaw

Raymond Wood set about making a very robust machine

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A variable lead threading machine A simple tapping device An aid to silver soldering

Ted McDuffie presents a design for his Myford Super Seven 7 An idea from Ron Wallman A simple feeder/shield device

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Special material tools

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Electricity in the workshop

Here the basics are discussed for those setting-up a new workshop or contemplating a spot od rewiring

coated tools, tungsten carbide, tool setting, replacement tips, brazing tips to parent stock. new methods, basic electricity, direct current, alternating current, voltages, three-phase electricity, connections, series, parallel, ring mains, positioning of sockets, safety cut-outs, low voltage circuits.

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Trade counter Welcome to the workshop A simple trepanning tool Quick tip Low voltage lighting

Drawings and castings, useful catalogue, as vice clamp. Arthur Casebrook Cutting large diameter holes in very thin sheet can be a problem. This little trepanning tool does the job very well and is easy to make. Cheap paper kitchen towels Bluey sets about organising some low voltage lighting

the body, the shank, the tool bar, the adjuster, the cutting tool, using the tool. the first experiment, stage two, a lamp for the lathe, the lamp cover, notes on quartz halogen lights, transformers, safety. safety, work and tool holder, height gauge, wobblers and wigglers, back to height gauge, starting work, depth of cut, feed, holding the work.

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Tyro time Swing clear tool post Quick tip Swing clear tool post Small knurling tool

Getting started with your first lathe pull-out drawing Using old fat for tapping

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High temperature soldering A visit to Jack Sealey Ltd Small piece storage Quick tip

the extension, the tee slot, tee slot cutters, strengthening bar, the tool post, the tee nuts, the handle. the slide plates, the arms, the pivots and spindles, the clamp, the holding bar. torches, the work area, the brazing bench, the soldering operation, unsightly work, the materials, fluxes, high temperature soft solder, safety. A use for 35mm camera film cases Candle soot as an alternative for engineers blue the solution, other uses, the baseplate, making the dovetails, the spindle block, dovetail strips, the clamping block, the index collar, making the collar, the cutter spindle, the handle, assembly, using the tool.

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Hand milling attachment

A design by Les May

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Getting it right Quick tip Eliminating backlash Scribe a line

This article deals with two aspects of machining, accuracy and conversion metric/imperial Making identical plates G G Tardwell tackles the problem

dial test indicators, the method, fixings, the cross slide, the saddle, the vertical slide, the milling machine, the down feed, backlash, other uses. the original conclusion, updating the idea, construction. where to get materials, specialist screws. the bed, bed spacers, headstock fabrication, switch arrangement, bearing housing, the spindle, dust seals, screw collar and locknut, motor table support, headstock spindle assembly, tailstock, handrest support, stand, wiring.

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Make the Chipmunk wood-turning lathe

By Dyson Watkins no castings required

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On the editor's bench In our next issue A gearbox for the ML7

Stan Bray the design, the case, central bearing pillar, dismantling the leadscrew, shafts, the gears, front plate, testing, adapting the leadscrew, the information plate. cutters with shanks, cutters for the faceplate, using flycutters, the cutting tool. the Paralux motor, revised 'H' frame, checking the motor, testing, starting problems, lubrication. tee bolts. meaning of datum, the use of datums, datum marks, the datum edge, centre line datums, datum surfaces, multiple datums, machine graduations as datums. normalising, distortion of metal, annealing, hardening, tempering, heating the material, visual observations, case hardening. to use the clamps. parting off metal, theory of cutting tools, selecting the proper tools, details of the spring tool, conclusions.

An article by Alan Buttolph for the more experienced machinist

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Flycutters

Simple construction and ideas on how to make use of them

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A power hacksaw update Clamp up Quick tip

John Brittain describes an easily obtainable motor unit Tips for using clamps Mill or lathe cleaning tip

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Reference points

This article explains what a datum is and how to use it

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Quick tip Heat treatment of metals Small work holding clamps Parting off made easy Quick tip

from Mr A W Stirling on quenching oils Softening, hardening and tempering Bob Fletcher describes a neat clamping arrangement Ted McDuffie gives us his ideas Neater brazing by Malcolm Woodward

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A visit to machine mart Finger clamp Screw jacks Electric arc welding Bottle holder plan the ball races, the body, the drive shaft, drive roller, bearing retainer, bearings housings, belt tensioning bracket, the lock-nuts, tensioner shaft, idle roller, belt tensioners, mounting frame, the table, assembly, fitting the motor, safety precautions. the large casting, marking out the slots, milling the slots. the bottle holder, the pillars, the lead screw, the nut, the lifting arm, the handle, the base, assembly, finishing. Simply made clamp the body, the fork, adjusting rod, hand wheel, the finger. materials, construction, extensions. the equipment, oil cooled welders, air cooled welders, electrodes, safety, the arc, direction of weld, coverage, cast iron, bronze welding, conclusion.

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A home made belt sander

Bluey describes how to set about it

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A Keats angle plate Pass the port Quick tip Adjustable height tool posts Quick tip Speed reduction of machine tools

Castings by College Engineering Supply A Christmas treat From J W Thomas alternative bandsaw Three simple versions Mr Maycock protects the tailstock point A design by Ernest Haddon-Deering

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Micrometer stops Torque about flea power Quick tip Heavy duty running centre

Ideas from Les May A light hearted account Thread measuring tip A design by Bill Morris

use on a mill drill, other uses, operation of SC2B speed control. adjustable length bar, the brackets, the micrometer head, the thimble, divisions, cutting the screw, numbering the divisions, further uses for the tool.

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Scribe a line Trade Counter On the editor's bench In our next issue Dividing on your lathe a roller cutter, a taper turning tool Stan Bray

the bearings, making the taper, the bearing housing, the spacer, the centre, screwcutting, assembly. comments from readers, formula for machining arcs, assistance needed and help given, watch and screw threads.

Ted McDuffie explains easy ways of dividing in the lathe

latching arm, dividing plate, drilling the plate, dividing with a tape, using dividing equipment, use in milling and drilling.

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Fitting a chuck backplate Scribing blocks

Fitting a chuck to a backplate is not so difficult as it sounds Make your own

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Abrasives Quick tip A machine vice

Some information on how to treat them and the potential dangers involved Cross drilling in the lathe Make a machine vice from stock materials

backplate castings, machining the casting, the screw fitting, using dividers. a home-made scribing block, the base, the pillar, the pivot block, the pivot, the scriber, the pins, more sophistication. abrasive types, mounting grinding wheels, use of grinding wheels, finishing, abrasive papers ands cloths, liquids and powders, safety. where to start, the lead screw, the screw and handle, the moving jaw. drilling, reaming, boring bars, homemade boring bars, mounting work, machining operations, other methods, mounting work on the saddle, between centres boring bar, tool adjustments, adjustable bars. marking fluids, copper sulphate, felttipped pens, marking brass and copper, the scriber, datums, using the scribing block, scribing angles, dot punching, dividers. Multiply across flats by 1.37 or 1.15 help wanted, improvements on designs, low voltage lighting, speed reduction of machine tools, three-phase electricity, brine for quenching. grindstone heights, drill sizes, the base, the body, the pillar, the drill support, drill holder support, the back stop, the carrier, the large jig, indexing spindle, drill holder and back stop, other carriers extending the versatility, Slocombe drills, using the jigs, jig positioning.

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Boring

Boring in the lathe

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Marking out

Some tips for the beginner

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Quick tip Scribe a line A dot punch

Calculating size of round bar to make square or hexagon

Useful device

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Simple drill grinding jigs

Two jigs designed and described by Geoff Oakes

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Quick tip A rule holder Chuck stops

Dealing with stripped threads Almost essential for good marking out use of chuck stops, rulers and depth Often a job calls for several pieces of identical length protruding gauges, tailstock stops, the spider, from the chuck internal stop, the advanced form of stop, using the stop. the base, the swivel block, the holder, Useful and simple to make pivot and bolts.

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A micrometer holder

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Quick tip A sturdy bench Trade Counter DIY weightlifting Simple division on the small lathe

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A small filing machine

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Thin piece chuck

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Geometric chuck (1)

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On the editor's bench In our next issue Fixed and travelling steadies A tee slotted cross slide

Hacksawing large diameters A Warco bench test assembling the bench. Plastic gears, a small powerful electric motor, milling for the model engineer Mr C J Austen relates how he coped with the problem of moving the arrival, the lift, conclusion. heavy workshop equipment Ted McDuffie describes a simple method the bracket, gear fixing. filing speeds, the motor, the frame, crank movement, the base, the slides, the sliding block, the crank, connecting rod, wiring the motor, the case, improvements, a gearbox, fitting an alternative motor, use of the machine, safety. making a simple jig, the outer shell, fitting the shell, inner section, making the Holding very thin work collet, using the chuck, chuck for larger machines. a couple of handy hints, backplate boss, geometric chuck backplate, first slide bearing, fitting end blocks and adjusting screw, turning piece, top of slide, centre Much used by ornamental turners and example by Mr Allard bearing, centre wheel, large bearing, wheels NOP, cutting gears and making tumbler reverse gears, retaining disc, g sidepieces, steel centre bearing. Stan Bray Harold Hall explains how he made suitable steadies from stock materials at a terrific saving in cost Bill Morris describes how he set about making his own a suitable design, construction, the base, the clamp, improvements, travelling steady. milling the slots, the circular tee slot, the dovetail, the stepped hole. Division, power for attachments, the milling head, the Super-7 top slide, making the ball handle, safety, getting started, cutting the ball handle arms, cutting the slot, cutting the splines, assembling, conclusion. an inverted parting toolholder, the design, the body, the guide rails, the clamp.

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Retractable ball handle

Ted McDuffie describes his milling attachment for his Myford Super 7

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A useful workshop storage unit Parting off on the Hobbymat

D O Coe describes such a system which is also cheap l Maycock give details of how he copes

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Lathe tool height gauge Scrapers and scraping Collets for square material Quick tip Scribe a line

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Milling cutter chuck Drawing of clutch for ML7 Stop Thief A drilling machine depth gauge A cross drilling jig Quick tip A parting tool holder Trade counter A circular saw for the Chipmunk Scribe a line A cam driven pump unit Quick tip Quick tip

accuracy, construction, setting the tool accurately. reasons for scraping, the tools, R J Loader describes how he learnt and passes his expertise on sharpening, using the flat scraper, to readers finishing. Turning square material is a problem. Here H K hall describes a separate jaws, fitting square to round, way of doing so getting the dimensions. Storage space crocodiles bite, lathe help, Halogen bulbs, angle plate improvements, no mistake, the miller's tale, hose it done?, Hero revisited. materials used, manufacturing Vertical mill collet chuck by Harold Hall procedure, making the mating taper, making the collets, using a fixed steady. A sophisticated gauge described here by Harold Hall Bluey describes how to make an electronic scare alarm D O Coe shows a way of making a very accurate depth pointer that is easy to construct from stock materials This one by L J Riley guarantees perfect accuracy Reducing chatter when turning This tool designed by H K Hall is simple to make and solves many of the problems associated with this type of work Welding: a safe practice, open days at Mercer, Gripfill The Chipmunk wood turning lathe describe earlier by Dyson Watkins gets an attachment upper blade guard, the table, support bracket, riving knife, riving knife bracket, spindle, under table guard, fence, tailstock nearing support. three phase electricity. fuel pump design, inlet and outlet, the cams and cam followers, electrics and safety, mounting the unit. so what to do, how it works. a Clarke drill. the body, the clamping plate, improvements.

Brian Taylor describes a useful and cheap pump Using WD40 to remove stuck taps Using correction fluid when brazing or silver soldering

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A clutch for the ML7

Alan Buttolph describes how to make one for the Myford

materials, keeping the lathe in service, the countershaft, the clutch boss, clutch material, drive pulley, fitting the clutch to the pulley, the thrust block, adjustments and assembly, modifying the guard, usage.

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Geometric chuck (2)

This challenging project is the work of reader Mr Allard

wheels, support, work holder mandrel, adjusting screw, faceplate, wood base, chuck and pillar support plate, hand turner and bracket, turner spindle, main end piece, pen housing, pen holder.

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On the editor's bench In our next issue An automatic boring and facing head Quick tip A cantering device for the lathe Trade Counter Boring tool holder A 'professional' slotting tool A simple belt sander Turning a Morse taper Quick tip Threading for beginners Workshop wander

Stan Bray Don Unwin shows how to make an automatic boring and facing head in the simplest possible way while finishing up with an excellent highly accurate tool The body, the slideways, feed screw block, the cutter block, feed screw assembly, the cam ring, top-retaining plate, assembly.

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Knurling

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A ball turning tool Quick tip Quick tip Scribe a line

preventing chatter marks when countersinking Bob Fletcher shows how to make a simple indicator as an aid to setting-up New products from Hemingway Harold Hall describes a tool holder that solves the problem of securing the bar and height adjustment if one has a fixed height tool post. The design by Peter Robinson uses the lathe cross slide for it's the body, the anchor, clevis, ram, the mount handle, using the tool. Terry Lane gives brief details of how he made such a machine using hollow section material In this article a novel idea by Harold Hall could sole many of the problems associated with taper turning Stopping nails splitting wood thread forms, the core, the pitch, thread The article offers a few hints on the subject and gives details of angle, taps, tapping, problems, dies, die some equipment that can be used to improve thread making adjustment, purchasing tap[s and dies. Photographic record of Tony Meeks of the complete construction of his new workshop good and bad knurls, the knurling process, knurling from the tailstock, the A combination of several articles giving readers the chance to taper, the body, the arms, the pins, make a knurling tool of their choice adjuster, a universal knurling tool, an improved knurling tool, general. requirements, the base, body, tool Can be made form scrap materials adjuster, the handle, using the tool, refinements. Preventing file clogging Drilling into cross-holes Vial rumour, saddle stops for a Myford, abrasive comments, alternative worktops, flats by formula, a locating punch.

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The art of hand turning is one that is nearly forgotten however it methods, the tools, working practice, the is a useful skill well worth the effort of learning toolrest, the rest, locking screw. The base, clamp, pillar, the clamping A finger plate Easy to make from scrap material nut, adjusting screws, using the finger plate. Quick tip Gadget to hold thin items in a chuck making the vice, the moving jaw, fixing the moving jaw, the drive screw, the A small tilting vice Castings available from College Engineering Supplies jaws, the base, tilting mechanism, when things go wrong. making a multi-tooth cutter, the mandrel, marking the teeth, shaping the cutter, Make your own milling cutters and gears Don Unwin shows how to make special shaped cutters including making the teeth, heat treatment, (1) tee slot cutters, dovetails and radiused tools sharpening, form relieved flycutters, cutters for clock gears, the involute form, form tools for cutter blanks, metrication. the holder, the steady discs, using the A Jacot tool Don Unwin tells how to set about making one Jacot block. Al Longworth offers a neat device which can be made from method of dividing, the principle, usage, A simple to use dividing device stock material or casting from Model Engineering Services checking for accuracy, manufacture. Quick tip Using double sided tape to hold work Grandpa enters the computer age Geometric chucks and a computer program first principles, history, bare bones, the co-ordinates of the tracing point, nomenclature, the programs, the parameter tables, of further historical interest, a supplement, conclusion Quick tip A drill stand for popular sizes Quick tip Mill/drill and old car steering wheel On the editor's bench Harold Hall takes over as editor In our next issue geometry of the device, the micrometer Derek Winks has produced a very nice design for a taper setting device, guide bar connections, Tapers on a Toyo attachment form his Toyo 210 lathe cross-slide disconnection, setting the device. A miniature wood turning lathe Dr R Cutler designed this small lathe for a friend Ogival clock wheels cutters, proportions, Make your own milling cutters and gears Don Unwin concludes his notes on home-made milling cutters small radius cutters, cutting gears, small (2) and gears pinions, bevel wheels, repairing gears, spiral gears. Gordon Lewis tells us how he made a collet chuck for the Emco the fixture, the body, collets,, slotting the A collet chuck for the compact 5 Compact Five milling machine collets. Hand turning

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Using edge finders

In this article we indicate the various methods of employing the wiggler for component edge finding in the milling machine

edge finders, recommended method of use, use on a round bar, alternative methods, test method, testing for consistency, testing for accuracy, additional attachments the needle point, an alternative edge finder.

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Quick tip Trade Counter

Replacement vice jaws Tandy taper reamer, compact drifter, Starrett blades, Emco's new Maxima super II cutting remarks, basic physics, wavy washers, ML7 gearbox, pump proportions, be warned, clutching at straws, Alan Buttolph replies, matter arising. A little project for that spare hour Typist correction fluid Can be made on the lathe Don Unwin A simple dividing device, make your own milling cutters and gears, scribe a line saddle stops the drill, the design,, base and table, head, use as a router, assembly. types of collet, chosen type, the body, closing ring, an initial failure, the collets, machining jig, slotting the collets. threaded inserts, roll taps, self-tapping screws, taptite screws, cutting lubricants. drilling flat plate, drilling holes on a PCD, conclusions. original design, modified design, construction, downfeed dial. the headstock. problems, the solution emerges. construction. converting decimals into fractions, factors. sizes available commercially, variety of uses, drawings/.proposed sizes, the screw mechanism, manufacture, casehardening.

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Scribe a line

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Small tool holder Quick tip Toolmakers clamps A division line cutting tool Project updates A mini drilling machine Plan A design for a simple lathe Lathe collet assembly Quick tip This sheet tapping Quick tip Using drilling jigs Milling machine dials A simple lathe Cutter clamping in boring tools Precision marking out Number crunching for the home workshop Quick tip

A range of collets for the Myford Super 7 and other lathes Hanging storage bins Putting tapped holes in this sheet Mixing small amounts of resin adhesives Harold Hall Changing fixed to friction dials Mr J T Bergin describes a smaller lathe Ivan Law gives some ideas David Lamas uses vernier callipers DR Mark Philips uses his home computer DTIs prefer lubrication before use

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Quick tip MEW survey On the editor's bench

Mixing silver solder or brazing flux Harold Hall silver steel, snatchy milling, Tee slots alternative, finishing metals, parabolic mirrors, suds pumps, odd Myford, Mystery lathe, toolmakers clamps, more on clamps, two jaw chucks, circlips, fasteners, colours in the workshop. faulty manufacture, poor soldering, wrong component fitted, component fitted the wrong way round, component not fitted, damaged by heat, stripboard tracks not cut correctly, integrated sockets. deep hole boring tool, joining the halves, the holder.

Scribe a line

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Electronic production

How to gest started

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Deep boring tool Back facing Quick tip Guide dodge for the blind A vernier height gauge A clock depthing tool Quick tip Diving by computer DTI carrier An economic angle plate Keeping rust at bay Welcome to the workshop Fair weather friend Thin work holding Quick tip Workshop wiring wisdom Quick tip Toolmaker hammer drawing Quick tip

Getting to the bottom of it Reprint from Model Engineer 1963 Top slide angle of 6 deg gives 1 thou cut for 10 thou movement Brian Taylor offers help and advice David Lamas uses his vernier caliper John Jennings Tilt indicator How to print a dividing plate template Clarification of last issues idea H M Turnbull makes his own Keats angle plate

relating to model engineering, the method, a good start. description of instrument, the scriber, the clamp, using the height gauge. construction, runners.

condensation why?, the answer, surface treatment, for the technically minded. R J Loader explains all A design for Christmas Using collets Transferring blind tapped holes Chris Boucher describes the requirements of the IEEE regs To remove mill scale from black iron Close with paper safety devices, supply cable selection, workshop installation. the design, an alternative approach, to suit larger sizes, manufacture - the onepiece type, manufacture - the removable jaw type.

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Making an edge finder

D J P makes one

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Digital read out

Make your own DRO

construction, pressure pad, wobble bar, holding the ball, assembly. the display solution, the pulse generator solution, the final specification, general principles, the counter requirement and facilities, the leadscrew encoder, pulse and direction shaping circuits, mechanical pulse switches - a warning, alternative to pulse shaping, the method employed, the power supply, the mechanics, pulse generating discs, testing, fault finding.

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Quick tip Extras for the Toyo ML210 Quick tip Trade Counter Economy mill table calibration rings Chasing vibrations In our next issue A four-way toolpost Quick tip On the editor's bench

Hardening and tempering small drills Derek Winks describes a toolpost and auto-feed gearbox Making a simple reamer digital multimeter, compact turning machine Emco compact 5, Machine Mart Roy Clark modifies his Warco Economy mill/drill Bill Morris cures his lathe adjustable dials are a must, positive adjustment. locating the problem, the solution. construction, testing for strength, the index mechanism, the clamping components. Storing machine electrical plugs not in use Harold Hall attracting recruits, batch work, Jacot tool more versatility, history of machine tools, a computer program, wigglers, CAD/CAM help sought, Raglan lathes, sine bar clinometers, condensation and electronics, white metalling, odd Myford the solution. Finding space J V Haynes ideas for neutralising the return spring on a drilling machine Frost auto restoration catalogue, dividing plate Mr D J Unwin's idea Mr R W Lange has a program for Mr Smiths patter generator Use for an umbrella frame general descriptions, parameters, combining the movements, notes on the computer program.

Scribe a line

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Quick tip Feed lever tapping aid Trade counter In our next issue A small drill sharpening jig A computer simulation Quick tip Reader survey report

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Filing rests Quick tip Cross drilling jig A tailstock die holder Quick tip An oilsink cutter MEW index Protect that slide A small chip guard Vertical toggle clamps (1) Lathe mounted band saw Quick tip Band saw drawing A visit to Inter City Machine Tools A low speed countershaft

An design by Stan Bray Idea for cheaper surface plate Mr Harries gives some methods By Dyson Watkins Brush and spray enamelling John Jennings spherical version Keeping your mill/drill lower slides clean By F J Loader

universal jig, a collar drilling jig, precision description, making, dieholders, use.

the material. principal of operation, limitations, the designs, manufacture. materials and construction, the blade, setting up.

Mr GT Gray's ML7 design Use of stub drills

D P Winks makes one for his Toyo ML20 lathe

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3 phase in the workshop Quick tip

Mr Boucher tackles old motors in surplus machines Variacs

odds and ends, cross-slide stops, micrometer feed dial, mandrel handles, carries. why three phase, how to achieve a three phase supply, three phase converters in operation, three phase wiring and safety. the power supply, the DC power supply tag board, packaging the electronics, testing the completed display unit, the pulse wheel mechanism, the table pulse wheel enclosure, extending the leadscrew, the lower pulse wheel enclosure, pulse unit internal construction, pulse disc carriers, pulse wheels, the final installation, adding pulse generators to the machine, positioning the display unit, retaining the technical information, a final thought, postscript. a bit of history, wood and loads, stresses and strains, making a start, turning test, final check. topslide method, taper turning from the tailstock, taper attachment, the design, manufacture, the mathematical principal.

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Digital readout

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Aligning a lathe Quick tip

Bill Morris takes us through it 35mm film cassette storage

Taper turning attachment for the Myford It incorporates precision setting the angle 7 series lathes

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Cutting racks On the editor's bench

Don Unwin provides the answers Harold Hall digital readouts, long term models and hams, wiring safety, 3 phase electrics, clear lacquer and calorific values, clinometers, odd drills, program improvements, cross hole drilling, gears and gearcutting, Don Unwin replies, aids for the disabled, lathes, workshop safety. Don Unwin updates his article printed in ME 1980 Tailstock locking habit Slot drill tip A useful accessory More permanent marking Help speed up the process

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Scribe a line

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Engraving attachment Quick tip Quick tip A lathe back stop Quick tip A vice positioning device

their design, manufacture, in use. the problem, the answer, manufacture, checking and calibration. construction, pivot block, operating lever, ball handle, two-part using Emco quill, one part quill, machining the tailstock casting, odd bits, assembly, depth stop. the index plate, the turret, the body, the main shaft, threaded stops, saddle stops, saddle stop holder, assembly, using the stop. single phase, types of motor, three phase. the base, the vial carrier, accuracy, spacers, assembly, calibration, storage box, greater precision. the circle, the triangle, lever for toggle clamp, divisions on a pitch circle diameter, geometry.

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Compact 5 conversion

John Jennings makes a lever tailstock

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Quick tip A six-station saddle stop

Using old chucks in the vice By C J Vickery

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Starters and motors for machine tools A engineer's level Bandsaw part 2 plans Workshop mathematics Trade counter Model engineer exhibition 1992 Horizontal toggle clamps (2) Quick tip Screw cutting on the Toyo

By Chris Boucher Make your own

Useful calculations plastic shims, catalogues, sources of supply.

manufacture, material list, heat shrink. Assess your material Mr Winks finishes his project screwcutting gears.

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Milling for beginners (1)

types of machine, size of machine, speed range, using the machine, safety, ancillary equipment, the vice, studs and nuts, clamps, clamp bar packing, the angle plate, other accessories. Extra Mr P D McQueen modifies his B&D drill stand Terry Lane makes a set of box spanners keeping rust at bay. design, construction, assembly, in use.

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In our next issue Scribe a line A tapping fixture Spanner-making the easy way Further comments on belt sanders On the editor's bench

Harold Hall

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metrication, material wants, electrical safety, the history of machines, this month's request for articles. Holding thin workpieces, 10 in Regal lathe, Holtzapffel lathe prices, workshop safety - high profile, down feed problems, unknown 3 phase connection, metric micrometer, plate glass availability, field clinometers, suppliers of surplus motors, three phase motors on single phase, a mystery lathe.

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Workshop geometry Quick tip

A few procedures used to markout Making LH dies construction, angles, reducing the rake, thinning the web, countersinking, drilling oversize, drilling undersize, flat bottoming, materials, long series drills, stub drills, flat or spade drills, ways and means, drilling in the lathe, drilling from the tailstock, other drilling methods, speeds, sharpening.

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Drills and drilling

R J Loader fills in some gaps in readers' knowledge

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Quick tip Quick tip

minimising storage Adapting Dore Westbury for Arrand holder types of cutter, fly cutters, end mills, disc type cutters, slitting saws, milling cutter holding, end mill chucks, holder, long taper collet plain shank, threaded collet, conclusions re end mill holding

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Milling for beginners (2)

Cutters

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Quick tip Coolant delivery on the cheap A medium duty fret saw Quick tip

Roller filing rest Derek Brooks comes up with a cheap form of suds pump gravity The prototype used second-hand sewing machine motor and assorted scraps Old drill = deburring tool

the motor, the size, the materials, the design, manufacture.

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Making a small four jaw chuck Quick tip A visit to Millhill supplies Four jaw chuck drawing Workshop visit Quick tip An elegant ball turning tool A centre square In our next issue Improved chuck boards Museums of interest Mechanical variable speed drive

Mr Loader makes a 3 1/4in chuck for his Unimat 3 Making packing from cans by Mr Loader Chris Ford's 4 x 4 feet workshop Hand cleaner Mr G W H Swallows serious attempt to improve on other designs This simple device intended for finding the centre of circles can also take the place of a normal square in some circumstances A simple device to ease the process of fitting and removing large chucks from the lathe mandrel Places to visit A design by Mr A Longworth

backplate, drilling methods, preliminary drilling, front plate, body machining, jaw screws, screw retainers, centre bearing, finishing the jaws.

construction, setting and use. making the centre square.

infinitely variable speed controllers, design parameters, notes, two belt cone pulley assembly.

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Trade counter Slitting saw carrier Milling machine downfeed modification Quick tip Backlash

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On the editor's bench

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A fret saw/filing machine Quick tip Quick tip

Vertical alignment device, anti condensation heaters, sources of supply, some new requirements, catalogue from Flapstock Ltd, electric motors, the Modeltoy milling chuck, continued expansion at Machine Mart, Contect duck oil and Tufagena hand cleaner Reduce the need for a hacksaw saw sizes, the holders, construction. Downfeed stop and universal holder by Mr Corps Setting square stock in a four jaw chuck Drawing projections Mach '92, safety, 14 1/2 deg pressure angle gearing, students, MIG welding, Harold Hall mill/drill down feed modifications, raw materials, this months request for articles. jaw lift, chucks, clinometers, wind generators, encouragement from the young, clinometers, square shanked drills, white metalling of bearings, spanner collection, a light in the darkness, Kerry lathes, Grayson lathes. Following the very popular lathe mounted band saw Mr G Gray provides this heavy duty fret saw cum filing machine colour coding drills Oasis temporary drill stand

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More museums of interest Jack the ribber W Brian Taylor recounts making a hydraulic press M LeMarchant has made this excellent little wheel engine largely from scrap Mr Swallow continues making handles armchair tuition (for some), achieving the finish, removing the bulk, the fixtures, taper attachment or top slide, making the flat, material, ball handles. a foray in to the scrapyard, SWL 3 tons, gripping thin wall tubing, back to the press, work on jack, trials and tribulations.

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A wheel engine from scrap

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Turning ball handles Quick tip Attachments for the Hobbymat Mach '92 Quick tip Universal bender A milling machine stand Back to College

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Milling for beginners (3)

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A garden gate Quick tip In our next issue

Heating Loctite for removal Chris Ford suggests these simple attachments for the Hobbymat tailstock pusher, swarf guards for MD65 lathe compound slide, steel base. Brief report of international exhibition of machine tools and manufacturing technology Penny washer packing Toll from C Z Scientific in use, types of bends. John Cartwright provides this simple but effective design Expand your workshop's capabilities choice of cutter, large surfaces, small surfaces steps and slots, methods of workholding, positioning the workholding Having dealt with the equipment side of milling in the past two device, fix cutter in the machine, issues actual milling operations are now being discussed choosing the correct speed, peripheral speed, position the workpiece relative to the cutter, width and depth of cut, conclusions, milling in the lathe. In this garden gate we have a novel project provided by Sid Reid an oven baked recipe, fittings. Bolt and set screw preparation new small 3 phase converter, permanent magnetic positioners, local suppliers of raw materials, Frost Auto Restoration Techniques ltd, Machine Mart ltd, square silver steel, new items for the Hobbymat and universal bender, E951 magnetic variable clamp, 920 magnetic adjustable clamp, E952 magnetic variable clamp, sources of supply, some new requirements.

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Trade counter

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Improving a milling vice

This article aims at improving a poor example to acceptable standards

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MIG welding

Bill McClean

making a true sliding surface, bore a hole in the base, bore hole in vice, machine base upright side faces, machine lower face of vice, machine top face of slide ways and fixed jaw face, machine keep plate slide ways, machine the moving jaw's sliding surfaces, keep plate and assembly, machine the moving jaw face, machine first side, machine second side, make hinge pin and washers, assemble and measure slope, the base sides, the jaw top surface, jaw lift a final thought. specification, equipment, safety, welding principles, reinforcing, a corner joint, lap joint, butt joint, fillet joints, multi-layer welds, spot welding, bar welding, positional welds, distortion and control, machining, aluminium welds, stainless welds, copper welds, shielding gasses, video, conclusion, electric arc welding.

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Quick tip Quick tip Making a four jaw chuck

Useful source of steel balls Use a nut to shorten threads Bill Morris methods of jaw adjustment, jaws first, the chuck body, a diversion a Tee slot cutter, finishing the body, the feed screw arrangement. types of flat bit, how they cut, general information, making flat bits, the shanks, the inserts, checking accuracy of inserts, heat treatment, using shop-made flat bits.

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Drills from flat stock

Peter Jones provides an article on making flat bits for wood

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Quick tip Quick tip On the editor's bench

gear train backlash umbrella gouges Harold Hall sources of supply, comparative testing, answer this question, this month's request for articles. electric furnaces, tailstock die holders, screwcutting wisdom, filing in the lathe, why don't they?, food for thought, ball handles, a useful jig, linear encoders, wind generators, plate v float flats, white metalling, drilling from the tailstock, hole crunching, a Raglan query, nippies.

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Quick tip Turning hardened steel MIG welding A modified live centre Quick tip Hobbymat MD65 modifications Quick tip

Transferring a hole centre from one frame to another This interesting article on the use of cobalt-titanium tips for turning is provided by Yves Rayssigiur Bill McClean has added some further thoughts G K Bartlett suggest some interesting modifications to a live centre which increase the range of tasks it can perform Reducing scaling in a muffle furnace Mr Shepherd offers some simple modifications Conversion from gas mark to centigrade (gas mark x 11 +140 = degrees) if tempering in the oven In this article Dave Lammas describes his experiences in renovating an old compressor Centre punching stainless steel Reducing filing work Geoff Gray offers a suggestion for a simple device to aid hand tapping Using a Emco Unimat PC Hex tee bar for use with fourway toolpost, dial test indicator probes, lockwire drilling jigs, slide hammer, stud setters How to make a set

getting started, dummy spindle, tailstock die holder, in conclusion. belt tension, tailstock handles, tailstock pointer, index scale modification.

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Renovating a compressor Quick tip Quick tip In our next issue Tapping square Drill stand for small drills Five quickies Parallels

the first step, cleaning and external inspection, dismantling and internal inspection, operations, making new parts, assembly, motorising, testing.

Machining on the Unimat, using a drilling jig, marking the drill sizes, expanding its accuracy.

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38

Bearing remetalling

This detailed article is offered by Fettler who has a long association with the bearing remetalling industry

the sizes, manufacture, edge machining fixture, end machining, lapping to size, storage. why whitemetal, so you want to try your hand, equipment and consumables, working environment and safety, making a start - jigs, workpiece preparation, running-out, tinning, preparing for pouring, pouring the melt, examination, further considerations, last words.

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Quick tip Jeclanide handwheel drawings Quick tip Trade counter A Jeclanide handwheel The Unimat PC assessed Screw blueing tools

How to get your ideas in print Make a plug for your tailstock Woodworkers vice, electric sharpeners, low cost digital readout, machine mart ltd, project lathe kit by W B Taylor The Editor gets to grips with Emco's popular Unimat John Jennings provides these simple devices to assist in Blueing trays, blueing plate. satisfactory blueing

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Quick tip Quick tip

Alternative face plate Metric tapping drill size formula is dia of screw minus pitch (10 1.5 = 8.5mm drill) In this article by the editor the question of using form tools is considered This excellent lathe-mounted milling attachment is provided by A Longworth tapered, adjustable, shell, chucking, home-made reamers, making 'D' bits, whistle reamers, ways and means. the mandrel, screwcutting, making a start, the body, the dividing plate, the D J Scoggins made this attachment on his Unimat 3 lathe detent bracket, the simple dividing fixture in use. 62nd International model engineer and modelling exhibition, CAD, correspondence, history of machines Harold Hall and materials, Stan is back, drilling square holes, availability of materials, copy turning request for an article. Unimat ideas, filtering suds oil, an ML7 modification, limiting jaw lift, MEW aids in boat building, hardening steel another turning solution, videos as learning aids, Drummond lathes, electric furnaces, dropping chucks, breaking blades, cheap benches, nameplates etc., spinning, Arkansas stones, water of Ayr stones, India stones, a blast from the past, a book wanted. construction, drill guide, method of use, Derek Winks explains how this seemingly impossible job can be polygon hole drilling, uses, equipment, done quite simply quality. Locking screw anti-burr brass insert Mr Loader describes why reamers are better than drills terms and definitions, accepted methods George Eveniss describes the manufacture of an indexing chuck of cutting muti-start threads, a request which allows the cutting of multi-start threads on any and a solution, construction, graduation screwcutting lathe of the tool. Copper sheet from tube Chamfering rod before cutting thread the external radius tool, the chamfer tool, the slot cutting tool, the internal radius tool, making the combined radius ands chamfer tool, making the combined facing and chamfer tool.

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Lathe form tools

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Universal milling attachment Reamers and reaming

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Dividing attachment for the Unimat 3

14

On the editor's bench

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Drilling square holes Quick tip In our next issue An indexing chuck Quick tip Quick tip

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22 26 29 31

Steel, heat and crystals A small variable speed drive controller The Warco 220 lathe A fabricated drawing board

Bill Morris discusses the theoretical and practical aspects of modern day steels David Machin describes the controller he designed for use on his milling machine table feed Stan Bray tries out a new Warco A design by Stephen Vagg

equilibrium diagrams, mild steel, bright mild steel, case hardening. the motor, the controller.

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34

Dial test indicator accessories (1)

the basic design, fine adjustment attachment, the milling machine attachment, the lathe attachment, the universal clamp, making the parts, arms, arm clamps, milling machine arm holder, right angle arm, dial test indicator arm, fine adjustment unit. Making labels with a photocopier Ring parallels from an old ball race vee blocks, cutter chucks, the smaller A Longworth describes a method of sharpening the end faces of components, putting the jig to use, end mills and slot drills setting the angles, the sharpening operation, wheels for tool grinders. This simple marking gauge has been provided by Mr Langham and is made on the Emco Unimat lathe the shaft, slider, the scriber.

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Quick tip Quick tip A sharpening jig for slot drills and end mills Drawing for sharpening jig Marking gauge

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48

Using stub mandrels

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A vertical shaping facility Iron and steel the bare bones and teeth of the m/c tool (1) It's not all about models Workshop equipment on a budget A power traverse for a small milling machine (1) Quick tip On the editor's bench

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54 57 58 61 63 5

concentricity, irregular components, parallel faces, two step mandrel, the internal mandrel, construction, the This article discusses the advantages and disadvantages of the parallel mandrel, the tapered mandrel, a various types split mandrel, limitations and care in use, solid type - parallel, split type, long components. In this article Howard Moor describes an interesting approach to the shaping tool, mounting the vertical shaping workpiece, using the shaping tool. in the beginning, the blast furnace is Don Unwin discusses some early stages in the development of developed, the iron is rolled into bars, a iron and steel need for better spring steel, into the 20th century, early machine tools. A visit to the model engineer exhibition A T Davies suggests a source of equipment on the cheap David Machin provides this excellent design of a power feed for the design, manufacture the feedscrew, a Westbury milling machine the worms, the worm assembly Storing taps with your drills electric motors, readers workshop Harold Hall activities, new readers, quick tips, request for an article, final request.

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motorcycle model, why?, compressors and conversions, square holes, metric and imperial screwcutting, safety and students, oiling Myford lathes, modified belt sander, spinning, a Hobbymat handle, Barker lathes, speeds and feeds, white metalling, electric ovens. letter/number stamps G clamp with arm, general purpose arm holder, base, other uses, a heavy duty helping hand, magnifier stand, machining shroud, drawing carrier, dial test indicator inside adaptor. the basic motor, the induction motor, single phase induction motors, motor speed, other single phase motors, reversing induction motors, three phase motors star-delta connections, commutator motors.

15

Quick tip

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10

Dial test indicator accessories (2)

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17

Electric motors - AC (1)

On the subject of electric motors and their speed control. We consider single and three phase induction motors.

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Trade counter Quick tip Quick tip In our next issue

portable band saw, machine mart in the south west, source of supply, half round brass, suppliers of materials, craft supplies, Miniturn 200 lathe from C2 Scientific. Sheet brass hardening Card or paper labels back to basics, general description, modification of the castings, refitting the slides, the mounting arrangement, the long tailed Acme nut, feed screw bearing housing and graduated dial, the work mounting plate, the work holding facility, some thoughts on safety, safety guards.

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Crossvice to vertical slide

A design by Mr E G Hartwell

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Quick tip Quick tip A foot switch for a drilling machine Quick tip Workshop visit Metal spinning

Oil stone lubrication Makro trays Mr D O Coe design Setting tool height Albert Wallis Albert Jeeves provides this interesting article the tool rest, the spinning centre, formers, the tools, making the tools, oddballs and annealing. the danger, some improvements, connecting up, in use, materials.

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44

Making a box angle plate

As well as the box angle plate Ron Bernhardt explains the requirements for making patterns from which castings can then be made

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Building a garden workshop Quick tip MEW index A twiddle stick Hole gauges

M Hudson is full of good common sense ideas Caravanning store John Lennings comes up with a simple device to simplify the operation of the top slide on smaller lathes

grey cast iron, white or chilled iron, special process cast iron, spheroidal graphite/nodular/ductile cast iron, malleable iron, back to the box angle plate. design requirements, position, the concrete base, the timber structure, fitting out, thermal efficiency and condensation, cost breakdown.

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Evolution of the lathe (1) A power traverse for a small milling machine (2) Quick tip

Don Unwin provides a fascinating insight into the early days of the lathe David Machin continues with his explanation for manufacture of the Westbury milling machine power feed Chuck keys wear

achieving the required accuracy, smaller and larger sizes, storage. screw cutting, slide rests, Henry Maudsley, Alexander Masmyth, Charles Holtzapffel, Joseph Whitworth, Eli Witney, the first capstan lathe. final items, a few variations on a theme. made to show standards, made to be displayed to be used, DC motors, book from there past, magazines of the past, phone numbers, this issue's request for an article. metric threads on an imperial lathe, Elliott machines help wanted, electric furnaces, bending quality brass rod, shifting heavy weights and other ideas, literary sources, some electro mechanical thoughts, early issues required, a timely warning, a plea to our suppliers, a footnote to square holes, Drummond lathes, craft video, Zyto lathes, Little John lathes, more Drummond lathes, dropping chucks, a fitting tip, electric motors AC. the socket, the mandrel, the dividing disc, to use.

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16

On the editor's bench

Harold Hall

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Quick tip

Clearing swarf on a vertical mill The design for this simple and effective device has been A drilling machine mounted dividing unit provided by Kevin Young

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Unimat 3 top slide

This little top slide by D Scroggins uses a novel approach to making the dovetail slides

sharp tools, ,making a start with the base, the lower slideway, the leadscrew support, the toolholder, the upper slideways, toolholder assembly, Gib strip, the bush, leadscrew, modified M6 cap head screws, the handwheel, finishing, handle.

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Quick tip Quick tip A universal jig/machine vice Metal polishing Hidden detail Quick tip In our next issue Trade counter Quick tip Quick tip Readers requirements ML7 tailstock lever feed Dial test indicator accessories (3) We look at Derek Brooks' workshop Seen at the exhibition Plan for a top slide for the Unimat 3 lathe A power traverse for small milling machine (3) Quick tip Milling machine table stop Evolution of the lathe (2) Files and filing Quick tip Quick tip A glossary of Swiss file terminology

Drilling and tapping a machined surface Cross drilling shafts This small jig cum machine vice is another interesting item by John Jennings for his Emco Compact Five By Alan Jeeves Finding missing items Sharpening spring joint dividers Camden books, workshop videos, change of address JA Crew and Co, female live centre, sources of supply and services, tool grinding, non ferrous castings, a useful book. Large tin lids File 'pinning' This quick made accessory by Mr Coe Concluding part 1993 International model engineer and modelling exhibition

the base unit, the rear vice jaws, the front jaws, clamping fingers, T-nuts. equipment, mops, speeds, polishes, polishing, buffing, notes on the selection of pulleys.

fixed clamp, moving clamp, remaining parts, assembly. accuracy, manufacture, straight arm, right angle arm, small parts.

David Machine suggests ways of adapting this design for the Westbury mill to be fitted to other makes Heating soldering iron with gas Made in an hour or two

the problem, the solution, in use. using files, ways and means, the shape for the job, special files, keep them clean, some more things which aren't in the books, safety, re-cycling.

Mr R J Loader provides another article Making parallel and taper punches Making polishing sticks

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The Clarke band saw reviewed A tool and cutter grinder (1)

Clarke CBS45MC 4 1/2 in By Derek Brooks method, rotating head, engraving, protection for the ways, powering the tool, assembly. DC commutator motors, power, motor power, the basic theory - tongue, the basic theory - speed, shunt wound motor, speed control, intentional speed variation, unintentional speed variations, shunt field speed control, combined armature and speed control, motor cooling fans, reversing, permanent magnet motors, smaller motors, series connected motors, speed control, unintentional speed variations, intentional speed variations, high output torque, reversing, split series motors, in simpler terms, shunt motors, series motor, AC commutator motors.

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Electric motors DC (2)

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A boring bar block Quick tip

Mr S T Clark makes a block for his Taiwanese 10BS lathe Protection from welding spatter in this issue, no cheap route, DC motor speed controller, Bough Superior motor cycles, club newsletter, correspondence received, material specifications, mark it, though provoking, reads survey. Denham lathes, making a box angle plate - ageing castings, Peatol lathes, a thinking curve, stainless steels, esoteric materials, stainless steel in boat building, square and polygon holes, Boxford information sought, quick tips a bumper bundle, weather vanes, garden workshops, going metric, oiling Myford lathes, Hobbymat modification, dodges for threading, Balzar or Belzer - can anyone assist. outline, motor, drive system, spindle and mounting block, footnote creep of bearing racers, modes of use, sources of supply.

17

On the editor's bench

Harold Hall

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Scribe a line

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Milling/drilling spindle for the lathe Quick tip Quick tip

Tony Skinner discusses the design for a small milling/drilling spindle cross drilling cheap Casio fraction calculators

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The worshipful company of turners annual awards Using the tool and cutter grinder (2) Quick tip A wood planer Quick tip Quick tip A tee slot cutter In our next issue Reader survey A drill sharpening jig Quick tip Quick tip Quick tip Sharpening wood planer blades Quick tip A "screwy" history

Bronze medal goes to an amateur engineer Derek Brooks gives some details on the various wheels which he employs cheap marking out with a drawing Terry Gould provides this design for a wood planer marking out Taiwanese mill/drills draw bar Perhaps cutting tee slots is not a daunting task as we imagine the problem, a possible solution, manufacture, the cutter bit, in use. recycling, the first planer, the spindle, the main frame, table tops, the blades, setting the blades, the bearings, the drive. dressing the wheel, tool sharpening, grinding reamers, using a cup wheel, using a disc wheel, suggested further reading.

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22 25 27 30 32 36 38 38 41 44 44 44 45 45 46

Mr C M MacEke provides a novel design recycle broken centre drill file and chalk identifying stamp orientation Geoff Gray suggests an easy way marking graduated thimbles Don Unwin turns his attention to the endeavours of making to make screw fastenings Heavy duty base Machine Mart expanding, an interesting catalogue, motorcycle fuel tank repair kit, the Faster Blaster, the Hart, a super CAD system, soft iron, new mini soldering irons from Weller, diamond tool holder from D&P burke, clip on magnifier from asset optics. quenching odd shaped items

drill chuck holder, slide item, winding gear and base plate, motor and pulley plate, dowel, guard, to use the tool.

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50

Dial test indicator base

the earliest example, the first standard threads. a heavy duty industrial base, experience in machining tee slots, clamping securely, machining cast iron, inadequate table lock, supplier details.

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Trade counter Quick tip We visit - Geoff Walker's workshop

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59

The Rishton Promill-35

Milling machine by Precision Engineers ltd

first lathe, making some accessories, a novel idea, college attendance, an Adept No 2 hand shaper, stationary steam engines. AC variable speed controls, how delivered, specification, the machine in detail, using the drilling facility, conclusion.

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Making a Dore Westbury milling machine Quick tip

Derek Brooks built his machine in two weeks sharpening sprung dividers

the alternatives available, starting work, a variety of parts, a wooden steady for the lathe, minor problems, assembly, useful photographs. types of single phase motors, series wound motor, repulsion motor, induction motor, three phase, principles of an inverter, points to watch, prices, postscript by the editor. safety equipment, lady readers, reader survey, articles this month's request, a word of thanks. Masmyth's tumbler reverse in error, the Drummond lathe saga, stainless machine tools surely not, reaming a matter arising, an easy intercom unit, a reader comments, uses for ma shaping machine, foot switches, dovetails and Unimats, resolving bandsaw problems, copying attachment for a Hardinge lathe, don't fall foul of the law, specifications, an answer tot he editors problem, scrap boxes and their contents, a poem remetrication, a mystery lathe, tooling identified, wanted help on a knurling tool for a Raglan lathe, White metalling in industry, file storage. marking out, the tools, imperial/metric conversion, acknowledgement.

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Speed control of AC motors (3)

Chris Boucher explores what is commercially available

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On the editor's bench Quick tip

Harold Hall parallel storage cases

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Workshop basics for beginners Trade counter

Louis Parke offers some sound advice Redthane belting, engineering fastenings, Edding 850 marker, metal finishing in small quantities, new manuals, new catalogue.

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18

A lathe mounted fretsaw

Bob Fletcher made this lathe mounted fretsaw

the design, construction notes, the crankshaft, the crankshaft bearing housing, frame support, the saw frame, saw blade clamps, tension rod, top guide brackets, lower arm guide, roller keep plate.

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Quick tip Quick tip All that glitters Quick tip A simple oil can

sewing needle scriber, smoother crossfeed uses for correction fluid W Brian Taylor gives details of oversize models Absorbent towel

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A micrometer boring adaptor A height gauge using an inside micrometer Instrument makers vice Quick tip Bandsaw vice improvements Quick tip A metal bender Hole aligning clamps Quick tip Swivel base Workshop visit - Harold Newman Quick tip Shapes and types of lathe tools Quick tip A visit to Tilgear Backlash In our next issue A tool post grinder (1) Quick tip Quick tip

Al Longworth suggest replacing one of the chuck jaws which is fitted with micrometer adjustment N Smith suggests a simple height gauge Putting the Promill-35 to work 35mm cases

the replacement jaw, in use.

the design, some design changes, machining the casting, the remaining parts, masking the vice, the Promill-35. the problem, an additional fixed jaw, moving the fixed jaw, improved jaw fixing, conclusions.

Belt dressing by Terry Gould Dave Clegg provides us with a simple device marking mild steel, polishing block, double speed worm made by Terry Gould

the main base, clamping bar, hinge.

a novice, recent expansion, modelling his main interest, small geared motor, a universal grinding rest, recent equipment projects. off-cuts Mr Loader concentrates on lathe tools their shapes and applications screw threads of progress system, grub screw slot A selection of letters received external grinding, face grinding, internal grinding, the dynamic design, accessories, finishing assembly and operations, problem resolution. standard shapes, the choice of tooling, boring tools, parting tools, cranked tools, special tools, carbide tooling.

Gordon Cordell has designed an excellent toolpost grinder picking stuff up from the road File and chalk

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DC motor speed control methods (4)

19

On the editor's bench

Harold Hall

19

Scribe a line

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14 18 20

A micrometer adjustable boring adaptor for 3 jaw chucks Bending strip material A double design drill

Al Londworth adapts a set of soft jaws for a three jaw chuck Mr R Harries offers some useful suggestions regarding bending strip materials using the minimum of specialised equipment This small drilling machine has been provided by J Neave

the drive block diagram, power supply, control equipment, the motor, transmission, load, drive system requirements, effect of control equipment, effect of power supply, possible systems, voltage dropper, stepped voltages, chopper drives, thyristor control, precision control, regeneration, AC versus DC, high versus low voltage, make versus buy, postscript. change of publication date, DC speed controllers, MEW authors, safety specs, early home workshop machines, the flywheel effect, articles. a word of caution, reluctant tapers, Warco 220 lathes, no more lost parts, imported machine tools - good value?, insulation - heat and electricity, bandsaw modification, would this help?, bandsaw blade breakages, band saw repairs, knurling wheels, computers in home workshop mode, a timely tip, black holes, Southbend lathe - information sought, reader identity and square holes, tool design - and lessons learnt, identifying stock materials, lathe chuck square, Southbend lathes - another request. an easy to make alternative, modifying the soft jaws, using alternative diameter boring tools.

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28 31

Adding a flywheel to a mill drill Backlash

Philip Amos proves that it really does improve it's operation Reader views regarding mill drill flywheel

base board, base plate, adjustable stop, assembly, both systems, weight return system only. drill mill modifications, spindle slog, brake, centre pulley mount, bolt length adjustment, belt cover, quill to spindle block, milling vice.

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32

Micrometers with a difference

height measurement, back face measurement, tube wall thickness measurement, other special micrometers, wider range micrometers, Mitutoyo micrometers.

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We visit home and workshop machinery The planer, slotter and shaper (1) Don Unwin describes how there was a special need Machine Mart move into Scotland, the Trihone from Chronos, Trade counter catalogues received, Record's first combined catalogue, Whistons, erratum. Making a lathe filing rest Pull out plan Dividing computer program H M Turnbull provides us with a simple program

construction, assembly. types of press, hydraulic press, toggle press, lever press, fly press, accessories, operations performed, hole punching, larger holes, required tonnage, strippers, hole positioning, nibbing, batch production.

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Using a bench press (1)

This short series fills in the background

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51 54

The model engineering exhibition Holding countersunk screws

Don Unwin explains how to carry out machining operations mandrel, short cover plate, riveting the clips, assembling, abrasive types, grinding wheel features, the grit, the bond, grinding technique and safety, grinding wheel problems, out of round, glazing, loading. machining procedure. model engineer exhibition MEW display, tailstock turrets, CAD, the reader survey, MEW index, articles received, telephone numbers, back issues. instantly useable, for the beginner, why CAD?, for those without computer experience, computer operating methods, the menus, grid and snap, final comments.

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Off hand grinding attachment for the Unimat 3

R J Loader explains how he saved space

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Grinder tool post (2) In our next issue On the editor's bench

Details for making Gordon Cornells excellent tool post grinder

Harold Hall's commentary

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CAD capabilities (1)

Computer assisted draughting

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Quick tip Trade counter Link up Quick tip

Locking end mills in the collet Chronos new catalogue, Minicraft, New DIY welding videos from BOC, craft supplies, Planet manufacturing Cutting small glass tube

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Rotating centre

By Dyson Watkins

the body, boring for the thrust race, internal screwcutting, a reminiscence, spindle silver steel, hardening and tempering, retaining collar, shim washers, assembly, bearings required.

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23 23 23 24 26 28 28 31 31

Quick tip Quick tip An inexpensive suds pump Faceplate/angleplate clamps Quick tip We visit Alan Cambridge Quick tip From the ME postbag Quick tip

Making hand cleaner BA screw threads increase in size by 13% C W Plummer uses car spares a shortage of hands, one thickness limitation, a range of sizes, a compact clamping system, useful jacks, thread size, manufacture, conclusions. Easier ring release Triangular file E W lathes. Interchanging BS brass threads with BS cycle threads cast iron, high carbon steel, medium carbon steel, low carbon steel, case hardening, pack hardening, high speed steel, stainless steel, stellite, carbides, heat treatment, hardening, softening, tempering, normalising.

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32

The plain man's guide to materials (1)

Mr R J Loader

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34 36 37 39 39 40 42

Quick tip Quick tip Using a bench press (2) Quick tip In our next issue A differential screw micrometer head A differential screw micrometer head drawing

Obo nails as centre punch Knife from hacksaw blade Metal bending explained Holding and aligning small washers with a magnet By Bill Morris the mathematics, barrel, guide, plunger, spot grinding. bending strip and plate, bending thicker materials, other uses.

20

45

Building a small compressor

Martin Howel describes his method

introduction, the compressor unit, the electrics, the plumbing, a few simple checks, trying it out, the reservoir, the chassis frame, electrics and final finishing.

20 20 20 20 20

51 53 54 56 56

Quick tip Quick tip Cutting left hand threads The Yortek award Quick tip

Milling formulae Cap head screw depth = thread diameter Joe Briffa overcomes the problem on his Emco Compact 5 lathe Surplus taps and dies similarities

20 20 20 20 20 20

57 58 59 62 63 64

We review the Pencut attachment Quick tip The slotter (2) Reader survey report Quick tip Using a surplus motor

Baking trays Don Unwins describes the slotter and shaper early days Cooling HS drills after grinding Follow on from Zanussi z900 motor aluminium alloys, locknuts a myth refuted, left hand threads Warco 918 lathe, older magazines, simple but effective, re-cycling old containers, another old magazine sought, a mystery resolved (3 1/2in Drummond), a timely idea, an anonymous ML10 gearbox, band-saw mod, compressor from i.c. engine, footswitches and safety, calling Scotland, safety hints, Pyrometer pencils, twist drill geometry, welding safety, Little John lathes and auto punches, reaming, Drummond lathes. link up, model engineers' workshop data book, CAD, quick tip error, corrected quick tip milling formulae, the 64th model engineer and modelling exhibition.

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65

Scribe a line

21

11

On the editor's bench

Harold Hall's commentary

21 21 21 21

12 14 15 16

Link up Trade Counter South Bend lathe accessories, South Bend spares, detach yourself with Loctite, a new milling head from Hobbymat, act immediately, new catalogue, changes at Myford. R McKenzie has made this rather nice tapping attachment for use in the lathe tailstock. drill press adaptor. history of the institute, the B.S.I comes into being, the first of many, past standards, real standards, what constitutes a British standard, the use of standards, standards of other countries, standards today, conclusion. a tool storage cabinet, a storage trolley for strip and bar stock. construction, a mandrel stop, use of the stop, first revision of the original plan, the post, fixing the magnet, scriber holder, the rule holder, final note.

In our next issue


Tailstock tapping device

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18

Alan Jeeves gives us an insight into the very history of British Standards, and concludes with a very useful list of present day British Standards for amateur engineers standards that have some relevance to the activities of the amateur engineer. Small tool and materials storage We present two ideas by John Pooler which go a long way to solving this problem J>H>Frost suggests an easy and economical approach to obtaining small magnets and offers a design using one of these in a magnetic base scriber block cum rule holder Geoff Hunt tip

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21

21 21

22 23

A magnetic post Cleaning swarf

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Memory aid for drawings

Geoff Hunt tip CAD, computer specifications, some basic definitions, hardware, software, media, backing up, operating system, the three worlds of personal computers, computer memory, the ROM, the hard disk, the RAM, units of memory, computer speeds, computer types within the IBM compatible world, 8086/8088, 286, 386, 486, portable computers, coprocessors, the mouse, colour monitors, printers and plotters, printers, compatibility, plotters, final words, organising the hard disk, DOS activities, windows, utility programs, backing up, training, learning CAD, prices and sources of information, postscript by the editor. a Grayson lathe, a tidy workshop, a twin cylinder oscillating engine. the review machine, fit a math coprocessor, 2D drafting, some software packages reviewed, outstanding features, draft choice, autosketch, easycadz, features compared, scaling, repeat operations, changing settings mid operation, text, undo and redo, alternative methods, picking a group, adaptability, manuals, final comment on the three systems, three dimensional drawing, system requirements, obtaining the software, other packages, turbocad, designcad, modelcad, pcb drawing, for further details.

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Consideration before purchasing a computer for CAD

Michael Oppenheim sets out to describe the ideal computer for use with CAD

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31

We visit -

Gordon Barber

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CAD systems (2)

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38 40 44 46 48

We visit A lathe milling attachment Sharpening small drills The Hart multi purpose grinding rest (1) Tapping blind holes

Chronos Ltd This horizontal milling attachment designed by J.Neave for fitting to a centre lathe overcomes the limitation of lack of adjustment added advantage, height adjustment, whilst giving an additional 1 1/2in of working height above the machining sequences, safety hints. cross slide machining slotted arm, the base, the table, vee blocks, finishing the castings, other parts.

21

52

Tungsten carbide tipped sawblade

Peter Bowes tip copper, free-cutting brass, an apprentice memory, cartridge brass, bronzes, casting bronze, wrought bronze, gun metal, aluminium, cast aluminium alloys, wrought aluminium alloys, duralumin, tin, lead, zinc. gearcutting set-up, design considerations, dividing head theory, choice of drive ratio, main components, constructing the main frame and register plate, constructing the output shaft, the brake assembly, the worm carrier assembly. operating a fly press, setting up for hole punching, setting up for bending, punches and dies, unhardened punches and dies, using a pilot, considerably increased use, specially shaped holes, bending thicker materials, conclusions, hole punching tonnage. South Bend lathes, the address, another new reader, how to run a lathe, suppliers of accessories, a satisfactory replacement, similarity with Boxford, similar micrometers, adjustable die stocks, a sober thread, one size only, the history, chipmasters, comments on CAD, praise where praise is due, methods of the past, Morse tapers and parcel tape, machine tool quality, select a band saw brazing machine, a similar device and a simpler device, the method, tempering by colour, models without a machine stop, editorial preferences, some further design changes. the 63rd model engineer and modelling exhibition, scribe a line, link up, steam correspondence circle, attending college, index.

21

53

Plain man's guide to materials - non ferrous (2)

Mr Loader continues his plain man's guide with some valuable information on non ferrous metals

21

57

A dividing head for the Peatol lathe (1)

Tony Jeffree

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Taps and dies surplus similarities

Alan Jeeves tip

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Using a bench press (3)

In the final part of the series the Author's methods of operating are explained

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Lathe light grip

Alan Jeeves tip

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68

Scribe a line

22 22

11 12

On the editor's bench Link up

Harold Hall's commentary

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13

Thread cutting attachment for the Unimat 3 lathe Chuck clearance A bench mounted support for the lathe Horizontal mill large job holding The Hart multi purpose grinding rest (2) Felt tip pen for marking out Dismantling a Jacobs type chuck

J.H.Frost has made an attachment which avoids the requirement to use the gear train David Dumble tip Derek Walters offers his solution for mounting a medium size lathe on an angle iron frame and wooden topped bench Hugh Mothersole tip We conclude the article Hugh Mothersole tip Doug Cooper lets us into the secret

construction, the drive rod, the saddle clamp, the drive link, the handwheel, the guide block and general alignment, using the accessory, final version, the improved device in use.

22 22 22 22 22 22

18 20 21 22 25 26

final thoughts about the kit, putting the rest to use, supplier details.

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27

A dividing head for the Peatol lathe (2)

Tony Jeffree

22 22 22

30 32 33

Low voltage lighting Large turning between centres A three way tailstock turret

J.M.Service has made a low volt system M.J.Devlin tip This tailstock is made entirely from stock materials

the indexing arm and detent assembly, the division plates and plate carrier, using the protractor to cut hole circles in the division plates, the adaptor plate, the sector arms. suppliers addresses. manufacture, body, three way turret, taper, minor parts, boring the turret, finalising the turret, final assembly, chuck adaptors, four or six way turret. shaper construction, the drive, the stroke mechanism, checking it's accuracy.

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40 42 43 44 44 47 50 53 55

First strokes with a shaper (1) Model engineer's workshop data book Easy fitting large chucks True up a disc in the chuck Aluminium and steel storage Dividing funny numbers International model engineer and modelling exhibition The mathematics of taper turning Trade counter

Bill Morris provides this series of three articles on the machine P.Wilton tip David Dumble tip Alan Jeeves tip Geoff Gray had the need for dividing of 113 and 73 divisions

quantifying the errors, the calculations, a large taper, a smaller taper, conclusions. the quick step mill, duradrive a screwdriver with muscle, revolutionary new pro-bond superglue pen. product review alkaline degreaser, pre-conditioner, blacking solution, dewatering oil, test pieces, method, result, corrosion resistance, safety, supplier.

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Black-it

22

59

Plain man's guide to materials - non metallic (3)

Mr Loader discusses the subject of non-metallic materials

natural materials, glass, rubber, stone, synthetics, nylon, polythene, P.V.C, polystyrene, Perspex, P.T.F.E, polycarbonate, thermo-setting plastics tufnol, epoxy resins, carbon fibre. general layout, notes on individual items, conclusion. improved rotating centre, emphasis on safety, preferred correction fluid, Drummond lathes and steam aviation, no expense spared, no need for errors, a note of appreciation, another south bend look-alike, a surface grinder maybe?, tri-lever attachment, left hand drills and broken screws, tools at the ready, a professional CAD user, a timber frame, vertical power hacksaw, a satisfied CAD user, the ideal MEW index, hand cleansers, a bandsaw problem, one way only. shaping up, computers and CAD articles, the bench press, air tools, types of articles wanted, index, help needed, REMAP

22 22

62 64

Blueing Alan Jeeves tip Quick change gearbox for the Myford M Mr G.Pratt shows how he adapted it for his Myford M series series lathe

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Scribe a line

23 23

11 12 16 17 18 18 19 20

On the editor's bench Handy screw jacks Drill grinding geometry Re-tang sleeves A large tap holder Using marking out fluid Plastic envelope of brushes A small staking tool

Harold Hall's commentary Alan Jeeves suggests that every machinist should have a set

23
23 23 23 23 23 23

13 Boring bar setting device

Neat little device by Eddy Rebbeck


Following the letter from Anthony Walton, F. Fallows produces an attachment for the Worden tool grinder Alan Jeeves salvages Morse taper drills and reamers E. Powell produces an effective and very easy to construct tap holder Anton Vella tip Roy Clarke buys some brushes John Jennings suggests making a small staking tool by modifying a small embossing press Terry Gould gets bending Alan Jeeves tip Hugh Mothersole tip

the material, in use.

the problem, the solution, making the holder, alternative designs, conclusion.

23 23 23 23 23

23 24 24 25 25

The methods of a professional Fitting drive keys Link up A hone driver For sale

a small staking tool, initial machining, anvil plate, punch holders, punches, finishing the anvil plate, anvil holder and anvils, number punch holder. unhardened punches and dies, useful in the home workshop.

23

26

Metal bench planes reconditioning and construction Adding a flywheel to a mill/drill We visit -

Peter Jones gives us another metal working article with woodworking connections P. Wilton modifies his mill/drill

the 50p plane, the flexible frog, eastern promise, adjustable nose, second thoughts, old irons, sole licence, sole flattering, the bevel, 19th century wins, final note.

23 23

33 34

23 23 23 23 23 23 23 23 23 23

37 37 38 40 40 41 41 42 43 49

Hobbing a concave knurling wheel A for operated saw table Diestock alternative Trade counter Layout fluid alternative We visit In our next issue Model engineers workshop data book Laps and lapping Unusual tee nuts

a brick built workshop, another happy Tri-leva user, making workshop equipment, items made the MEW designs, a welcome chat, suppliers. knurling wheel, hobbing holder, knurling For those into clock making and repair this article by Ian Dermott wheel holder, female centre, hobbing on making concave knurling wheels will be of interest set-up. Leslie Broomfield Hugh Mothersole tip tin coated drills, new catalogue, change of address, 3 phase inverters, precision gluing, lathe milling attachment - castings available. Alan Jones tip Maidstone engineering services In this issue we visit Don Hedger in his workshop. His main interest is in the making of workshop equipment

Alan Jeeves lets us into the secrets of this process

first process of lapping, choice of materials for laps, lapping compounds, flat laps, internals laps, external laps. modifying an economy drilling vice, minimum removal of metal, the method adopted, moving jaw, keep plate, jaw plate, final machining, final fitting, two sizes of vice, fixing to the table, supplier details. manufacture, fixings, final assembly, conclusions. lathe adaption's, an early universal mill, early days of milling in the home workshop.

23

50

From drilling to milling vice

Make a useful alternative for light duty for a fraction of the cost

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55 56 60

Drill/Mill down feed stop A platform for the Hart The history of the milling machine

Another simple modification Improved approach for the Hart grinding rest Don Unwin provides us with another insight into the early days of machine tool development

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65

Scribe a line

more computer considerations, CAD mastered, bearing life, float glass flat of not flat, locknuts required?, E.W. Lathe, REMAP worthy of our assistance, Tee nut manoeuvring, another MEW gearbox variation, not a bad buy, select a tooling, spring back, revised opinion, editorial preferences 50:50, model crane without machines. Alan Jeeves tip Harold Hall's commentary Mark Burgess provides this short article REMAP, photocopies of MEW articles, editorial ignorance. the stud, dowels, dowel diameter, dowel length, dowel materials, dowel positions, fitting. construction an alternative idea.

23 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24

69 13 14 15 16 18 19 20 20 20 22 23 25 25 26 27 29 30 31

Cleaning bearings On the editor's bench Studs and dowels MEW index update Making division plates A simple steady Link up For sale Drilling deep holes Large capacity two part vice Bits and bobs for a universal bandsaw Recycling reamers Plastic bending In our next issue Graduated saddle stop Reaming allowance Throw away cutter holder Trade Counter A small height gauge

George Swallow describes how he set about making a plate for that frequently missing number 125 Alan Jeeves suggest some simple approaches to the problem

Alan Jeeves tip The two part vice from Alan Jeeves R W Clarke makes suggestions for a range of modifications Alan Jeeves tip G R Barker tip In this article Peter McQueen provides the design for a saddle construction, assembly, in use, a word stop for the Emcomat-7 about accuracy. Alan Jeeves tip Derek Walters offers a design for a throw away cutter holder for the Hobbymat MFE65 drill/mill it will also fit the nose of the MD65 nose a completely new cyanoacrylate system from Tufloc, compressed air in the home workshop, special offers on books. Alan Jeeves provides us with a little project with a useful end the base product new on-off switch, G cramp clamping plate, indicator for blade jammed or stopped.

24

32

Safe thinking

Joe Ginn in this article prompts us to give more thought to the subject

the lathe, milling machines, drilling machines, grinding machines, fitting grinding wheels, hand tools, screwdrivers, files, hammers, chisels and punches, spanners, electricity, fire, asphyxiation, head injuries, eye protection, foot injuries, falls.

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34 35 36 38

Emery cloth alternative Floating reamer chuck Removing broken drills and taps Softening jaws

Alan Jeeves tip starting work, the floating head, drive Alan Jeeves explains the need for precise alignment of hole and keys, retaining plate and assembly, reamer. He then offers a design for a floating reamer using the chuck. Ken Gibson tip Alan Jeeves tip no volt release, limited overload setting range, obtaining a foot switch, John Steele suggests a professional approach to one aspect of connecting up, earthling integrity safety essential, worth every penny, supplier details, editor's postscript. requirements for precise angles, methods available, the combination set, Here we consider the options for carrying out this task universal bevel protractor, sine bar, in use, thoughts on a home made sine bar, an extract from Mr Tomson's letter. N Smith tip Alan Jeeves tip the deciding factor, a difficult site, the workshop, shelving, drawing storage, the electrics, unit of measure, the lathe and milling machine, other machines, hand tools, measuring, cutting tools, small tolls, purchase of smaller items, a final comment.

24

39

Drilling machine safety

24

42

Measuring and marking out angles

24 24 24

42 45 47

Model engineers workshop data book Coolant tip Acquiring abrasives

24

48

John Steele's new workshop

John Steele explains his experiences

24 24 24 24

54 55 56 58

A simpler graduation tool Systematic storage Hardening tip More strokes with a shaper (2)

R W Buck suggest a design K J McLaughlin tip Alan Jeeves tip Bill Morris continues his series Derek Walters suggests making an adaptor for fitting chucks used on a BFE65 mill onto a Myford series seven larger task, the correct speed and safety factors, moving on, checking for parallelism, security problems, shaping the tee slots, a need for concentration.

24

64

Hobbymat to Myford adaptor

24

66

Scribe a line

Domestic premises and storage of gas, buyer beware, successful beginner one of many!, a case of lateral thinking, Anglo-Swiss mandrel, covers for workshop equipment, Drummond lathe manuals, link up working, furnace temperature, material hazards. Alan Jeeves tip Alan Cambridge provides us with this accessory Harold Hall's commentary early machine data, model engineer and modelling exhibition, inflation plus, toolmakers clamps, data book, tailstock turret, TIR error, end of term. introduction, construction - basic attachment, mounting, calibration, operation, footnotes. a precise angle device, description, construction, the pivot holes. actual manufacture, safety notes, the centre punch, using the centre punch. with the needle, how to make it.

24 24 25

69 70 11

Countersinking diameters Thin piece vice accessory On the editor's bench

25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25

12 20 24 26 27 29 39 32 35 37 39 39 40 41 42 43

Taper turning attachment for the Myford B J Cursor provides owners of the Myford 254 lathe with a 254 lathe design Accurate angles The construction of a simple optical centre punch A brass oil dribbler Final strokes with a shaper (3) File storage Sharpening end mills and slot drills A vernier conversion We visit Toolmakers clamps Tapping stainless steel Slot drills preferred Chain drilling A four way carriage stop Model engineers workshop data book Fabricated faceplate for the Unimat David Lammas suggests making an accessory Ted Hartwell provides us with a simple design for an optical centre punch Alan Jeeves provides this elegant and attractive solution to the problem Bill Morris concludes his series John Steele describes his method Tony Skinner details his own endeavours in this direction This vernier calliper to height gauge conversion by R J Loader benefits by it's simplicity Guy Keen's workshop John Steele start to put his new workshop to use An Alan Jeeves tip An Alan Jeeves tip Pat Twist suggests a methodical approach Bill Morris suggests one such aid

the base, the packing piece, the scriber and clamp. tank locomotive Titch first model, degree in mechanical engineering, suppliers. an idea from scribe a line, avoiding knurling, the pros and cons, next project.

Bob Loader provides another of his excellent articles

the base, quadrants(1), lining up the parts, marking out, the quadrants, assembly and machining, special tee nuts.

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48

Looking at stainless steels

Alan Jeeves shares his knowledge on the subject

25 25

55 60

The birth of the large machine tool Link up

Don Unwin continues his occasional series

what are stainless steels, austenitic steels, ferric and martensitic steels, identification of grades, alloying elements, precipitation hardening steels, some of the grades in common use and their applications, Austenitic grades, Ferric grades, Martensitic grades (all hardenable and magnetic), working with stainless steel, milling stainless steel, drilling, grinding, forming threads, storage, additional notes for mariners. vertical boring mills, a need for large bore cylinders, a slow process. roller assembly, main frame, bearing housing and mountings, bearing mounts, assembly of bearing mounts to the main frame, plattens and work table, top roll guard, motor/drive.

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61

Vertical belt grinder

This design for a vertical belt sander is by Malcolm Leafe

25 25 25 25 25 25

66 67 67 68 68 68

Trade counter Toolmakers clamps and milling operations Pilot drill sizes for stainless steel Simple slotting Recycling allen keys A clean start

new catalogue, keeping rust at bay, K.J.C horizontal milling attachment for the lathe, workshop electrics, digital readout, black alloy cutting tools.

Alan Jevves tip R J Loader tip C Washington tip C Washington tip shaping tee slots the easy way, another automobile gearbox, dividing high prime numbers, TiN Titanium Nitride, radiused bottomed grooves, CAD warning, tee slots in mild steel, indexing device, tapholder simplified, machining stainless problem solved, novel dividing, milling safety, safety first. Welding rods Alan Jeeves tip Alan Jeeves tip Bimetallic corrosion Alan Jeeves tip R J Loader tip Harold Hall's commentary Dennis Major suggests a simple method of making one tumblers, smaller articles, link up, telephone numbers, shaper article, MEW index. a revised design, in use.

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69

Scribe a line

25 25 25 25 26 26

70 70 70 72 11 12

Stainless steel in marine applications Clock lubrication Stainless steel in marine applications Easy starting On the editor's bench A tailstock taper turning attachment

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13 14 15 15 17 18 22 22 23

Link up A 4-way toolpost for the Peatol lathe A quick change tool holder Quick tip Quick tip A fabricated vice Trade counter Reader survey Self holding taper sockets

By Geoff Gray by N Bowness Angle grinder use Tap restoring A Bob Loader design New catalogues, ornamental turning, Saupe SD400 powerturn lathe, further Hobbymat accessories, baby Record. sockets in use, step down sockets, special sockets, care of sockets, Brown and Sharpe tapers, Jarno tapers, socket reamers. brief history, selection and purchase, punting the chuck, safety and general precautions, workpiece holding and protection, holding castings, machining rectangular sections, additional notes on accurate workholding, indexing in the four jaw chuck, care and repair of the four jaw chuck, worn external jaw surfaces, broken jaw screws, screw retaining bearings, chuck keys, other uses for the four jaw chuck, safety notes. an industrial process, easily available drums, RPM or metres per minute?, extracting the dust generated, more experimentation needed, two drums beneficial, readers experiences requested. the problem, the solution, a final thought. a milling operation, the base, the guide bars, the screw, finishing the jaws, retainer, final fitting. toolholders, parting tool holder, toolpost, clamp spindle, checking and testing before hardening, working experience.

Some facts and figures provided by Alan Jeeves

26

27

Making the most of the four jaw chuck

Provided by Ted Hartwell

26

33

In our next issue

26

34

The rumbling tumbler

Terry Gould carries out some experiments

26 26

38 40

Making a precision angle plate Model engineers workshop data book

John Steele takes us through the process ISO metric spark plug threads, ISO metric conduit threads, Unified threads, BA threads, BSW threads, model engineer threads, BS brass threads, BS cycle, BSF threads. Gordon Cornell describes his unique lathe attachment

26

41

A universal milling/dividing attachment

comments on the final design, making the attachment, manufacture, calibration, assembly and finishing.

26

49

Introduction to broaching

Alan Jeeves gives consideration for future projects

26 26 26

52 58 60

A ball turning tool The quest for Mr Morse Saddle stop and index arm

Phil Thomas' well thought out design Bob Loader goes in search of a story Geoff Gray incorporates a simple indexing system

typical uses, the construction of broaches, broaching blind holes, how to use broaches. requirement for a ball turning tool, development of the tool, the micrometer adjustment, construction of the tool, standard turning, conclusion.

26

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Stepper motors

Ray Stuart provides us with a short article

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Scribe a line

27

11

On the editor's bench

Harold Hall

27 27 27 27

12 14 16 17

A wheel dressing jig Winding small springs Quick tip The Griptru chuck

by S J Curtis R Harries on the subject of winding springs Tap restoring Allan Jeeves discloses the secrets of the Griptru chuck

stepper motor characteristics, motor construction, how a stepper motor works, bifilar windings and unipolar drives, other drive sequences, steeper motor applications. long term owner, Ajax still in business, cutting metric threads, higher furnace temperatures, drilling machine control, shaping tee slots the easy way, accurate angles, earth lead security, drilling brass, ear defenders, swing clear tool holder. the model engineer exhibition, disappointing response, reader survey, a confessional, index, payment for articles etc., encouraging signs, telephone number update. construction, assembly. tension springs, compression springs, springs for drive belts, volute springs.

27

18

A computer controlled X-Y table

Ray Stuart provides us with an article

27 27 27

27 30 32

A boring head A drilling method from the past Light duty drilling/milling spindle

C M MacEke provides a design that will cover very small up to 200mm Bob Loader proposes a method for adding a little more accuracy to your drilling Geoff Gray provides us with a design for a simple light duty spindle

the stepper motor drive system, power supply, motor drive circuit, limit switches, printed circuit board, assembly, testing, test software, table mechanics, CAD systems, CAD package set-up, the software package, adapting the system to existing equipment. construction, body, tool carrier, pivot pin, retaining washers, worm retainer.

27

34

We visit Simon Trendall

A younger reader M D Pengelly converts an economy cross vice into a vertical slide for use on his lathe Harness comparison W B Taylor solutions to a couple of problems Have you a drill chuck which has lost it's precision, Yves Rayssigiur suggests a method of achieving a new lease of life sines, cosines, tangents John Steele makes one Lathe tools and centre height 0.125mm shim stock source a little design work, the clamp body, fitting the clamp, milling the clamping pad socket, drilling the clamp body, the cover, final fitting, clamp screw and adjusting nut. A method for machining No 2 Morse taper shanks simple design intended, manufacture, the body part, the tool carrier, the body and carrier assembly, the minor parts, assembly. mounting position, adapting the cross slide vice unit, mounting bracket and double tee bit, double tee bolt, mounting bracket, working with the unit, conclusions.

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36

Low cost vertical slide

27 27 27 27 27 27 27 27 27

37 39 40 41 42 42 43 44 47

Quick tip Link up Two ways to pull a fast one Truing drill chucks Data filing Model engineers workshop data book A boring head for the Hobbymat BFE65 Quick tip Quick tip

tools required, possible methods.

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48

Adding a fine feed to a digital vernier

Bob Loader set about adding his own

27 27 27 27 27 27 27 27 27 27 27

50 51 51 52 53 53 55 56 59 61 61

Quick tip A tangential skiving tool Quick tip Quick tip Quick tip Quick tip An 'easyset' tailstock dieholder Three way tool post A low range torque wrench Trade counter A quick change toolholder

Cutting compound and corrosion Ron Bently provides an article Parting off lubricant Screws for screw jacks Grinding wheel cushions Grinding wheel dresser Clive Washington comes up with a simple method Dave Lammas describes how A design by Geoff Oakes Dexion storage systems, better than a third hand, new home user drill press introduced. Correcting an error in issue 26 construction, facing, machining the sides flat, milling the tool slots, tool clamping screws, indexing stop, the tools. calibration.

27

62

Uses for the Emco 3 mill/drill head

Derek Walters adds one to his lathe

27 27 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28

68 69 11 12 16 18 19 20 21 22 24 28 32 33 34 37 40 41 42

Scribe a line In our next issue On the editor's bench The sweeper - a lathe tool grinding fixture Cutter frame Hand punches explained Quick tip Quick tip Accurate division with simple tools A drawer for a lathe cabinet Change wheels and screw cutting Gearing and gearwheels Internal chasers Trade counter Dividing attachment for a Boxford lathe Making a hand shear Quick tip Two approaches to "C" spanners A toolmakers vice Harold Hall John Scoggins suggests a simple fixture for the sharpening of lathe tools on the off hand grinder Geoff Gray provides a design for a simple gear cutter frame

uses, limitations, similar small mill/drill head units, bonus for us older folks, important dimensions, parts to purchase, boring head, manufacture of motor mount assembly, used as a stand alone high speed drill, used as a tapping aid, safety postscript. beginner seeks help, a small engineering world, Alan Jeeves comments on his discovery, gearbox origin solved. some things don't change, some things do. manufacture, assembly, the sweeper at work.

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43

Model engineers workshop data book

centre punches, other variations, pin Bob Loader explains that there is more to punches than we may punches, recycling, chisel steel, special first envisage punches, an ambitious project, accuracy when punching. Holding small drills Grinding precaution, circle to internal square ratio H S Harvey suggests a method for making division plates Sid Reid adds a draw to his Myford cabinet in a position which is otherwise wasted space idlers and left hand threads, formula, This article explains the principle of using change wheels and setting up change wheels, thread methods for overcoming the problem of missing wheels indicator, easy to achieve gear changes. Don Unwin describes the development of gearing Alan Jeeves recycles old taps to make internal chasers Useful brushes, converter runs 3 phase on single, black-it review update. A W Shirras makes this simple indexing device for his Boxford 4 machining, assembly, faceplate. 1/2in lathe from castings By Terry Gould the main frame. Useful containers Designs from Derek Walters and John Noakes design changes, machining the main casting, a start on the moving plate, John steel concludes his series using the boring head, the turned parts, assembly. Screwcutting - changewheel combinations, leadscrews 4tpi, 6tpi, 8tpi, 10tpi

28 28 28

45 48 51

Cross slide bracket for an electric pistol drill A fretsaw attachment for the lathe Quick tip

Derek Brooks makes a number of useful items Terry Gouls makes an attachment GT85 - WD40 alternative

tee bolts, clamps, boring bar, indexing, using the device. construction, the frame, saw arm assembly, crank assembly, blade clamps, saw table, an improvement. essential workshop facilities, types of white metal bearings, lubrication systems, action prior to re-metalling, bearing preparation, rough boring and oil grooving, refitting shells, shims, rebuilding, the nipping-up process, direct metalled mains and big ends, bush bearings, in line boring of main bearings, suggested clearances, boring connecting rods, connecting rod alignment, final assembly.

28

53

Machining white metal bearings

Article by Ted Hartwell

28 28 28 28 28 28 28 28

59 59 60 61 64 64 65 65

Tailstock turret Quick tip Quick tip Gear cutting without complex cutters Quick tip A simple press tool In our next issue Link up

From B Jackson Clear stamped characters Holding external threads, setting screw cutting tool Barry Holt suggests an alternative Circle to internal square ratio worm wheel, an unusual moulding technique, the cutter spindle, proof of the pudding, spur gear.

28

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Scribe a line

cannon borer on display, more tumbler information, material specification sought, soft centre with certainty, milling on the drilling machine, tumbling experience, soft jaws, easy metric screwcutting, chain drilling, stainless steel cleaning and polishing, machining spherical surfaces. Simple depth gauge Geoff Sheppard Bob Loader describes a neat tool which will soon repay the couple of hours making it by getting those centre pops where you really want them Who is Geoff Sheppard, future policy.

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Quick tip On the editor's bench A centre punch guide

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Keys and keyways

In this comprehensive review Alan Jeeves surveys the systems available

plain parallel keys, taper keys, Woodruff keys, other types of key, key steel, cutting keyways, hand cut keyways, milling keyways, other methods, blind keyways, box square clamps.

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Data book error on page G Quick tip Quick tip Quick tip Quick tip Quick tip Draw bars A slotting attachment for the mill/drill Modern paint finishes Trade counter

Methylated spirits is a useful solvent epoxy or polyester resin Using epoxy or polyester resin mix in paper cup Masonry nails and pin punches Wetting agent for flux Easy view drill sizes Jim Canner suggests a design Alan Jeeves has devised an attachment Some hazards and how to avoid them RS new catalogue, new drilling machine from madding's, four new items from Clarke, a new approach to small part storage. main assembly, the worm and dividing plate assembly, lazy man's hint, direct Mr T Taylor provides a design for a small dividing head used on dividing facility, drilling the division his Unimat plates, a few calculations, drilling the plates. Source of 'O' rings Tapping compound alternative Millimetres to inches, tangents Protecting leadscrews Harold Hall's pair small fly cutter, large fly cutter, cutters. Dyson Watkins holder reduces chatter materials, starting work, the ram, the split sleeve, the lever, assembly, the slotter in use, square holes.

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A small dividing head

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Quick tip Quick tip Model engineers workshop data book Quick tip A pair of fly cutters Swan necked turning tool holder Reader survey report In our next issue The 64th international model engineer and modelling exhibition The evolution of drilling and drills We visit Chester UK ltd Getting more out of your rotary table Soldering aluminium Quick tip Quick tip Quick tip

Don Unwin continues his series attachment to drill/mill, holding work, Philip Amos describes how he has extended the versatility of his working at angles, use on lathe, material table handling. Gordon Read questions a long standing myth and finds that the soft soldering can be done, hard solution has been around for almost as long as the problem soldering (welding?). Wetting agent for flux Lathe tool packing Protecting leadscrews

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Link up A releasable mandrel handle Quick tip Quick tip An apology

Stan Bray Marking through holes To test a set square the quest for Mr Morse, Sentinel type 58 universal milling machine, 'Far Eastern' combined lathe/mill, Martin Cleeve toolholders and E W lathe modifications, E W lathe data, protected ears, and clean hands, a vice from the past, clean data, safety when grinding, how to supress radio interference, low melting point alloys, eliminating backlash safely. Geoff Sheppard model engineering summer school. Gordon Read introduces a technique which will allow expression tool making, holding the tool, practice of our artistic abilities cutes, fancy turning. preparation, crack detection, checking for bow, journal wear/condition, the regrinding process, the throw block machine, the orbital machine, tolerances and special requirements, other aspects of reconditioning, balancing, static crankshaft balance, basic crankshaft Ted Hartwell describes the refurbishment dynamic balance, full crankshaft dynamic balance, combined crankshaft and engine balance, suggested action for the rebalancing of a reconditioned crankshaft, crankshaft failure/fracture, undersize or malformed radii, aggressive journal grinding, fatigue failure. scribing block fine adjustment Cleaning tee slots

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On the editor's bench Hand turning

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Crankshaft reconditioning techniques

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Quick tip Quick tip Link up First steps useful tools Coils for a novel application Concentric morse taper spindles Mill/drill modifications Quick tip Quick tip

Edward T Haas needed some unusual copper coils David Dew describes the method he used to create the taper in SPAM a versatile milling, drilling and grinding spindle Hobbymat BFE65 Sorting small parts made easy Plans available

the gauge, the internal taper, the taper mandrel. the need to conserve space, essential dimensions, a worthwhile modification, D J Lindford.

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Quick tip

Sheet 1, GA Alan Jeeves gives us an insight into the very history of British Standards, and concludes with a very useful list of present day standards that have some relevance to the activities of the amateur engineer. Inching towards metrication Jim Canner is at home in two worlds Jim Canner develops draw bars End mills and lathe chucks, alternative storage millimetres to inches tables, useful electrical formulae Mark Figes gives us detailed instructions on the manufacture, includes a modification to the Geo H Thomas design Bill Morris describes the characteristics the spider, and it's draw bar. base materials, enamels, preparing enamel, metallic oxides, the kiln, firing and safety equipment, first aid, fire hazards, work handling, applying the colours, firing work, finishing off.

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An introduction to enamelling metals

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Quick tip An electronics engineer who favours mechanical drives No holds barred Quick tip Model engineers workshop data book A 5 7/8in dia geared rotary table Amore angles on the sine bar Quick tip Quick tip Quick tip

preliminaries, base, wormbox, assembly, finals. sine bar characteristics, making the sine bar, adjustable parallels.

Stainless steel wire Millimetres to inches Using epoxy or polyester resin Pat Twist provides a design for a simple to make slotting A slotting device for the Myford S7 lathe attachment for a series seven lathe The Offa plastic cutter, die holders from Tracy Tools, a vernier Product reviews height gauge from Chester UK, from the new Chronos catalogue, Castell engineering supplies Co-ordinate measuring on the cheap J Freed offers an economic solution manufacture, microscope, illuminator, brackets, uses, a caution. side grinding, X-Y table query, a source of treasure, accurate division with simple tools, counter-productive adverts, more on the Lammas toolpost.

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Scribe a line In our next issue On the editor's bench A modified grinding attachment for the Unimat 3 A tilting table Sheet metal forming rollers for the workshop

Geoff Sheppard Bob Loader took a look at the tool grinding attachment which he described in an earlier issue and decided that a re=work would improve things

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Marking out angles

and now for the not so good news. wheel arbor, toolrest bracket, wheel cover, riveting, eye shield assembly, the attachment in use. the body, the table, milling the slots, tee Mark Figes set about fabricating a tilting table slots, finishing. design options, gearing, starting work, Alan Jeeves describes the differences between the two types of the rollers, the end frames and base roller and describes a set of pinch rolls plate, fixed and sliding bushes, sundry parts, using the rolls, conclusion. 90deg, 45deg, 60deg, 30deg, dividing Harold Hall has been giving some thought to the subject of an angle, accuracy, other angles, centre getting them accurate square.

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Maximising workshop space The other guy's shop Workshop security Model engineers workshop data book Making the most of the home workshop Quick tip Link up Tailstock for a small lathe

David Machin gives some advice Peter D McQueen, Henry Kratt, The editor has been giving it some thought millimetres to inches tables, electronic component marking Philip Amos describes his The extra convenient vice mounting Alan Bourne was faced with a missing tailstock and made a replacement

lathe, drill, bench grinder, mill, shaper, power hacksaw, bandsaw, planning the layout, foundry extension.

Big collets for the Myford Super Seven 7 Jim Canner moves on to holding devices lathe Trade counter My way to a workshop A backwards look at gearcutting Scope soldering irons, metal from Mindon, high quality inspection equipment, clean hands, Kirjeng catalogue, corrosion protection John Rockey describes how he achieved his ambition Don Unwin surveys the methods used up to the mid 19th century

motorising the lathe, the casting, making it fit, boring on centre, the works. an unusual means of location, machining the collets, boring, slitting, even larger collets.

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whitemetalling bearings, interference from the ACS200, coils for a novel application, accurate centres, hard soldering aluminium, x-y table suppliers, breech mechanism, more on hand turning.

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On the editor's bench

Geoff Sheppard Brian Cocksedge brings us a simple attachment which will help Adjustable stop bar for a milling machine in milling operations and suggests some alternative alternatives arrangements Quick tip Reducing bolt lengths Quick tip Tapping blind holes The 65th Model Engineer exhibition Quick tip Marking through, tapping through holes Another Quorn a score of years or more Do you have a set of castings tucked away? Here Theo Gooden on provides some tips as to how to complete the machine chain drilling the easy way, another way John Brittain describes how he added a swivel base to the vice Modifications to a machine vice around the problem, securing bolts, fitted to his shaper and adds some tips on chain drilling graduate or drop-out. A suggested modification to the Myford Pat Twist has come up with a modification which will increase casting availability slotter the capability of the unit Link up Alan Jeeves describes a method for turning tapers in which he Taper turning using gears compound gear trains. uses the change wheels to set-up the taper

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Buying and renovating a second-hand lathe Now how do you get it home?

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Hand shapers vee blocks

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Lathe inspection

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A raising block for the Unimat 3

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A two jaw chuck

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getting it home, cleaning and inspection, David Machin describes his experiences and gives some tips to reconditioning, headstock assembly, those who may be setting out along the same path other mandrel bearings, sliding surfaces, the drive motor. Don Titus tells us some of his experiences of moving heavy machinery and gives advice about the best way to go about it the cutting tools, the design, the A recent revival of interest in the hand shaper encouraged machining operations, final machining, Harold Hall to acquire a secondhand example and to assess it's the clamp, hand shaper a viable capabilities by machining a pair of vee blocks proposition, casting supplier. general inspection, the bed, the headstock, the tailstock, the saddle, the Bill Morris shows us how to inspect a lathe to professional leadscrew, formal inspection, alignment, standards and gives us some dimensional tolerances against the bed, the spindle, the tailstock, the which we can judge a secondhand machine leadscrew, turning test, correctable errors. some design considerations, templates, case-hardening, block, end plates, centre plate, a little milling, fitting the end Bob Loader sets about increasing the capacity of his Unimat plates, finishing the vees and flats, upper vee, fitting the upper vee, upper flat, a small difficulty. does your faceplate run true, preliminaries, lathe method, mill method, Mark Figes has devised this 5 inch diameter unit which will jaws, fitting jaws to body, finishing the accept a variety of jaws body, jaw screw glands, hardening and tempering, final assembly. Painting castings Sumitome insert lathe tools, tool catalogue from Germany, an Australian boring tool, a wood cleaning solution, new engineering epoxy resins, heavy duty angle grinder. readers get together, biography of F J Camm, workshop security, more on interference, extending the technology, quart in a half-pint pot and material supply problems, thoughts on going metric, Arch Gibson's method of metric screwcutting, 'Griptru' chuck instructions - a correction. George's tool evenings, the Olympia exhibition, women in model engineering, MEW index. Mike Delaney set about understanding the limitations of using a cross vice modifications, control of head drill press movement, safety. Geoff Sheppard

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In our next issue On the editor's bench A poor man's mill

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X-Y table update Cross drilling jig for the lathe A backwards look at gear cutting (2) Quick tip

Ray Stuart put together an number of matters arising

pen raising and lowering, software enhancements, HPGL without a cad systems, conclusion.

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Trade counter

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Playing with spirits Quick tip Quick tip A simple dividing device

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Punching holes with an Arbor press Tools at the Northern models and Midlands exhibition Index for issues 9 to 20 of MEW Model engineers workshop data book

Dyson Watkins describes a simple jig which will take the pain taper shank, body, swing clamp, Vee. out of this operation Don Unwin looks at the generating and grinding of the tooth the search for greater accuracy, cutting form bevel gears, gear grinding. Chuck key safety new items from Minicraft, low temperature casing alloy, Record tools winter promotion, hands free wrench from Frost auto restoration techniques, co-axial hand tapper from Arrand, boxed sets of M>E> taps and dies from the Tap and Die Co, digital caliper offer from KPL, insure your workshop and models, new collet chuck from Chester, 'A' clamps from Powergrip, Tapinline from Easilock products. estimating sensitivity, increasing sensitivity, thinking spherical, tubing, Bill Morris tells us how to make the vial for a sensitive spirit level lap-making, lapping the vial, graduations, closing the ends. surface plate Stub drills construction, back and front plates, Colin MacEke found a very simple unit which proved easy to set detent ring, base plate, detent plate and up pin. test results, increased tonnage, Harold Hall relates how he evaluated an arbour press to see if it modifying the press, Bolster and stripper could be used as a punch plate, supplier of arbor presses

Spanners, conversion chart in to mm Mark Figes passes on some hints and tips and describes a useful pipe bender Chip breaker Colin MacEke Cloisonn work, Filigree work, Champlev, Basse Taille, En Ronde Bosse, Piqu-A-Jour, painted enamel work, lustres, other methods of applying a design, suppliers. general considerations, radius, fitting pipework, bending by loading, the tube bender, tube hooks, pressure slide, assembly, using the bender, material availability.

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Tube bending

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Quick tip Workshop visit

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Advanced enamelling

Alan Jeeves surveys the more expensive process

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Mini-Jenny Quick tip Quick tip Quick tip Link up In our next issue Fireside reading

Malcolm Leafe devised this simply constructed sheet metal forming machine lifting and shifting Lathe tool height setting Caliper dodge

construction.

Workshop electrics by Alex Weiss, workshop construction by Jim Forrest and Peter Jennings, designing and building a metal cutting bandsaw by Vincent R Gingery

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a bit of trigonometry, body, mandrel, the male centres, the split bush, female A tailstock work support for the Unimat 3 Bob Loader describes some simple accessories which will assist centre, pressure pad, further thoughts, problems with centres, centre, nut. Philip Amos offers some suggestions on how to make clamping Clamping collars footnote. collars fit effectively a class at Harlow, centre drill angles, Scribe a line metrication content of MEW and other matters. finish on workshop equipment, Tom On the editor's bench Walshaw on metrication. the drive system, the power requirement, tooling tapers, bearings, When Mark Figes decided that he needed a turret milling head building the MMH, Dore-Westbury parts, A motorised milling head (MMH) (1) for his Senior M1 mill he concluded that he would make one mounting plate group, gibs, swivel plate assembly, tee bolts, mounting flange, spindle pulley group. Michael Jacot describes an angle table to suit his Proxxon A very simple angle table milling machine topslide settings, materials, machining a Gordon Read takes us through the steps required for the taper shank, the crucial test, adaptor Making your own morse tapers manufacture of Morse taper shanks and sockets threads and drawbars, taper sockets, preparing the hole. Ian Magowan tells how he came by the design and shares it with A simple filing rest readers first things, training workshops files and clapped machines, the drawing office, down to business, turning and the Biro Bob Loader takes time out of the workshop to reminisce and to How it was business, tricks not of the trade, drums ponder the current state of affairs along the benches, 100% inspection, extra things, characters, post war plunder, final thoughts. the drawer, fitting the brackets, More drawers for a Myford cabinet Sid Reid adds a couple more observations.

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Tools and workshop appliances at the 65th model engineer exhibition PCB manufacture for model engineers Index for issues 21 to 32 of MEW Model engineering workshop data book Ray Stuart introduces us to a technique which has a number of uses within the engineering field why the pcb evolved, manufacturing sequence, exposure, safety aspects, brass etching, cleaning, finishing and some alternative applications.

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Trade counter

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Quick tip A quick clamp Lathe steadies Quick tip A large capacity steady for the lathe Link up In our next issue

Gears involute form, A digital position read-out from the Channel Islands, Arrand introduce a standardised range of indexable tip carbide tools, fractional HP motors from Sheffield, Sandboss - a pneumatic sander attachment, wetstone grinder from Clarke Power products Demountable DTI D O Coe describes the conversion of a cheap grip wrench into a table lamp Alan Jeeves explains the principles behind the fixed and travelling steady Slip gauge substitute Alan Jeeves demonstrates how to make one of these accessories the basic design, main frame, spacers and blocks, the cartridges, using the steady. location and setting, other methods of setting, travelling steadies, the roller box, friction, capacities.

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Making a bench micrometer

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A simple indexing set-up for the Unimat Quick tip Modelling at your leisure

the bed, cast bed and headstocks, headstocks, finishing headstocks, Bill Morris brings us a design for a home made device which will machining castings, headstock bores, compete with commercial units bush, the table, assembly, making standard bars, supplier details. the index plate, link, plunger, nut, setting A few simple attachments enhance the capabilities of Bob up, another use, making index plates Loaders small lathe from scratch, a method using a jig. Chisel safety the metric debate a younger persons view, use of 3 phase equipment on single phase, more machine information sought Atlas, drilling from a new angle, an advantage of numerical control, tuition in model engineering. Trammel micro-adjustment, chain drilling jig

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Tom's tips On the editor's bench

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A milling/drilling table for the Myford ML10 cross-slide The story of the grindstone and the grinding machine (1)

Although designed for the ML10 Len Walker points out that it can be adapted to almost any lathe which has a tee-slotted slide Don Unwin traces the history of this machining process the development of the grinding wheel, the grinding machine. precision bench centres, materials, the bed, the dowel, the clamp bar, assembly, using the centres, fabricating the body, machining, scraping, how it used to be done.

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Simple inspection equipment

Alan Jeeves describes the manufacture of two pieces of equipment which will aid the checking of other work

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In our next issue Modified MD65 faceplate New half nuts for old Link up Philip Amos adds a postscript to his recent article showing an ingenious method of cutting a wormwheel segment A fiducial indicator for a bench Bill Morris describes how a highly sensitive piece of micrometer instrumentation can be made by simple machining techniques Alan Bourne takes a commercially available attachment for an Drill grinding a quiet way to use a handy electric drill and adds a number of features which make is more sharpener user friendly We visit Pat Twist (1) Model engineers workshop data book Centre drills, tapers A postscript on the rotary table A motorised milling head (MMH) (2) Mark Figes three slot faceplate, method, making the The Hobbymat MD65 lathe faceplate only has three slots Harold spigot, making the slots, tailstock Hall shows how this can be overcome adaptor, final comments. Gordon Read shows us that home made replacements are not the cutting tool, half nut blanks, thread difficult to machine cutting, slitting and fitting.

principles, instrument making, trial assembly, cover, final assembly. the self-contained unit, spindle alignment, electrical safety.

belt box group, assembly, belt guards, jackshaft pulley group, pulleys, Sheave grooving, motor pulley group, assembly, head quill and spindle group.

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It need not be complicated to produce a good result


Mandrels pegs and split pins

Pete Glenister joggling jig


Bob Loader discusses a change of useful workholding devices

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mandrels, collared mandrel, threaded mandrel, tapered mandrels, split pegs, split bushes. back to basics, crankshaft materials, forms of crankshaft materials, source of a suitable material for crankshafts, Ted Hartwell surveys some of the materials and processes model crankshaft proportions, cutting Machining model crankshafts - materials available to those wishing to produce crankshafts for their model tools, the machining of model crankshaft tooling and methods projects from various forms of steel or cast iron, suggested methods for fabricated crankshafts, oil hole drilling, balancing, hardening/heat treatment.

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Trade counter

Home foundry supplies, tools for small scale work, ten new air tools and table saw from Clarke, comprehensive tooling catalogue, mechanical modelling and other prototyping systems offer lathe braking, mill/drill modifications, in praise of Bob, oil in small quantities, CNC supplies. an appeal from Crofton.

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Scribe a line On the editor's bench Screw threads An adjustable test bar Tool and materials suppliers - Wessex The story of the grindstone and the grinding machine (2) We visit Screwcutting on the Unimat 3 Geoff Sheppard John Robey looks at threads ancient and modern

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A very sensitive level Model engineers workshop data book Brighton and Harrogate shows Motorised milling head (3)

general arrangement, spindle, discs and Another essential aid to accurate lathe alignment is described by carriers, assembly, bed alignment, Bill Morris centres alignment. Ted Hartwell lists some of his local suppliers Don Unwin continues with the story of the development of the grinding stone Pat Twist (2) In this article Bob Loader recounts the trials and tribulations of making the parts, making the adapter. making parts for a telescope the need, invention, structural design, Peter Peters takes a different approach to making a sensitive design of the adjustment, design of the vial vial, making the instrument, assembly and zeroing, back to the beginning. Dividing Mark Figes concludes this series with the final items new range of Taiwanese power tools, Hemminway on the internet, new catalogue from Woking Precision models, Camden booklist, Power Capacitors introduce a new motor speed control system, abrasives galore, Hobbymat lathes and the universal metal bender, waterborne polyurethane acrylic coatings, steam heritage museums and rally guide, indices for Acorn RiscPC machines Ron Page Alan Cambridge was concerned about double jeopardy arising when checking bores using caliper and micrometer methods. Here he sets out a very effective way of overcoming this problem depth stop assembly, Dore Westbury parts, set-up.

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Trade counter

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We visit A bore comparator Link up

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A beginners guide to the lathe (1)

Harold Hall has put together a series of articles which will take them through the basic steps

the lathe, choosing a lathe, what to buy, capacity, basic turning, turning tapers, speed control and range, screw cutting, fine feeds, electrics, accessories, metric or imperial, buying secondhand, milling on the lathe, making the choice. slip gauges, the blocks, the use of blocks, metric slip gauges, comparators, improvised comparators, comparing internal dimensions, the Wykes gauge. more on lathe alignment, PCB design, Martek drill sharpener, oil in small quantities, help on an Atlas milling machine, and on a James and Barnes lathe, use of wood, mill/drill table for ML10, metrication an Australian experience, centre drill angles, news of Danish lathe, harness the new technologies, praise for an trade supplier. more the theory behind the practice, an extra issue of MEW, exhibition time again, red face department. cleaning, stripping, repairs, re-assembly, oil, set up and operation, speed, tension. principles of use, standard uses, sizes available, cutting speed, savings/economy, arbors and mandrels, accuracy, costs, swarf, general uses, lathe use, uses in the milling machine, sharpening. surface grinders, workholding, special tooling.

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In our next issue Slip gauges comparators and the Wykes Alan Jeeves take a look at some aids to precise measurement gauge

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Scribe a line

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On the editor's bench Reconditioning a Thiel die filing and sawing machine

Geoff Sheppard Our contributor 'Ballaarat' came across a Poduro 111 unit in need of a little TLC so set about reconditioning it

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Rotoborach an introduction

Peter Rawlinson has used it professionally and in his own workshop and describes it's characteristics and method of use

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A late development the story of the grindstone and the grinding machine Link up A stripped chuck

Don Unwin concludes the story of the development of the grinding machine

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Button Boring

A well proven method of setting hole centres is described by Bob Loader

old fashioned methods, button boring, the buttons, making buttons, keeper plate, using the buttons, measuring the distances, setting the buttons from the datum, alternative setting methods, other ways of making datums, check before machining, boring the holes.

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Trade counter

End mill sharpening from Devon, RS catalogue on CD=ROM, Warco on the move, Safety equipment from Seton

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Lathe coolants and systems

Paul Boothby discusses the nature of coolant fluids and describes a tray and pipework system which although designed for the Myford could be adapted to other machines

why do we need coolants, what is cutting oil, what is Suds, Suds or oil, equipment and hardware needed, Suds tray, raising blocks, installing the tray, plumbing, Suds pumps, suitability of alternative pumps, power for the pump, mounting the pump, sump/drain, tube/pipe work. body, cutter bar, tool bits, safety.

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Model engineer's workshop data book A Trephining tool We visit - Pat Twist (3)

standard screw dimensions Dyson Watkins investigates surgical terminology before describing a hole cutter which has a more familiar name Bill Morris describes how he persuaded a friend to join him in making more of those useful pieces of test equipment

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tickling a grinder, grinding in the lathe, construction, testing. types of chuck, which type, the three A beginners guide to the lathe (2) jaw, maximum workholding, normal Harold Hall continues this introduction to lathe work by exploring choosing and using workholding chucks usage, the four jaw, make you own, some of the types of chuck which will be encountered - three and four jaw methods of mounting, safety, maintenance, buying secondhand. An adjustable lathe stop for under $15 Don Titus sends us detailed instructions for making this preparation, stop body, clamp, bushing, (dial indicator included) accessory for a South Bend lathe finishing touches, footnotes. base and column assembly, the knee, keep plates, knee adjustment assembly, bed, end bearing, leadscrew, handwheel A clock pinion mill David Penney describes it's construction and bushes, cutter arbor, tailstock, dividing head, mandrel and collet, dividing plates, wooden base, motor, suppliers. Bob Loader, the journeyman moves on and begins to acquire How it was (2) new skills introduction, depth of cut, feed rates, Philip Amos gives an explanation of why things don't always turn control of cut depth, tool materials, Finish and dimensions out as anticipated cutting speeds, conversions, limits and fits, conclusion. more theory please, printed circuit Scribe a line capacities, translation nomenclature. Quick tip useful containers gas-air torches, the Olympia exhibition, On the editor's bench Geoff Sheppard good news on subscriptions, copyright of designs. How square is my square?

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Metal spinning for the beginner

Philip Amos decided to learn the techniques of metal spinning

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A light toggle press

Readers who have studied earlier articles by Alan Jeeves have asked for more details Ted Hartwell set about designing and making this ingenious attachment for his hand-held a half inch variable speed electric drill

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A friction screw driving nut

safety, equipment, tool rest, tools, formers mandrels and chucks, pressure pad follow block follower, theory, blank size, material thickness, annealing, lubrication, technique, trimming, problems, conclusion. the toggle joint, the links, calculating the efficiency, the main frame, the ram and link assembly, the anvil, assembly, using the press. design parameters, basic calculations, principle of operation, method of manufacture, assembly, the initial trial, final outcome.

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A set of super soft jaws

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A beginners guide to the lathe (3)

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We visit Model engineers workshop data book A unique dividing head Link up A thread dial indicator for a Boxford 5in lathe

Holding soft or delicate work securely without damaging previously finished surfaces often presents a problem, J Neaves alloy jaws, assembly. offers his solution the centres, turning between chuck and centre, using a rotating centre, centre Using headstock and tailstock centres Harold Hall reviews and drilling in situ, centring longer under used but inherently accurate method of supporting the workpieces, turning between centres, workpiece special circumstances, tailstock alignment, items to make. Will Mowll Standard screw dimensions, leadscrew 10tpi, leadscrew 8tpi base and uprights, nut, clutch register, Pat Twist describes a dividing head which incorporates a novel disc adaptor, mandrel, detent bar, brake feature arm, assembly. Mark Figes describes the manufacture of one for the popular Boxford lathe David Machin describes the manufacture of a tool which may prove to be of use on those larger jobs gear, body, dial, spindle, mount, finishing the body, setting up on the lathe. construction, first aid, internal screwcutting, the easy way out, dealing with the castings, alternatives using a milling machine. eye protection in the workshop, another successful Martek conversion, gas-air blowtorches, an appreciation of help from readers and some useful information, if all else fails, slip gauges a different approach.

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A cluster of Sash clamps

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Scribe a line

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In our next issue

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On the editor's bench Two sheet metal folders As the results from his first attempt didn't satisfy T Gould he made a second, larger version Three pens in one from Rotring, lathe steadies from College Engineering, insert tools for turning boring and milling from Penco, finer finishes from Bruce Engineering, white metal casting kit from Tiranti, new tube benders from A J Reeves, sash cramp kit from Hemmingway. Alan Cambridge describes some quick release work stops which are simple to make and fix

more MEW per year, the 66th model engineer exhibition, Loctite 601 a query, serendipity. the larger folder, eccentric clamping bar, optional items, operation.

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Christmas gift ideas

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Quick release backstops

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Universal bandsaw modifications Response to questions and other meanderings Link up Quick tip

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Don Titus replies to some queries arising from an earlier article

eight ideas from Glen Roberts, an additional blade guard from John Vickers, two sawing guides designed by Brian Cocksedge. roll back car carriers, lathe moving, other misnomers, on the net.

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storage of circular dies, magnetic picking-up device, dry storage for powdered flux Dyson Watkins draws on his industrial experience to explain a hard and soft soldering, applications of Processing by induction heating modern production process. induction heating. Model engineers workshop data book cable rating features of the tooling, manufacture, types of locking arm, specific applications, DTI back lug clamp nut, Tony Skinner describes an ingenious method of overcoming Six-position locking clamping arms for a Myford M cross slide and vertical slide, some accessibility problems and suggests that accuracy and variety of purposes ML7 cross slide, suggestion for Super 7 finish of turned components could benefit too cross slide, saddle lock for Myford M, machine vice, clamping nut for Quorn wheel-head collar. In our next issue base plate, vee block, draw bar, clamp, A small vee angle plate The editor finishing the vee block, the angle plate in use. manufacturers specification, morse taper collets, draw bar operation, other operating methods, advantages, A beginners guide to the lathe (4) Harold Hall on choosing and using workholding chucks - collets disadvantages, uses, peripheral uses, non-round collets, collets in use, milling cutter chucks. More Christmas ideas Books from Camden, model engineers handbook 3rd edition.

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The Unimat 3 small but useful

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Metric pitches on an English lathe A centre drilling attachment for the Myford ML10 topslide Scribe a line

a convenient machine, a versatile machine, turning, make it easier for the lathe, turning tools, use the centres, a useful boring bar, turning short angles, Bob Loader takes a wider view of the lathe and it's capabilities holding large diameters, four jawed chuck work, drilling, milling, other applications, indexing, a nice little mover. the pukka way, a cheaper way, nothing David Dew describes how it's done and has prepared workshop to buy, BA - metric screws for modellers, tables which will help to reduce set-up times pays your money - takes your choice. Len Walker describes making his PCB track current rating, Martek drill sharpener the next stop, in praise of linkup, experience with a Griptru chuck. Ted Hartwell, out and about, for the Geoff Sheppard younger element, a new Unimat lathe and a generous offer, a success. and so to work, if you use another make Bob Sims devised this accessory for his Dore Westbury but can of sensor, and now to metalwork, take be adapted for use on any similar machine care. the aims, working practices, the headstock, now to the reel work, cleaning and clear work space, removing the chuck, mandrel tail-end John Shrubsole renovated his and added some new facilities nearing thrust ring nut, the main bearing ring nuts, withdraw the mandrel, cleaning and inspection, trial assembly, final reassembly. Geoff Bartlett couldn't resist a bargain and found that with a few caution, operations on the quill, hours work he had a very useful machine assembly, a motor puzzle. D O Coe shows how one of the many plastic items now available can be transformed into a handy piece of workshop equipment Mike Delaney added some accessories to his router the saddle boring method, a simple saddle boring bar, problems with centre drilling, the design stage, design Bob Loader shows how to make a Unimat 3 tackle jobs beyond features, almost a costly mistake, the it's capability boring head, spindles, cutter holder, insert, the soldering, indexing screw, indexing dial, modified screws, a small assembly problem, the testing.

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On the editor's bench

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A milling table indicator

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Lathe upgrade on a budget (1)

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Modifications to a very low cost drilling machine A simple cleansing tank An electric shooting board

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Saddle boring

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Cylindrical grinding in the lathe A lubrication for the lathe steady Model engineers workshop data book

Philip Amos researched tithe subject extensively before trying it for himself Alan Jeeves brings added refinement conversion fraction to inches, ISO preferred numbers, hole punching, Harold Hall turns his attention to the faceplate

equipment, the job, results. acquiring a lubricator, mounting the lubricator, using the lubricator.

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A beginners guide to the lathe (5) The 66th model engineer exhibition Paisley machine tools and the engineers emporium

types, accuracy, using, balance, some further comments, secondary mounting, use on the tailstock, use elsewhere, safety.

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Trade counter

Sandvics new coromill 245 facemill at half price, room temperature metal blacking compounds, machine tool catalogue from Rotagrip, Phoenix precision paints, Fein sander/saw special offer, low cost bench drill from Rexon, Maxicraft 230 volt tools available in the UK, motorised milling head construction manual, new multimeter from Clarke

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Link up In our next issue Tyro days, LH tap requirement, screw cutting range, moving the motor, the smaller threads, other trains, LH device parameters, replacing the apron, design philosophy, apron redesign features, accessories, use friendly mod, conclusion, notes. abbreviations the future of the data book, grinding wheel retention, more on lathe braking, electroless nickel plating, gas-air blowtorches.

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Enhancing the Hobbymat lathe

E J Mac Mackenzie has developed a number of modifications and attachments

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Win a Unimat 4 lathe Scribe a line

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securing Morse tapers, Removing broken centre drills, getting broken centre drill tip out, tapping in the lathe Derek Pearce looks back at the achievements of three stalwarts What's in a name of metrology On the editor's bench Geoff Sheppard Ken Whiston early misgivings, a very useful item, Tungsten carbide tooling doesn't have to Suitable toolholders can still be very expensive, Bob Loader set making the holders, single ended holder, be expensive out to makes his own double-ended small holder, 10mm double-ended holder, tipped boring bar. Quick tip

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Computer control for practical engineers

Richard Bartlett describes how to drive the system from files created in a simple computer aided drawing package

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A simple number/letter punch jig

Paul Boothby describes the manufacture of a device which will make the task easy

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A beginners guide to the lathe (8)

Harold Hall discusses drilling reaming and boring

recap after parts 1&2, this is CNC machining, part 3: use of computer aided drawing (CAD) programs, pie in the sky, meanwhile back in the shed, in conclusion. introduction, principle, dimensions and units of measure, tolerances, equipment and materials required, construction, performance and observations. drilling: the methods, workpiece rotation, deep holes, accurate hole size, reamers, D bits, boring holes, large hole small lathe, lever feed tailstock, drill rotating, using the top slide, using the cross slide, using the tailstock, drill types, speeds/feeds, lubrication.

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Fireside reading

The clock repairers manual by Mick Watters, electric motors in the home workshop by V J Cox, the backyard foundry by B Terry Aspin. Philip Amos describes a number of modifications which he has made in order to increase the versatility of his example electric motors, taper pins Solving a handling problem led David Dew to develop a simple setting up device a weighty problem, setting the angle, a simpler solution, manufacture, test results. motor, motor mounting, motor covers, pulleys, belt, belt guard, wheel guard, conclusion.

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Driving and guarding the Quorn Model engineers workshop data book Myford taper turning attachment improvements In our next issue Precision bending bars Link up

Len Walker describes some very simple tooling which continues construction. to give him job satisfaction

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tribology, cosmetic finishes, specified surfaces, valleys and peaks, symbols, gauging the finish, other finishes, Alan Jeeves presents an over-view of the subject and makes lathework, lathe tools, carbon steel tools, Surface finish on metals some suggestions on how to obtain the desired finish improved lathework finishes, milling cutters, grinding, filing, scraping, lapping, polishing, maintenance of polished surfaces. improvements to the vice, speeding the cut, better connecting rod bearings, The improvements David Machin made to his Blackgates power steadying the bow, securing the drive Improvements to a small power hacksaw hacksaw will have a much wider application in particular those sprocket, an auto-stop, a suitable switch, he made to the machine vice mounting the switch, circuitry, improved gib strips, non-ferrous slide paths.

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Scribe a line

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On the editor's bench

Geoff Sheppard A reader spotted this useful attachment on display at an exhibition and suggested that it would be a good subject for an article. The builder, Eric Ball has supplied the following details model motors direct, new catalogue from E.K.P supplies, liberty recreational trailers, catalogue from Frost Auto Restoration Techniques Ltd, new sanding and blade catalogue from CSM Just Abrasives, Release 2000 lubrication for the new millennium.

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A calibrated filing rest

a Taylor and Fenn vertical milling machine, is anything new, disposal of chemical waste, a larger lathe information sought, South Bend lathes, request for a cutting speed, back numbers of MEW and a search for a DC speed controller, still room for the vertical slide. tribology, news of exhibitions. base, locating plate, clamp plate, vertical support, side clamps, adjusting plate, rollers, roller spindles, support rod, adjustment screw, dust excluder, adjustment support, disc.

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Trade counter

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Shelly Curtis sets out to add the same facility to the cross slide Y-axis stop attachment for Senior 'E' mill of his 'E' mill and suggests that it can be adapted for other makes of machine Many attempts have been made to devise the ideal locking system. Alan Jeeves describes a device which may provide a solution in some situations

use of stock material, clamp base, end plate, gib, sliding stop, stop housing, rail, rail support, spacer, base plate, stop, Tee nut, stud for Tee nut, fitting attachment to the machine.

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A 'Stocknut'

From the plans service - high speed Edgar T. Westbury sensitive drilling machine
Combat condensation Brian Cocksedge quick tip

construction notes, casting supplier. using lathe steadies, purpose, fixed steady, setting the easy method, setting the not so easy method, precision, a production problem, hinged top, economy of material, travelling steady, cutter following, cutter leading, very long parts, screw cutting, lubrication and adjustment, Jacot tool, temporary steadies, make your own. easy release mandrel handwheel, refurbishing electric motor commutators.

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A beginners guide to the lathe - Steadies Harold Hall continues the series by describing the use of these (9) essential accessories

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In our next issue Tom's tips Tom Bartlett the former workshop superintendent of the SMEE returns with more items from his vast store of experience

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CNC for practical engineers (4)

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Far reach vice square Model engineers workshop data book A bed stop for the Unimat 3 and an improved tailstock clamp Sharpening end milling cutters Fireside reading Link up Ball shapes on the end of "you name it"

actually cutting it, terminology, general notes on steppers, do use proper Richard Bartlett amplifies the information on stepper motors then switches, power supplies, screwcutting goes on to describe some practical machining tests he has under CNC, putting it all together, carried out using an advanced version of the software adapting existing machines to CNC, programming for screwcutting. There are many jobs encountered in the workshop for which it would be convenient to have three hands. Peter Rawlinson Construction. describes a handy tool which makes one of these tasks much easier. Bob Loader continues his favourite small lathe with these two simple items stop body, making by filing, clamp, clamping, stop pin, a tailstock clamp. background, introduction, shape of an Philip Amos presents a detailed description of the sharpening of end milling cutter, practice, sequence of an end milling cutter and describes some accessories for the operations, ancillaries, sharpening Quorn tool and cutter grinder which will facilitate the task procedure, conclusion. home workshop hints and tips, spindles. how it works, set the zeros, fist cut, subsequent cuts, last cuts, right hand side, shaping the ball, finishing, conclusion, references. standards of measurement, basis of length measurement, translation from standards, traceability, calibration, accuracy, error, uncertainty, repeatability, angle measurement, other The science of dimensional measurement is often ignores in the measurement, calibration laboratories, , home workshop, but in this survey, David Boote explains the measurement and the model engineer, background and points out that it impinges on our suppliers conclusions, choice of measuring equipment, general, British Imperial standard yard vs. American standard yard, calibrating a micrometer, recent changes in standards. John Shrubsole continues this occasional series by describing power feed speed reduction two modifications which have improved the operation of the modification. power feed on his early Myford lathe disposal of sulphuric acid, MEW projects successfully completed, Logan lathes information from the manufacturer, control of DC speed, and an alternative solution, using carbide tips. Many items of workshop equipment require ball handles. Ted Wale of Porters Lake describes a method of producing these to a level of accuracy which will suit most purposes

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Dimensional measurement for model engineers

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Lathe upgrade on a budget (2)

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Jim Canner, an elusive IC, power capacitor seminar offer, our friends of On the editor's bench Geoff Sheppard the trade, another treasure located, international model show. the base, the column, the turntable, the A 'swing' surface grinder Alan Jeeves has constructed a neat unit bearing, wheelhead mounting block, the collars, the pinch screws. Here Derek Brown describes a lathe attachment which facilitates the main anchor block, the follower, Machining large radii the turning of larger radii radius templates, using the tool. The Holbrook 'C' lathe in miniature Dennis Major describes the building of Bob Mellows lathe Seeking a controlled method of engraving clock dials Doug Ball A clock dial engraving tool devised this attachment for the mill/drill background, introduction, precautions, Phillip Amos continues his short series of the sharpening of Sharpening slitting saws with the Quorn design, construction, operation, cutting tools conclusion. John Shrubsole continues to improve his early Myford lathe by lathe bed and saddle wear, the eliminating wear on the sliding portion between saddle and bed. Lathe upgrade on a budget (3) modification, re-assembly, saddle hand By changing the saddle handwheel system he provides a more wheel. natural feel to the machine Index for issues 33 to 44 of MEW Model engineers workshop data book Link up turning tools for the job, one piece tools, two piece tools, the major problems, shape basic principals, front and side clearance, front and side relief, side and Harold Hall now discusses the cutting tools required for basic A beginners guide to the lathe (10) top rake, variations in published data, turning tool shapes, parting off tool, grooving tool, boring tools, top and side rake, sharpening tools, final comment, supplier. In our next issue three different methods, restoring a worn stone, side plates, drilling, riveting Bob Loader recreates a piece which should be in every self techniques, take care with the hammer, Making a 75mm square respecting engineers tool cabinet version 2, stock, blade, finishing off, checking the sureness, precision checking. building a small overhead router, to In this instalment Richard Bartlett extends the capability of his engrave a label, converting to a relative small lathe to be able to engrave such items as nameplates then CNC for practical engineers (5) file, effects of mixed gearing, designing he has a go at machining components for the telescopic drive your own characters, a compucutters shafts contact group, power supply problems.

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Folding handles for machine tools From the plans service - WE34 headstock dividing attachment

Peter Rawlinson, tired of painful encounters with the handle of his milling machine, set out to improve the situation designed by G Thomas

machining the trunnion, the mount item, final assembly, modified lathe handles.

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On the editor's bench

Geoff Sheppard

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Replacement for a Dewhurst switch

Correspondence in MEW prompted Bob Stark to investigate alternative methods Terry Gould shows how to make some very simple units which he first saw in use as an aid to assembly Alan Jeeves completes his description of his vertical column surface grinder Rex Galway designed this version of the calliper type knurling tool to fit his 58mm centre height machine a generous offer to readers for MEW from Chronos, three useful bench shears, power and hand tools from minicraft, metal supermarkets expanding, Bob King tool available from L.A. Services, Carver introduce a range of non-metallic clamps. A. Jonson quip tip Quick tip Pat Twist quick tip Harold Hall reviews a number of methods of producing tapers and gives some practical hints We have seen many examples of the ubiquitous wobbler but A. Johnson's version is the simplest and most easily made yet Club exhibitions are often the best place to pick up a bargain. Geoff Sheppard looks at a typical club show

larger lathes, handy magnetic base for dial gauge, information sought on a smart and brown lathe, blackgates power hacksaw, data book information on electric motors. an extra issue of MEW, contributions to MEW, a glimpse of the future, that elusive IC - news of a replacement, secretarial support, red face department in business again vertical support y-axis stop. the reason for this system, operation, description of the electronic control unit, detailed description, latches, delay circuit, circuit operation, construction, detectors, electronic no-volt release. construction. wheelhead distance pieces, the leadscrew, the wheelhead, the electrics, the wheelguard, the handle, assembly, setting up, using the machine. making the pieces, assembly, using the tool, question.

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Adjustable parallel jacks

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A swing surface grinder (s)

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Knurling tool for a compact lathe

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Trade Counter Link up Saving white spirit Old film canisters Parting off Model engineers workshop data book A beginner's guide to the lathe (11) A centre locating tool Do you know what you're missing?

methods, lathe tool setting, taper turning in practice, setting the angle, other methods. construction, use.

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From the plans service - WE40 Hardness tester Tailstock drilling attachment Sharpening taps with the Quorn and thread grinding

Design of the late Dave Lammas Peter Rawlinson describes a self-powered attachment he has constructed for this purpose Philip Amos continues his series assembly, operation. background, introduction, design, constriction, operation, thread grinding, related matters, conclusion. cutting speeds, more on the electric shooting board, sharpening end milling cutters, Dowduing and Doll lathe query, another form of locknut, Tungsten Carbide tooling. seasonal greetings. the powered cross-slide, project overview, on with the work, the front half, graduation rings, assembly and operation, the electrical system, covers. surface grinding machines, surface grinding techniques, workholding, faults, other uses for the surface grinder, surface grinding safety, spot grinding, specialist surface grinding machines, cylindrical grinding, external grinding, internal grinding, workholding, the universal grinding machine, grinding attachments, grinding work between centres, the magnetic chuck, the conventional chuck, summary.

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On the editor's bench Lathe upgrade on a budget (4)

Geoff Sheppard John Shrubsole describes a major modification which he made to his early Myford lathe

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Grinders and grinding

Alan Jeeves reviews the grinding process and looks at some of the types of machine available

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A small instrument vice Model engineer's workshop data book Restoring an automatic centre punch A beginner's guide to the lathe (12) The miniature Bridgeport milling machine Internal grinding with the Quorn In our next issue Where there's a will there's a way Mill/drill centring device

Len Walker describes a neat little vice designed to be held in the larger bench vice Dick Marks gave the treatment to this eclipse marking out tool Harold Hall now examines some aspects of the actual turning process Barry Jordon tells how the project started and promises us a fuller description Philip Amos addresses two modes of internal grinding Peter Gerrish recalls a few instances where ingenuity was required Peter Rawlinson describes an ingenious but simple device which will assist in the majority of cases what makes it tick, the problem solved. tool positioning, rotational speed, feed and width of cut, parting off, achieving accuracy, achieving a fine finish, final; comment.

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introduction, sharpening threaded dies.

application, manufacture, the accessories, main block.

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From the plans service - WE32 combined vertical slide and vice

A Martin Evans design simple engraving using custom characters or virtual type, cutter principal, machining set-up, reverse In this the final article Richard Bartlett expands on the engraving engraving using custom virtual type, of characters your Qbasic program, reducing interference, system developments, what next?. modern industrial methods and the home workshop, but more on the IC in question, link up answers, magnets and hacksaw blades, sable lathe information, and a request regarding a Zyto lathe. Geoff Sheppard Alan Jeeves describes the composition of grinding wheels and forms in which they are available a cautionary tale. wheel adhesives, wheel bonds, the structure of wheels, wheel shapes, periphery forms, mounted points, identification of wheels. the nuts, the inserts, the feedscrews, assembly, modification for CNC.

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CNC for practical engineers (6)

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Scribe a line

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Link up On the editor's bench Understanding grinding wheels (1)

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Adjustable feedscrew nuts for the Warco Peter Smith suggests how to restore table feedscrew Minor mill drill assemblies flexible shaft for the Dremel Multi, a new brochure and an Trade counter upgraded lathe from Warco, glass enamelled badges Bill Morris discovered an idea for an interesting piece of equipment in a Russian publication and set out to design his version

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A universal parallel clamp

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A beginner's guide to the lathe (13) Lathe upgrade on a budget (5) Model engineer's workshop data book Quick release soft vice jaws Bob Loader's calivider From the plans service

general arrangement, main body, clamp plate, large top plate, steady block, straight edges, sine bar, square, spot grinding, angle plate, sliding block, small top plate. In this penultimate part of the series Harold Hall looks at three knurling, a method, dial test indicator useful accessories holder, tailstock die holder. John Shrubsole's description of reworking an early Myford lathe lathe speeds, a little more detail, now reaches the point where he turned his attention to the drive replacing those missing parts, the toggle arrangements lever and link, caution. endless belt drives, turning tools Peter Rawlinson finally lost patience with the ineffective soft vice design constraints, manufacture, jaws so he set out to devise a more durable system facings, hole positions. materials, the tricky bits, a bit more Bob shows us how to make an elegant and versatile marking milling, two useful gadgets, assembling, and measuring tool final adjustment, Unimat belts. WE33 the Eureka continuous form relieving tool for gear cutters

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Sharpening reamers with the Quorn

Philip Amos surveys the types of reamer and similar cutters available ands suggests how they may be sharpened

background, introduction, characteristics, parallel holes, tapered holes, sharpening - general considerations, technique - general, technique - detail, conclusion.

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Link up In our next issue new machine concepts, spot welders experiments with a transformer, tungsten carbide tooling, coolants collets and welding gas, simple indexing, cast iron welding and urgent plea, DC motor speed control, cutting speed tables. Geoff Sheppard introduction, concept, requirements, attachment, spindle lock, holding the workpiece, truing the grinding wheel, guarding, grinding dry, setting up, workpiece dimensions, technique, awkward shapes, typical jobs, conclusion. filing rests, dividing, batch production, ball turning attachment, mandrel handle, vertical slide, milling head, milling/drilling spindle, the lathe as a power source, tool post grinder, centre finder, coolants, a final comment. selection of wheels, mounting wheels, wheel dressing, wheels in use, notes on portable grinders, safety and grinding wheels, importance of maximum operating speed, care and storage of wheels.

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Scribe a line

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On the editor's bench

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Surface grinding on the Quorn

Getting even more uses from the wheelhead of this incredible versatile machine. Philip Amos shows how the Quorn can be used to produce acceptable results on smaller items.

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A beginner's guide to the lathe (14)

Harold Hall concludes his series with a look at some useful accessories for the more advanced user

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Understanding grinding wheels

Alan Jeeves continues his survey of abrasive wheels and their application

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A boring head with a difference A retracting screwcutting toolpost A simple leadscrew drive for thread milling From the plans service Model engineers workshop data book

Richard Vaughan comes up with an alternative design of slideway Victor Elsendoom decided that he needed a helping hand while cutting threads in the lathe David Machin describes how he devised a set-up for thread milling WE26 a small swivelling vice screwcutting changewheel combinations sliding tool holder, mounting block, Gib strip, crank and crankpin, finishing and assembly. drive motor, motor mounting, banjo hang-ups, changewheel set-ups, machining a hob, other applications.

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A sine plate

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Parting Teasers Tools at the ME exhibition Link up In our next issue

introduction, units, range, dimensions of the table, width, length, accuracy considerations, an adjustable parallel, surface grinding, round bars, materials and tools, tools, descaling, construction, Peter Dawes give us detailed instructions on the construction round bars, stop buttons, tee nuts, and use of a precision accessory marking out, height packing bars - the poor man's Jo blocks, linishing, Martin Cleeve's gauge bars, using the sine plate, stack assembly, conclusion, overhang. the process, the 'pip', avoiding dig-in, the Geoff Sheppard reviews the process and introduces a couple of rear mounted parting tool, tool geometry, ideas to remove the errors costs. Solutions

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PCD marker set

Peter Rawlinson has devised this marking instrument which eliminates most of the measuring S H Muffett Ltd extend their range of gearboxes, high quality toolcheasts. Eurotherm drives for 400v operation, BW Electronics - new address, new catalogue form Chester UK, the Hemingway catalogue.

how to use PCD marker mk 2, drawing a pitch circle, manufacture, the rule, the guide, vee base, assembly, 90 deg arm, 45 and 30 deg arms, final assembly and testing.

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Trade counter

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Scribe a line BHI open days On the editor's bench Myford Super 7B lathe enhancement A digital adaptation of a vernier height gauge Stan Bray went along to the 1977 open weekend at Upton Hall Geoff Sheppard's commentary Derek Oxley recalls some of the modifications he has made Hubert Peters describes the result of one such experiment

welding cast iron, drive belting suitable for the Unimat, Little John lathes and motors, drain cocks - LBSC's method. relocation, change of personnel, exhibition news, the Centennial celebration collection, a price increase. modifications, accessories, a further modification. application, removal of swarf.

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A quick change tool holder system for the lathe

the design, manufacture, machining the half round slots, the more critical Harold Hall studied the design of commercial quick change lathe dimensions, body, spacer, toolholder, tool holder systems and decided that a simplified version could clamp assembly, operating piece, be made locking spindle, some further comments, making further toolholders, final comment, postscript. Raymond McMahon used 'O' rings to help retain this lathe depth stop in position Alan Jeeves happened to become the proud owner of a large steel blank so he decided to turn it into a useful 4-jaw chuck first thoughts, the design, turning the body, heavy drilling and tapping, milling the jaw slots, the standard jaws, extended jaws, adjusting screws, using the chuck. difficult times, my first attempt, the Mk II version, the coil assembly, winding the coil, testing, suppliers. leadscrew extension, then plates, motor shaft extension, 45 tooth wheel and driving dog assembly, sliding dog, spacers, assembly, actuating lever assembly, power supply, speed control, top panel. background, historical, present day drill types, commercial drill grinding attachments, specialised toolroom drill sharpening machines, conclusions. preparing the band saw, assembly and fitting.

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Link up A lathe spindle depth stop

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A home made 4-jaw chuck for the lathe

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A magnetic 'V' block

Peter Rawlinson came up with this design

A model engineers workshop data book changewheel combinations and cutting worms

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A self-act for the milling machine (1)

Stan Wade found hand feeding a chore so devised a drive employing a surplus windscreen wiper motor

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Drills and drill sharpening

Philip Amos reviews the types of drill available and some of the possible methods of sharpening Shelley Curtis modified his machine by adding a damper strut

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A band saw damper Trade counter Improving the imprecision of a mill/drill In our next issue

new multi vice from Minicraft, Alexander machinery spares, Kity 417 fretsaw, Loctite super glue brushable Many users complain that the setting of the head location is lost fixing the rack, fine adjustment of the if it has to be raised or lowered. Yves Rayssiguier decided that rack, to conclude. the problem had to be fixed An introduction to robotics by Harprit Sandhu, model engineering a foundation course by Peter Wright, building simple model steam engines - book 2 by Tubal Cain, the model locomotive from scratch by B Terry Aspin, steam heritage museums and rally guide 1998/99 from Tee publishing.

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Fireside reading

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From the plans service

Digital plan printing metric pitches with a gearbox, water based coolants, tungsten carbide tooling, a cautionary tale, is it all done by magnets or was it too much of the hard stuff?, repairs to cracked cast iron components and alternative methods, so you want some little nuts?, more lathe information sought. T D Walshaw, Ivan Law writes, the editor comments, health and safety and model engineering, SMEE100 the centenary exhibition, tools for self reliance. assembly of column to base. the new problem, gears and thrust bearings, Arbor bearings, oil bath, oil seals, 'O' rings, woodruff keys, machining components, assembly, mounting the shaft. a simple collet fixture, Morse taper fixture.

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On the editor's bench

Geoff Sheppard's commentary

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A bench magnifier

Len Walker adapted the lens from an old slide viewer into a useful workshop instrument. Peter Rawlinson missed the facilities of his horizontal mill so he devised this right angle drive to fit his mill Barry Jordon's 1/5th scale Mk I Clarkson tool and cutter grinder J Neave describes some simple accessories which will allow larger end mills and Morse taper shank drills to be held safely

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A right angle drive unit for a vertical mill

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A miniature tool and cutter grinder Accessories form the smaller lathe Stuart 10V engine exploded view

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jigs and fixtures, square parallel and concentric, photographs, roughing and finishing manufacturing sequence, Harold Hall shows how additional home made tooling can assist cylinder, box bed, flywheel, crankshaft Jigs and fixtures and the small lathe in the manufacture of components particularly where casting bearings, valve chest cover, valve chest, and forgings are involved - Stuart 10V cylinder covers, connecting rod, eccentric strap, eccentric sheave, gland, drilling, remaining parts. An autostop for the milling machine self- Stan Wade completes the modification by adding an auto stop switch box, making the switch case, act (2) system actuating plunger, wiring. Annual model makers festival at the |Primrose Valley holiday Modelling by the sea village Model engineers workshop data book abbreviations Philip Amos gives some useful information on the adjustment general description, guillotine, The triple machine and use of this device pressbrake, rolls, conclusion. objectives, minor modifications, E J Mackenzie describes a major revision of the cross slide and bearings, materials, adhesives, bearing More modifications to the Hobbymat top slide feed arrangements housing and index collar assemblies, conclusion.

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The Harrogate exhibition An air compressor for the garage or workshop In our next issue Trade Counter Picador revival, Clarke introduces new drill press range, power tool accessories from Minicraft, Camden spring catalogue, Devcon adhesives for the new millennium, lathe bed and saddle reconditioning by Myford taper turning problems, metric pitches on the Super 7, Vee blocks what did they really cost?, is it all done by magnets, classic workshop equipment designs, Halifax lathes, tools from MEW designs - a plea for help, the poor man's vee block, centring and cross drilling, help needed with parting off problem, Metalock repairs. the centennial celebration collection, the Shuttleworth collection. the bush, the tapped hole, marking out, drilling, fitting the cat-head, using the cat-head, refinements. attributes, construction. resuscitation of a moving steady, replacement spring for calipers. John Noakes gradually collected all the items necessary to build safety valve, one way valve, pressure this useful air compressor system. He describes the switch, pressure regulator, gauges, components and gives hints and tips on assembly and testing assembly, electrics, pressure testing.

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On the editor's bench The turner's cat-head

Geoff Sheppard's commentary Alan Jeeves describes another addition to the practical lathe worker's inventory General purpose indexing devices can be pressed into service when cutting clock pinions but Doug Ball decided that a purpose built unit would bring better results Philip Amos recalls two jobs which gave a new life to defective items mill/drill centring device, gears for obsolete machines, variable speed scroll saw from Rexon, International model show. A lathe work holding arrangement for awkwardly shaped or larger workpieces is described by Harold Hall

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Clock pinion leaf milling attachment Rectification and repair Trade counter Keats alternative Link up

the angle, the locating jug, four post alternative, easy set version. Background, camera, lenses, tripod, cable release, flash gun, film, odds and ends, the lighting saga, outside, choice of item, favourite film, influence of film speed, how close can you get?, show as much as possible, wide angle lenses, the indoor set-up, try to keep the position natural, reminders. using the tapping aid.

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Workshop photography

Judging by the letters we receive on the subject many readers would like to have a go at taking photos of their projects and workshop set-ups, Bob Loader agreed to tell us how he takes his pictures

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A simple tapping aid

George Walsh send us his idea for a tap wrench which will facilitate the use of larger taps in the mill/drill

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A face geared indexing table Model engineers workshop data book

Bill Morris constructs an indexing table of unusual design Steel specifications

face gears, general arrangement, top and base gears, spindle and nut, screw and lever, base, assembly, finishing off. the milling machine, machine design, control system, leadscrew and nuts, main slides, plotter pen, setting the datum, the CNC dividing head, spark eroder, the dielectric, tooling, the base, dielectric pump, the control unit. the Quick-Step mill, the Quick-step in use. now for what it can do, so to work, the spindle body, the gearbox components, parts for vertical slide. riveting, lathe chucks, chuck removal, the bench block, boring bars, home made chain sprocket. Tom Walshaw, that fascinating toy, secrets of the magnetic vee block, the George Thomas lathe tool grinding device, air compressors - some cautionary notes, the slender taper problem. SMEE 100, the 68th Model Engineer exhibition and the international model show, Tom Walshaw (Tubal Cain), Brooklands Museum. reamers, column, base plate, lower column support, anvil support bush, anvil lock screw, main arm, drive rods, slide boss, clamp, support bar, lever, knob, adjusting and lock screws, guide screws, anvils, centre and bush installers, assembly.

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Future projects

Peter Rawlinson has been busy designing and developing a number of interesting pieces

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An advance in lathe milling attachments The Quick-Step mill - a milling spindle for the lathe (1) Tom's tips

The editor has the opportunity to use an award wining lathe milling attachment which incorporates some ingenious features John Payne tells us how he came to design this versatile attachment for the lathe and provides first part of a short constructional series Tom Bartlett the former workshop superintendent of the SMEE returns with more items from his vast store of experience

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On the editors bench

Geoff Sheppard's commentary

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Clock bushing tool

Dave Penney combined his best features of a number of designs to produce this handy aid to clock repair

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A simple knurling tool A 19th century copper wheel glass engraving lathe - rescued and restored Simple aluminium soldering Link up

Alan Jeeves suggests that this knurling tool may suffice for light work Alan Bourne was just in time to prevent a family heirloom form being lost for ever T S Christian has been experimenting with a readily available material which is effective at lower temperatures the nature of glass, history and conjecture, design and construction, setting up a workshop, the use of a leather tongue. background, recommended procedure, equipment required, conclusions.

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A CNC milling machine (1)

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A four jaw chuck fixture

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An experiment in cutter holding Model engineer's workshop data book A failed attempt (1) Simply the best The Quick-Step mill - a milling spindle for the lathe (2) Some boring information In our next issue Trade counter

route 1, route 2, boring in the lathe, machine table, leadscrew nuts, Peter Rawlinson starts the detailed series on building a machine leadscrews, assembly of table which employs the Compucut control system by describing the components, limit switches, drive belt X-Y table and timing pulleys, stepper motors and motor boxes, conduit boxes, swarf tray. Keith Keen describes a simple adaptation of a lathe chuck that fixture use, description, chuck size, will find many uses suppliers. the remedy, the set-up, cutter holder Bob Loader has investigated some methods which will be of body, thread protector, adapter, locking interest to the users of smaller machines screws, testing, an afterthought, testing the sleeved cutters, sources. The elements Harold Hall thought he would improve the look of the dials of his tolls required tools, the dividing head, milling machine and ended up adding significantly to the the main assembly, spindle, bearings, capability of his workshop minor items. SMEE centenary exhibition at Brunel University In this concluding article John Payne describes the remaining the motorising assembly, gear box components and the assembly procedures assembly, electrical wiring, accessories. Philip Amos investigates the geometry of boring and trepanning introduction, axial, radial, accuracy, tools clearances, trepanning, conclusion. Chester UK Ltd new location, catalogues on CD ROM, 4D model shop creative materials centre, S H Mullens ltd, Maplin electronics, return of Hobbymat home built air compressors, looking for the Levitron, a cautionary tale, the Spendborough gear hobbing machine, making taper reamers.

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Scribe a line On the editor's bench

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Geoff Sheppard's commentary Simple items of tooling often repay time involved in making them A steady setting device (with other uses) very rapidly this lathe accessory from Maurice Turnbull is a good setting a radius. example Link up gantry assembly, Z axis slide system (manual), clamping systems, leadscrew Peter Rawlinson continues the description of this versatile A CNC milling machine (2) and drive, the Jeclanide coupling, motor machine control, turret Y axis slide and turret rotation. background, correction, approaches, Philip Amos faces up to these realities and suggests that there blocks, cylindrical, holes, threads, Fixing mistakes are ways of recovery avoidance, aids to accurate work, conclusion.

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The Holbrook model "C" type lathe in 1/16th scale

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Motor problems? Check your bushes

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A failed attempt (2)

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Model engineer's workshop data book Additions to the Quorn

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Trade counter

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A slow speed for a Warco 918 lathe

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A tale of two chucks

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On the editors bench

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A faceplate balancing fixture An off-set micrometer

the bed, cabinet stand, saddle, spindle, accommodation of the electrics, finishing Bob Mellows brings us up to date the headstock, drilling for leadscrew and shafts, coolant pump, taper turning slide. signs and symptoms, first things, getting the motor off, taking out the armature, a Bob Loaders Unimat is his only machine tool. When it started to bit of a mess, skimming commutator, misbehave he decided that action was necessary cleaning up, re-assembling, three phone calls later, if in doubt go Transatlantic, success. dividing systems, worm and gear Harold Hall thought he would improve the look of the dials of his attachment, division plates, index milling machine and ended up adding significantly to the fingers, the worm, division plate carrier, capability of his workshop minor parts, detent, final comment, one down. gear cutters the centre finder, using the centre finder, David Machin has devised two attachments which facilitate use the spiral head modification for centre of the machine drill restoration. Maidstone have moved, the Levitron, mains voltage power from Minicraft, riveting tool frames, new catalogue from J&L Industrial supply new pulley ratios and speeds, fitting ball races, modifying the door, making additional pulleys, extension to the lathe David Berrecloth has devised a modified arrangement which bulkhead, the location of the X shaft, removes some of the restrictions improving the bulkhead fixing, the small belt tensioner, the small belts, using an additional main belt. prelude, lathes need chucks, chuck no 1, jig requirements, jig making, grinder Ted Wale needed chucks for a refurbished Southbend lathe so making, jaw facing, chuck no 2, screw set about rehabilitating a couple of well used examples requirements, screw production, sockets, chuck keys, conclusion. Metric pitches on the Super 7B, more on making taper reamers, the face geared indexing table. the 68th model engineer exhibition at the Geoff Sheppard international model show, D E (Laurie) Lawrence. Harold Hall describes a fixture which will facilitate this task and the design, manufacture, remaining also allow the unit to be balanced transferring it to the lathe parts, assembly, in use, two down, mandrel postscript on the dividing head. Len Walker gives step by step instructions on how to achieve detail, final assembly and accurate zero accuracy setting.

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A CNC milling machine (3)

The description of Peter Rawlinson's machine covers the remaining mechanical components and their assembly

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Helical tube benders Quick tips Turning for pleasure Cutting thin discs Model engineers workshop data book Trade counter Link up

Paul Boothby describes the manufacture of two tube benders which will create helical coils in stainless steel tube Lathe cover John Edwards has put together these introductory notes Charles Darley was able to solve a couple of problems with some basic lathework slip gauges, sine bar, fluteless taps, machine tool axes letter reference magnetic vice jaw protectors from Smith Francis Tools, new email address for Wren engineering

spindle drive motor assembly, spindle support frame assembly, quill holder, the spindle, spindle drive assembly, z axis leadscrew and motor mounting, z axis leadscrew and drive, limit switches, assembly, alignment checking. introduction, large diameter tube bender, small diameter tube bender, using the small bender, appendix.

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Bandsaw improvements

Philip Amos recalls some of the published modifications to the popular horizontal/vertical bandsaw and suggests further enhancements

introduction, issues, instructions, corrections, cutting square, blade tightness and tracking, side roller guides, rear roller guides, squaring blade to base casting, squaring mitring vice jaw, trial, capacity, horizontal cutting, vertical cutting, workholding for horizontal cutting, workholding for vertical cutting, table construction, stowage, conclusion. so what camera, light source. drive arrangements, back gear, slow feed for traversing the slide rest, surfacing feed attachments, indices, tool posts, cutter frame and drilling spindle, drive to cutter frame and drilling spindle, filing rest, collet chuck and collets, change wheels, dividing, cross-slide stops and dial indicator read-outs, tailstock, fixed steady, travelling steady, locking arrangement for change wheel arm, an inward stop for the carriage with micrometric adjustment, a replacement cross-slide, locking and clamping arrangements.

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Spread the light

Photographer Ivan Trobe adds to Bob Loaders hints on how to obtain better workshop photographs

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60 years with a 4in round bed Drummond lathe

John Frazer has a round bed Drummond

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In our next issue Robert Newman gives detailed manufacturing instructions for an the body, the clamping beam, the posts, elegant clamping device which may be used on a range of clamping screw. machine tools home built compressors, the quick-step mill, early Myford lathe, ways and Scribe a line means, re-furbished horizontal milling machine, domestic heat source. On the editors bench Geoff Sheppard George Swallow revives an old idea which ensures rigidity when A fixed steady with bushes construction, using the steady. turning longer workpieces and which facilitate setting-up understanding the requirement, gear tooth profile, the involute curve gear Gear hobbing in the home workshop (1) Ivan Law explains the fundamentals tooth size, circular pitch, diametrical hobs and hobbing pitch, module, tooth proportions, enter the hob, producing hobs in the lathe. Len Walker describes two more useful items of workshop a glass surface plate (boxed with lid), a Aids to marking-out equipment which will soon repay a couple of evening's work marking-out centre. In our next issue introduction, attaching the drive to the Tony Jeffree describes adding a leadscrew from another small spindle, the tumbler support bracket, the Peatol plus lathe tumbler assembly, the dog clutch, fitting the clutch. Workshop techniques by Geo H Thomas, improvements and accessories for your lathe by J A Radford, how to run a metal Fireside reading working shaper and drill press, how to build a pipe bending machine by Vincent R Gingery The 68th model engineer exhibition Harold Hall describes a new changewheel quadrant for the the quadrant, manufacture, A changewheel quadrant for the Myford Myford 7 series which are equipped with a the quick change counterbores, die head chaser holder, 7B gearbox Morse tapers. Model engineers workshop data book Basic thread forms We visit EKP supplies electrical control equipment, safety, control system functions, control cabinet layout, wiring, stepper motor wiring, Peter Rawlinson concludes with the details of the control interference problems, dividing head, the A CNC milling machine (4) system. He also adds a number of accessories including a CNC main spindle and associated dividing head and steadies components, gearbox, tailstock, accessories, parts list for the electrical control system. Dr Giles Parkes has devised a simple method of fitting spring A Myford nose collet adaptor collets to the Myford S7 series lathe A versatile clamp

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Machine tapers

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The model engineer and the internet

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Scribe a line

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On the editor's bench Making small power transformers A Myford nose collet adaptor Peatol plus (2) Link up An auto-feed tap-wrench for the lathe and mill/drill

introduction, standard tapers, self holding tapers, coefficient of friction, coefficient of friction (static), standard Philip Amos surveys the types of machine taper which are likely accessories, manufacture, taper plugs, to be encountered in the home workshop and gives advice on taper socket, procedure, measurement, their manufacture and measurement taper plug, taper socket, example of manufacture, procedure, example of measurement, conclusion. what's it all about, email, the web, news Stan Bray suggest it is never too late to embrace new groups, how the system works, surfing, technologies equipment, more information, take the plunge, some useful addresses. face gear indexing table, soldering aluminium, motor problems, inexpensive motors and other topics, clock pinion milling attachments, correcting lathe taper, a failed attempt. Geoff Sheppard introduction, theory, safety, materials, Philip Amos gives some hints on making an essential part of rating, sizing, construction, assembly, may power supplies conclusion. A correction Tony Jeffree continues is description of the additions to his small the leadscrew, the split nut assembly, lathe by detailing the leadscrew and the screwcutting gear train the banjo components, fine feed set-up, components screwcutting set-up, a word on safety. Alan Munday suggests a way of providing a positive feed for a tap design and manufacture, in use, a thought for the future. the design, manufacture, the slide assembly, remaining parts, assembly, Harold Hall needed a means of marking the division lines on the the dials, turning, engraving, numbering, new dials for his milling machine the Y axis stops, lower slide apron, a final comment. endless belt drives, gear cutters

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Line engraving tool

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Index for issues 45 to 56 of MEW Model engineer's workshop data book

the device, the hob, gashing the hob, Gear hobbing in the home workshop (2) Dr Giles Parkes describes a lathe attachment which will form the cutting the teeth, single tooth gear a device for making gear cutting hobs teeth on a gashed hob blank cutters, slow drive train. A surface grinder made from odds and Hubert Peters relates how he built a small surface grinder ends Myford rear tool post for interchangeable tool holders, drill press Trade counter vice offer from Chronos

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Spark erosion machine

Peter Rawlinson provides information on the electronic control system and PCB

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An adjustable toolpost for the Unimat Quick tips Take a bow In our next issue

Bob Loader describes a simple toolpost which would make tool setting easier splash guards, superglue, high quality studs George Swallow was sure that he could improve on the tools used for a very special purpose

control circuit, printed circuit board, ultraviolet light source, a false start, safety, exposure, developing, etching the board, adding components to the board, precautions. choice of materials, ways of filing off large lumps, tool post, drilling the holes, rocker seat, rocker, drilling the rocker seat. the engineer's approach.

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connecting rod machining operations, gear tooth geometry made clear, South Bend lathes, evening classes with tuition - Castleford, reminiscences of a Scribe a line metrologist regarding face geared indexing tables, vernier couplings, 'B' series tapers, drilling matching holes, elusive bubbles, Unimat matter Bob Loader replies. Ted Jolliffe retires, welcome Anthony Watson, the H&S executive draft paper On the editor's bench Geoff Sheppard model engineering guidance on safe operation of miniature railways and traction engines. A fabricated adapter for a square shank Norman Hurst devises a way of using larger drills which can fabricating the adapter, the shank, the drill often be acquired relatively cheaply adapter in use. safety, iron and steel - general, iron and steel - applications, paint, zinc coatings, Selecting protective coatings blacking and of blueing, copper brass and some proces Philip Amos discusses the forms of corrosion which can affect a variety metals and suggests bronze, treatments, aluminium, silver, conclusion. a change of direction, patterns and castings, machining cast iron, a Morse The lathe that took fifty years to Rex Galway describes how he built his own lathe and gained taper tailstock barrel, casting white metal complete (1) many skills over the way bearings, the spindle, the motorised drive. Modifications to a milling machine vice Pat Twist amendments and corrections, main Peter Rawlinson continues his description of this interesting power supply, testing the control unit, Spark erosion machine machine switch motor wiring, stepper motors, wiring.

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A simple aid to accurate drill grinding The Jobs gear hobbing machine

C Heyes spotted this item on the wall of a workshop above a pedestal grinder origins, evolution, design specification, features, capabilities. the drawings, the design, the kit, manufacture, vertical slide bracket, hub spindle housing, bearing bracket.

Gear hobbing in the home workshop (3) Harold Hall describes how he machined some of the major building the CES hobbing machine structural castings Model engineers workshop data book end mills and slot drills, screwed shank dovetail cutters, domestic oven temperatures, speed measurement, taper pin reamers A re-fillable aerosol paint spray can, Hobbymat machines again available, lead-free pewter, clip-on magnifying glasses, new from Shesto, More and Wright return to the model engineering market, fohrmann-WERKZEUGE offer 25th anniversary discounts, machine manuals from L A services, a photographic aid

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Trade counter

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In our next issue Tools and equipment at Harrogate making the discs, engraving and numbering, numbering the discs, constructing the body, the indexing pin, the indexing plunger, the anchor, mandrel bores above 3/4 in, drilling the side indexing 50 disc, using the MHI, the inching handle, general points, a warning.

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A handle on mandrel indexing

Robert Newman devised what he thought was a new form of mandrel indexing device only to discover that the principle wasn't new after all

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Jack for a milling machine table Link up Scribe a line

Derek Oxley was unable to recall anyone explaining the basic logic of how to form a 90 deg V groove in the centre of a disc the value of industrial archaeology, electrical safety, fine feeds for small lathes, making printed circuit boards. the international model show, a new venue and a new date, the collection service, features, the competition. introduction, the machine, the software, adding a fourth axis, why CNC?, marking out and drilling operations, cutting circular paths, repeatable operations, tedious operations, more exotic uses, the competition, conclusions.

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On the editor's bench

Geoff Sheppard

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A taste of the Taig CNC mill

With six months experience of use Tony Jeffree reports on his findings

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Cleaning a Jacobs drill chuck

Bill Morris gives some hints on how to dismantle and clean this widely used piece of equipment

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Spar erosion machine In our next issue Trade counter

Peter Rawlinson now gives details of the head and the electrode mounting the electrode, limiting the feed mechanism travel. Sturdy drilling machine vice, new Minicraft products, uprated variable speed transformer, Pen Grip orbital sander, small turning toolholders from Chronos tee slots, the dovetails, housing work spindle, turned parts, leadscrews, hob spindle, gear and hob arbors, handles, graduated dial, the worm and wormwheel, flexible couplings, the flat parts, initial assembly, guards, the machine in use. vice operations, clamp blocks, lathe operations, simple, Lantern chuck derivative, manufacture, tailstock steady, conclusion. in use at last, impending retirement adds urgency, lathe specification. shaft housing, shaft, assembly, blade support, blade clamp, jockey block, links, frame, levelling adjusters, mechanism, riving knife support bracket, motor support bracket, blade guard, working surface, work fence subassembly, adjusting hand wheel, cladding, electrical wiring, painting and future refinements, safety. the large pulley, the small pulley.

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Gear hobbing in the home workshop (3) Harold Hall continues his description of making the major building the CES hobbing machine (2) components

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Model engineer's workshop data book Trimming bolts and screws The lathe that took fifty years to complete (2)

welding symbols, dovetail slide design Philip Amos describes some simple aids to achieving this end

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Rex Galway concludes the story of his home-built lathe

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A circular saw

Dyson Watkins constructed this workmanlike stand-alone unit

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Super slow

Maurice Turnbull explains how he modified the drive to his geared head machine

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Sharp tools for beginners

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On the editor's bench

the problem, the starting point, first Bob Margolis describes how it is possible to simply enhance the steps, an improved toolrest, making the capabilities of a bench grinder to help make tool grinding a rest, assembly, using the new rest, a pleasure rather than a chore sliding table, using the sliding table, wheel dressing, postscript. balancing the design of salvage, surface plates, ingenious locking device, the advantage of the involute gear, gear hob manufacture. the HSE guidance notes on the Geoff Sheppard operation of miniature railways and traction engines, engineering courses.

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A clock-wheel cutting machine Modelling engineering courses Link up

George Swallow describes his version of a traditional purpose built device which will be found useful by the keen clockmaker

main frame, horizontal slide, the hub and spindle, vertical slide, cutter frame, the machine in use.

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background, introduction, types, Philip Amos discusses some of the potential problems and gives geometry, material, shape, use, Travelling steady techniques some tips on it's use replacing brass points, setting accuracy, alternative method, conclusion. the support structure, machine table, the Peter Rawlinson concludes his description with details of the Spark erosion machine arms, the dielectric containers, the main support structure and the dielectric tanks circulation pump. manufacture, assembly, constant velocity, using the hobbing machine, Gear hobbing in the home workshop (3) Harold Hall concludes his description by giving description of the spur gear set-up, making gears for the - building the CES hobbing machine (3) manufacture of flexibly jointed and telescopic drive shafts machine, other uses, some final comments. Model engineers workshop data book Dovetail slide design, Tee slots, useful mathematical formulae Inspired by Barry Jordon's exquisite miniature rotary table Terry the table, worm and wheel, the body, the A simple rotary table Lane raided his scrap box to find the materials for this slightly rest, accessories. bigger version painting, bright work, choice of Dr Peter Clark reveals a few of his secrets and suggests that The appropriate finish for tools and materials, sharp tools, cutting fluids, similar results can be achieved by anyone prepared to spend a workshop equipment chamfers and countersinks, abrasives, little time and effort plastics. Chronos did offer a discount, Shesto offer a versatile headband Trade counter magnifier kit, Stuart Turner exhibition, Maplin Electronics new outlet. speed calibration, analogue measurement using a dynamo, Accurate knowledge of cutter and workpiece speeds can lead to Spindle and surface speed measuring surface speed, a practical more efficient machining Tony Jeffree suggests some methods measurement SFM/rpm meter, digital measurement of by which this may be achieved rpm, a simple digital rpm sensor, other measurement and display techniques. Robert Newman describes some simple accessories for the the sensitive tapping tool, tap holders, User friendly tapping pillar drill and the lathe which will avoid some of the problems the sliding carrier, the mandrel spinner, experienced when threading with taps the Arrand die holder. engineering courses, flexispeed lathes, PCB production, a helical tube bender a Scribe a line postscript, the taper reamer problem - a late entry. On the editor's bench Geoff Sheppard Alan Bourne and Gordon Read decided to investigate drill Simplified drill grinding sharpening from first principles and led to the development of a construction, using the jig. simple jig

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Turning parallel A tilting table Quick tips Exhibiting workshop equipment

Philip Amos gives some hints as to how this may be achieved with a greater degree of certainty patterns, turning the base, machining Bill Morris describes the construction of a substantial accessory the top, fitting base to top, graduating, for the milling machine stressful tee slots. Clearing up liquid spillage why should we exhibit our work, Peter Clark gives some hints as to how workshop equipment preparing the exhibit, presenting our may be best presented work, description and labelling, let us all see your work, acknowledgement. basic design, simple to use, Simple in concept but versatile in use the drilling machine vice manufacture, trunnions, clamp screws, has helped Peter Rawlinson to overcome some tricky work ball ends, ball joint straps, moveable holding problems jacks, assembly. adjustable stops, the overhead drive, the mill/drill spindle, indexing the chuck, a few words about leadscrews, the next moves. my reservations, installation, testing, improvements as a result of experience, conclusions. introduction, design objectives, using CAD, the breakthrough, adhesives, removing tools, the objectives summarised, design considerations, notes, conclusions. off-setting, pipe clamps and straps, a hole punch.

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A multi-jawed vice In our next issue

John Edwards shows that with the equipment found in most Ornamental turning for model engineers home workshops can be adapted to make similar items Model engineers workshop data book Four years with a Chester champion mill worms and wormwheels, additional information John Crammond gives us his impressions of a popular small milling machine E J Mackenzie relates how he set about specifying and designing improvements to his example of this popular machines Stan Bray describes a few gadgets which with a vice may be used for forming metal Vertical milling machine Tungsten carbide and diamond gritted products from Eternal tools, additional Worden kit from Hemingway, Garryson Minidiscs

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Modifications to the Hobbymat MD65 tailstock

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Going round the bend Barry Jordon's latest creation Trade counter

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Scribe a line

Peter Rawlinson's spark eroder, soldering aluminium, differential for a trike, isolating an artificial 3-phase supply, making small power transformers, drills and tapers, machining hobs, Jacobs chucks - a warning, model engineers 'on air', clockwheel engine. Geoff Sheppard

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Link up On the editor's bench

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Cutting sheet metal A discovered parting tool blade

Harold Hall considers some of the methods available and suggests ways of employing them Mike Delaney has found just the use for those damages carbide tipped circular saw blades

an auxiliary work table, uses for the table top, cutting sheet metal, hand tools, power tools.

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How it was (3)

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Quick tips Compendium of the Quorn Model engineering courses Link up

an interesting interlude, reputation made, in at the deep end, good news and bad news, fun and games, taking Bob Loader returns with more reminiscences of his working and chances, the affair of the phantom model making life machinist, special jobs for special occasions, five good years, a start in model engineering. Eye protection, safe and clean, painting the workshop introduction, goals, options and Philip Amos reviews the literature and adds a few elections, selection of construction enhancements of his own materials, errors and omissions, construction, tilting bracket clamping.

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rewiring the motor, control settings, the Shelly Curtis bought himself a lathe equipped with a three phase new control panel, a smoother start, motor support from the trade. background, commercially available Peter Rawlinson describes his experiences with commercial and equipment, mounting linear scales, build Digital read-outs for the home workshop home-made digital read-out systems your own, sensor options, my stretched wire system, linear encoders. Acme threads, metric trapezoidal threads, gears involute form, Model engineers workshop data book equipment protection see light with fabricated adjustable A couple of workshop quickies Russell Kenyon devised a couple halogen lamp, no more excuses for an untidy workshop. introduction, modifying the headstock, the brake shoe, the pinch bolt and A comprehensive dividing capability for Tony Jeffree starts description of a versatile attachment which tommy bar, the dividing assembly the Peatol lathe and mill (1) could also be used on any machine of a similar size mounting plate, modifications to the work wheels, the stepper motor mount. New catalogue from Maplin Electronics, Compucut goes 3-D, a Trade counter new sensitive bench drill from Minicraft Simple workshop devices by Tubal Cain, CAD for model engineers by D A G Brown, workshop materials by Alex Weiss, Fireside reading a treatise on oiling machine tools by Guy Lautard, plastics for modellers by Alex Weiss IMS update An evening in the workshop is all that is needed to complete this A precision spacing punch in use, equ-spaced holes on a PCD. useful marking-out device described by Alan Jeeves Operating a three phase machine on a single phase supply

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A lazy Susan for a file rack

Tony Birkinshaw describes his version

foraging for materials to make what couldn't be bought, method and order of fabricating the lazy Susan thrust race, dbit countersinking tool for Unified screws up to 3/8 in shank, hardening and tempering. South Bend lathes, machining cast iron, motor speed control, isolating an artificial three-phase, differential for a trike, blades for the Rapidor hacksaw. the implanted devices vacancy, the data book, new projects for MEW, a new millennium. the persuader casing, the crucible, pouring the lead, the quest, the dead blow hammers. a simple modification. principles, construction of holder, construction of buttons, aligning the buttons.

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In our next issue Scribe a line

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On the editor's bench

Geoff Sheppard Simple to make but invaluable when the occasion demands Robert Newman gives details of some unusual tools Harold Hall decided that a simple modification could enhance the performance of this useful grinding rest Norman Hurst used Don Unwins 1997 gear cutting article for reference but he felt that he could modify Don's system to suit his own needs

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Dead blow tools Modifications to the Hart grinding rest A modified involute gear cutter method Link up Compendium of the Quorn (2) A workshop gantry In our next issue

Quorn clamping, access, diamond Philip Amos concludes his review of the Quorn and suggest a shaping of wheels, engraving divisions, few more modifications and gives some hints on wheel dressing mounting, storage, conclusion. Stan Wade describes the construction of an aid to safe handling which was fashioned from materials which were to hand the circuit, PCB manufacture, testing, safety, using the logic probe, fitting the Ices, conclusion, component suppliers, component list.

Digital read-outs for the home workshop Peter Rawlinson concludes his article by describing the (2) electronic circuits and the associated test procedures Model engineers workshop data book collet chucks, material weights, thread indicator

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A comprehensive dividing capability for the Peatol lathe and mill (2)

Tony Jeffree describes the remaining components

controlling stepper motor end float, the simple and compound division components, the primary worm carrier, the secondary worm assembly, the index plate boss and primary worm shaft, the sector arms, division plates and hole circles, the indexing arm components, tailstock support, putting it all together, direct dividing set-up, simple and compound dividing set-up, simple division, using a protractor as an alternative to compound division, CNC dividing set-up.

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The midlands model engineering exhibition The special angle plate for the Myford ML10 cross-slide

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Trade counter

Another useful accessory from the drawing board of Len Walker construction. it would suit a variety of lathes of similar size High and low temperature solders, imperial size steel from Hemingway, Compu-edit graphics code manager, Uni-thread wire thread inserts, Wren engineering change of assess, Newline from Reevescene, new catalogue from Frost, Garryflex blocks, a message from Chronos cheap surface plates, electrical safety, three phase from an inverter, a lazy Susan for a file rack, tricycles, machining hobs, trimming bolts and screws, Little John drive belts, the Wade lathe. Geoff Sheppard Michael Shepherd made an adapter for his 3 jaw chuck which helps the process manufacture. equipment, pens and pencils, compasses, other items, rubbing out, drawing method, how many views, spacing, projection, reminders, datums, dimensioning, lines, sections, nominal dimensions, scrap views, abbreviations and symbols, numbering and lettering, fractions. my jig, six facets.

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IMS update

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Scribe a line

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On the editor's bench In the search for concentricity

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A plain man's guide to drawing

Bob Loader gives some advice on how to go about producing them

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Twist drill sharpening by the four facet method

Giles Parkes describes how a simple collet holder makes this drill sharpening method a practical proposition

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.The spark eroder and the CNC mill matter arising

Peter Rawlinson gives an update on his two recent major projects

spark eroder dielectric, pliers for bending PCB jumper leads, the CNC mill in use, the modifications, x and y axis gearing, new cutter drive motor, plotter pen auxiliary movement, quill dial gauge, z axis DRO, dividing head counter, etching tank, materials, construction, final assembly and sealing, air supply, PCB holder.

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The 69th model engioneer exhibition at the international model show Model engineers workshop data book Elegant pipework

section index, full index Derek Brown demonstrates how to achieve neat and accurate bends Harold Hall recounts some of his experiences of using one range and encourages readers to give them a try MEW computerised index, screwcutting made simple by Greenwood Tools, a diamond grinding wheel dresser introduction, plain mandrels, stub mandrels, axially clamped mandrels, shouldered arbor, tapered mandrel, expanding mandrel, multi-split tapered sleeve type, multiple blade type, Hick type, Yuile type, Le Count type. simple construction, the base, fulcrum loose spindle and spaces, anchor posts, levers, formers, operation, scaling. give it try, types of adhesive, preparation, some examples, material saving, final comments.

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Adhesives and fabrication Trade counter

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Workholding mandrels (1)

Philip Amos describes the types available and their use

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Powder coating Neil Munro tells us how to make a simple fluidised bed which will building the fluisides bed, using the fluidised bed. aid the process In our next issue machining worms, handling molten lead, rotating file racks, welcome response from readers, centring work in the 4 jaw chuck, engineering supplies, the big turn, the workshop gantry. merger of Highbury house communications and nexus media communications, the 7th national model engineering exhibition Harrogate, assistant editor required. expanding mandrels, washer or cone mandrels, pegs and split bushes, general remarks, conclusion.

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On the editor's bench

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Workholding mandrels (2)

Philip Amos concludes his review and goes on to discuss the use of slot drills

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Sharp tools for beginners new wheel flanges for the bench grinder

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A small universal milling machine

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Making life easier

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Avoiding the use of packing

the problem, materials, measuring the Bob Margolis turns his attention to the flanges which support the shaft, first operation, using a stub grinding wheels mandrel, future plans, postscript, a simple boring bar. construction, base and column, the head, the quill and spindle, feed A J Vantomme describes his versatile small milling machine arrangements, motor and drive, which is of fabricated construction compound worktable, horizontal milling, accessories. a long material rest for the band saw, Peter Rawlinson describes some ways in which he has made collet storage tray, film case storage time spent in the workshop more productive. system. the limitations of packing, something had to be done, construction, repeatability of John Brittain shows us how to make easily positioned location, accommodating larger tools, toolholders for both the Myford Super 7 and Harrison L5 lathes parting off, a version for the Harrison L5, postscript. tool rest construction, machining the body taper, the cotters, the rest post, the swivel post, the clamping handles, general notes, tolls for metal hand turning.

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Link up Robert Newman describes the process and gives details of suitable equipment A range of toolpost grinders for the small workshop, good quality BA spanners from Chronos, a review of the Meiji binocular stereo zoom microscope Stan Bray describes a small machine vice which incorporates features often found in industrial items sizes, the base, fixed jaw, first assembly, moving jaw, jaw plates, tightening bars, finishing. BA threads, how accurate are these, precision work, cutting BA threads on changewheel lathes, metric threads, worm thread pitches, accuracy considerations, practical recommendations.

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Hand turning (1) metal

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Trade counter A visit to Barry Jordon's workshop A job for the weekend an easily made machine vice

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Cutting BA metric and worm threads on Myford 3 1/2 in lathes

John Peters clarifies some of the mysteries of cutting those types of thread on both gearbox and changewheel equipped lathes the editor reflects on the use of CAD packages

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Engineering drawing Stolen engines

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twist drill sharpening, machining worms, treatment of burns from PTFE products, seeking a special rope, a veteran restored, Elliot mini-borers, those older lathes more help sought.

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On the editor's bench

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Measuring temperature

Philip Amos describes some of the available methods

HSE documents relating to passenger carrying miniature railways and road vehicles. introduction, general, liquid in glass thermometers, solid expansion thermometers, pressure gauge thermometers, digital thermometers, thermocouples, electrical resistance thermometers, colour temperature, crayons, magnets, optical pyrometer, radiation pyrometers, portable infrared pyrometers, pyrometric cones, conclusion.

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A genuine LeCount mandrel Hand turning (2) wood

Hugh Smith acquired a device which he was unable to identify until Philip Amos revealed all Robert Newman describes some tools and procedures which may assist readers who are not experienced in this medium Barry Jordon needed a test project on which to confirm the capabilities of his small home-built milling machine Derek Brown recalls the time when the subject was soft furnishing When Reg Crane exchanges his Super 7B for an ML10 he missed the headstock drive clutch so constructed this effective replacement Harold Hall gives some suggestions on machining one of the more difficult items Len Walker suggests that adding these simply made items to the workshop inventory would aid marking out and other applications Richard Bartlett describes some recent developments and describes the process of digitising from a template or similar solid model Norman Hurst tells how he extended the capabilities of a friend's woodworking machine Harry McCarty has devised a neat battery powered rev counter Nevil Frewin the turning tools, the tool rest, the cone drive, the handles, turning the handles, using then slicer tool, finishing. preparation, the test, the project, facts about the model FOBCO drill, just as a tailpiece some mole gripping stuff. radius tool, cutting the Torus.

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A testing product In our next issue Turning a torus A spindle clutch for the small lathe Making a small crankshaft Blocks and trammels

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CNC for practical engineers - acquiring data for CNC

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An attachment for a Bosch router Spindle and shaft speed measurement A wire brush substitute

one piece construction, turning between centres, other methods. precision matched blocks, grinding, a beam compass or trammel, for metalworking. to recap, going soft, a worked example, getting the data for the control file, the digitising board, proving the program, rapid prototyping, an alternative technique, the digitising tablet and electronic stylus, set-up, editing. the requirement, the solution, manufacture. transducer, converter, indicator, circuit description, construction, calibration, conclusion.

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Trade counter Electromagnetic devices (1) an introduction

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S J E Engineering can supply small fasteners, workholding with Climpex clamps, compression springs and O rings, news from A&D Barrowclough Ltd, refillable aerosol paint spray cans, spring offers from Tilgear. Tony Claridge describes some of these devices and the principles by which they operate.

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magnetism, units of measurement, quantitive analysis. calling Cuckoo Lane former pupils, further thoughts on machining hobs, engineering adhesives, lathe tool packing, tool and cutter grinder details, 9in South Bend lathes, more on older lathes. relaunch of the model engineer exhibition, H&SE information sheet, working precision models. introduction, character, position, hole centre, hole marking, jig drilling, drilling in the lathe, special positioning techniques, location of holes from each other or from workpiece edges, drilling machine or vertical mill, wigglers, hole axis direction, drilling across cylinders, achieving the required dimensions, finish and dimensions, coated drills, conclusion. a new key from an old file, modifying the column, machining the column casting, adding the column casting extension pieces, a new head elevating key, problems. general impressions, the CNC miller as a manually operated machine, the CNC aspect of the machine.

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Link up On the editor's bench

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Creating holes

Philip Amos discusses methods of location production and finishing

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A tapping compound dispenser Repeatable headstock location for a vertical miller We visit Dick Stephen The Wabeco milling machine In our next issue A direct indexing attachment for a Myford dividing head HSE passenger carrying miniature railways: guidance on safe practice

Peter Rawlinson cannot bear to throw anything away David Manchin tackles a problem experienced by many owners of small milling machines

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Clockmaker Dick Stephenson describes his experiences with the CNC version of the Wabeco 1200 series milling machine Raymond McMahon tells us of a modification to a workshop accessory which helped to speed up production

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machines, chucks, the fixed steady, cutting tools, dial test indicator DTI, Harold Hall devised a series of articles in which practical useful Lathe projects for the beginner smaller items, material, in-depth detail, projects are described and which covers the basics of lathework metric dimensioning, our first project a mini surface gauge, terminology. Low melting point alloys from MCP, spring/summer book news Trade counter from Camden, a new range of duplex brand machining accessories, new high accuracy torque wrench development, the toolpost grinder, quill Eric Eadon shows how he adapted a minidrill to carry out small A toolpost grinder for a Harrison L5 lathe housing, bearing clamp plate, final bore grinding tasks assembly, using the unit, safety. Spring in Yorkshire 7th National model engineering and modelling exhibition estimating the force available, estimating Electromagnetic devices (2) designing Tony Claridge continues his series by carrying out a number of the amp turns required, MMF electromagnets design studies calculations, designing the winding, a solenoid design study. the super collet fixture, face plate, clamp More accessories for the smaller lathe Jack Neave now adds an even larger collet holder ring, collets. Link up constant velocity joints, cutting sheet metal, securing a bush, etching printed circuit boards, on centre drills and bevel Scribe a line gears, another evening class and a cry for help, materials for electromagnets, tool holder article some corrections, dividing head puzzle. Turbocad relaunched, modellers in the On the editor's bench news. introduction, platen, plenum, vacuum, Philip Amos describes an interesting variation on the The vacuum chuck thin stock, stops, grinding wheels, trials, workholding theme suggested design, conclusion. programming basics, format of the An introduction to CNC programming Trevor Wain gives an introduction program, example program. Norman Hurst describes how he fabricated a matching unit for description, notes on welding distortion, A fabricated tailstock for a dividing head his indexing head manufacturing, aligning and assembly. the design concept, a second bite at the A tilting compound table Geoff Allen embarks on a major project cherry, supply of castings, order of machining. The vertical miller as a surface grinder David Machin the wheel guard, setting up for grinding. Model engineer exhibition news In our next issue experience with IONPLUS-dielectric Spark eroder dielectric Peter Rawlinson IME-MH, filtration, a filter housing, system pressure.

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Lathe projects beginners (2)

Harold Hall gives step by step instructions on the machining of mini surface gauge

base, centre drilling, facing an end, reducing the diameter, finishing cuts, producing the finishing tool, back to the base, using the fixed steady, method of adjustment, fly cutting.

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Link up Trade counter new Chronos website, Shesto website, spark erosion equipment in modular form from Concept EDM ltd cheap and cheerful welding, principles of operation, equipment, selection, rating, size and portability, buying secondhand, making big welds, additional facilities, build your own, safety, the importance of the flux coating, striking an arc. the stresses to which windings are subject, methods of making coils, alternative to enamelled copper wire, getting rid of heat, permanent magnets.

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Electric arc welding techniques manual metal arc welding

Trevor Marlow gives advice on the selection of equipment and use of the process

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Electromagnetic devices (3) winding construction A useful screw press

Tony Claridge gives some practical hints on winding coils

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John Harris describes converting a car boot item to solve a problem


constant velocity joints Atlas lathes, grinding Inconel turbine wheels, shaft speed measurement, an aid to neat drawing. engineering courses, searching for a bevel gear mandrel, chuck mounting, chuck backplate, chuck care, storage conclusion. the alignment problem, the solution, manufacture, the work holding problem, the solution, manufacture. the search, hardware modifications, G and M codes, microkinetics system, programming, worked examples, circular quadrants, sub-routines.

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On the editor's bench Those confounded chips

Geoff Sheppard Philip Amos discusses the care of threaded lathe chucks and the mandrel nose Norman Hurst addresses the problem of aligning the workpiece in the indexing unit Peter Rawlinson describes his quest for an alternative control system for his CNC milling machine

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Milling between centres

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Further experiments with CNC

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A tilting compound table Lathe projects for beginners (3) Life with a planing machine Index for issues 57 to 68 of MEW

In this second article Geoff Allen gives some hints on machining machining flat surfaces, procedures. the first batch of major castings the scriber assembly, thin piece collet, Harold Hall gives detailed instructions on machining the adjuster assembly, assembly, final remaining components of the mini surface gauge comments. Jack Frazer relates the story of the rescue of a scrapped planing adding milling capability, a self-act feed machine for the table, future developments.

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A rotatable vertical slide mount Trade counter A variable speed control for a Myford ML7 Honing jig for carbide lathe tool tips The 70th model engineer exhibition news update

Paul Boothby describes a simple adapter

material, accessories, required, construction, afterthoughts.

Affordable CNC milling Quantum CNC Tony Jeffree relates his experiences with a Newton Tesla speed early discussions, the package, fitting control package and setting up, problems. Derek Winks describes a simply made jig construction, the jig in use.

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Indicators - they aren't just for clocking

three useful indicators, the pencil method, setting work in a 4 jawed chuck, dial indicator, accessories for the dial Bob Loader surveys some of the mechanical types available and indicator, using the dial indicator, dial suggests a variety of uses test indicator DTI, using the DTI, setting for milling work, using a magnetic base, tell-tale indicator. Derek Oxley has devised this simple aid to accurate work setting Tony Claridge covers permanent magnet theory and materials how magnets work, sources of supply, using permanent magnets. sources of soft iron and some thoughts on brush retention, electro-magnetic vblocks, protecting a brass finish, brown and sharp dividing heads, headstock dividing, the Urwick triangular key, radiused centre drills, an effective abrasive.

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A milling chuck adapter for a Huffman centre locator Electromagnetic devices (4) Link up

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Scribe a line

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In our next issue On the editor's bench background, introduction, concept, shear failure, tools, punch and die, bench press, action of punch and die, action of other shearing tools, force available with the triple machine, cutting force required, sideways force, blade clearance, clearance adjustment, hand tools, brake press, conclusion. side plates, spacers, swing arm assembly, swinging arm side plates, swivel nuts, link, clamp screw, tommybar, draw bolt, finish. before you buy, the general condition, main headstock bearings, the renovation.

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Shear

Philip Amos examines the factors affecting the successful operation of devices which cut metal by a shearing process

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A machine work clamp

Dyson Watkins describes a simply made clamp which will help achieve a secure clamp Loris Goring describes the acquisition and renovation of a Myford lathe

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Getting started in model engineering

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Link up Quick tips Lathe projects for beginners (4) mparallel turning Trade counter A live centre Seen at the Midlands exhibition A tilting compound table (3)

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Nast steels horrible finishes and close tolerances Harold Hall explains how to go about achieving this and mounting requirements, an alternative, suggests an exercise which will produce a precision component cylindrical square, parting off, finishing for future use the part, the tailstock effect. Versatile lathe tool from J B cutting tools, slideway grinding specialists, motors direct relocate, easier handling of small components, steam fittings from E K P supplies a centre for a special job, taper turning, Alan Aldridge set about making something suitable the ball end, assembly, taper ends. Geoff Allen embarks on a major project

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gib strips, tee strips, castings. design considerations and a choice, materials and pattern making, making the new parts, machining the original Vee belt drive for a South Bend lathe Norman Eastwood describes his conversion to a vee belt drive cone pulley, belt tension parts, fitting the drive pin and lubricating the cone pulley, four speed pulleys and two speed countershaft, conclusion. system design, double sided PCBs, Peter Rawlinson investigates unipolar and bipolar stepper motor Further experiments with CNC using the bipolar system, power drive systems supplies, assembly and testing. Electromagnetic devices (5) - alternating sine waves, vectors, coils in AC Tony Claridge currents systems, transformers. Peter Peters has given much thought to a problem posed in a Balancing the design of a salvage transverse shear, torsion, bending. letter to scribe a line In our next issue air bearings for tool and cutter grinders, further thoughts on the electronic rev Scribe a line counter, constant velocity joints, securing a bush. On the editor's bench Geoff Sheppard A simple lathe stop system suitable for a larger lathe is mark 1, mark 2, general, design, Lathe spindle length stops described by Philip Amos manufacture, use, conclusion. We visit Derek Brown Dissatisfied with commercially available items led Derek Brown shanks, it gets to the part others cannot Nut runners to produce a set of spanners which met his requirements reach. Tungsten carbide and diamond tooling from Eternal Tools, make Trade counter waterslide decals on an ink-jet printer, MEW computerised index, welding protection from C G & W Young ltd The 70th model engineer exhibition news update

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lighting for the lathe, safe working, acquiring tools, heating the workshop, Loris Goring describes the installation of his reconditioned lathe Getting started in model engineering (2) levelling the lathe on it's bed, lubrication, and the preparation required to bring it into service connecting the electricity, getting the metal stock in. Link up Quick tips Drilling in the milling machine, stylus type DTIs and cosine error Lathe projects for beginners (5) turning Harold hall now considers the influence of the lathe tailstock on turning the test piece, fine feed parallel - the tailstock effect parallel turning quantified. Removing a broken tap Raymond McMahon describes how he resolved the problem taking care, useful cutters, a better way of holding cutters, the large cutter Bob Loader describes how it is possible to use the smallest of holder, holding work for milling, don't Milling on the Unimat 3 lathes to perform quite substantial milling operations forget the toolpost, other methods, vertical slides, clamping the work, essentials, home made cutters. Doug Ball of Letchworth describes his version of a device which Taper turning by offset tailstock centre simplifies taper turning capabilities of the machine, a bit of history, the kit arrives, the planning stage, making a start, tool holder slide Geoff Sheppard describes the construction of a machine tool The Worden tool and cutter grinder assembly, the table eccentrics, setting from a kit bar lengths, the table, metal finishing, the grinding wheel hub, the motor and control circuits, ready for use. main arbor assembly, drive shaft, Pater Rawlinson suggests another method of maintaining hardening, drive discs, release knob A drill extension alignment when more than one drill is used to create one hole assembly, tapping holder, tapping handles, the unit in use. a purchase you will never regret, why are MIG systems popular, how does the traditional system work, financial outlay, what will I get for my initial outlay, which should I choose traditional or no gas, Argon mixture or carbon dioxide, Electric arc welding techniques metal Trevor Marlow describes the equipment and methods used preliminary set-up, recurring problems inert gas welding when MIG welding their causes and cures, surface preparation, problems in welding on a good surface, rapid degradation of tips due to a damp workshop, wire feed problems, welding aluminium, welding stainless steel, spot welding with MIG, welding cobwebs. Tony Claridge discuses transformer design theory and Electromagnetic devices (6) the core, the initial design stage. construction

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Scribe a line In our next issue On the editor's bench Geoff Sheppard

varnishing brass, vacuum chucks. the Chronos Unimat millennium lathe prize draw, Geoff Allen's tilting compound table, MIG welding a note of warning. sequence, commercial industry, production order, drawing, sheet size, storage, format, drawing number, material list, revision column, accessories, route sheet, conclusion.

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Method and sequence

Philip Amos looks back at some of the older routines

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Quick tips Adapting the Vertex HV6 rotary table Quick tips Yet another knurling tool Trade counter

An anti-corrosion formulation Derek Oxley solved a couple of problems setting up this commercial milling accessory A quick oil can Gary Woodward describes his version of a caliper type A J Reeves 2000 - good news, small machine vice from Home and Workshop Machinery, a new Super 7 lathe from Myford, Warco 3 axis digital readout DRO system measuring and marking out, punches and scribers, precision measuring, gauges, cutting tools, lathe tools, holding tools. precision the problem, tool, in-feed method, hole gauges, taper stub mandrel, making gauges, making the mandrel, the handle, precision in length, terminology.

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Getting started in model engineering (3) Loris Goring covers buying basic tools for hand and lathe

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Lathe projects for beginners (6) precision turning - diameters The 70th model engineer exhibition news update

Harold Hall now brings a component to size

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Home -made cutters

Bob Loader shows that making them need not be a daunting task

d-bits, special d-bits, hardening, counterbores, ring cutters, cutters from files, cutters from broken end mills, taps, spade drill, home-made saws, odds and ends, a fly cutter holder. z axis, the power requirement, the mechanical components, the control system. upgrading the z-axis, upgrading the motors, first impressions. the problem, the solution, electrical considerations. electric motors, single phase motors.

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Link up Mill knee motorisation Upgrading the Taig CNC mill A safety interlock for a Warco mill Electro magnetic devices (7) Peter Rawlinson decided that something must be done Tony Jeffree reports on modifications Dr David Hall suggests a small modification to a popular milling machine Tony Claridge now moves from transformers to motors

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Simple gear shaping In our next issue Finding the centre

George Dimelow has adopted an industrial method to produce simple gears suitable for light duties John Payne decided that existing designs could be improved

making the cutter, cutting the teeth, correcting the tooth form, other applications.

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On the editor's bench Starting taps straight

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The evolution of stainless steels

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Renovating an Atlas horizontal milling machine

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Jacks and clamps

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Lathe projects for beginners (7) precision turning - length Fireside reading An autocollimator from the scrap box

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manufacture. with a little help from the angels, more on varnishing brass, current meter reading anomalies, excellent service, radiused centre drills, a little ingenuity taps an odd thread, oiling Myford lathes, turning tapers. reeves 2000, a new wall chart, our next Geoff Sheppard issue. commercial approaches, conventional Hand taps are some of the most frequent used items, Philip home workshop approaches, tapping Amos gives some hints on how to achieve a successful result under power, conclusion. the break through, classifications, Don Unwin surveys the development of a group of materials the hardenable alloys, austenitic steels, heat prime property of which was not immediately recognised resistant steels. not my first attempt at renovation, back to the Atlas, upgrading the electrics, help Mike Thurgood relates some experiences reconditioning a 1940 from the USA, replacement drive belt, American milling machine repainting, the machine in use, postscript. mill table screw jack base, cam type Peter Rawlinson describes some simple milling machine clamp for thin sheet fixing, calling Bill accessories Hinkle. making the gauges, setting a fixed steady, setting the top slide, Harold Hall describes the manufacture of a set of simple gauges measurement problems, outside dimension fingers, storage tray, boring holes, terminology. Making clocks by Stan Bray Bill Morris suggests that a useful basic device could be optical principles, general arrangement, constructed collecting the optics, test bench.

Drilling and tapping equivalence chart Saddle and tailstock handwheel dials for Shelley Curtis describes a simple enhancement to the a Harrison M250 lathe specification of his ex-MOD machine A dial gauge stand Simple speed reduction Link up Len Walker Gerry Ward relates how he fitted speed reducing systems to two milling machines base, column, arm clamp, column clamp, stud, large knob, arm, clamp bolt, small knob, preparation for assembly.

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My Potts universal milling machine A ready-made rotary table A tilting compound table Electro-magnetic devices (8) In our next issue

Alan Slater describes his variation on one of the themes A W F de Ville relates how he recycled components of a piece of domestic equipment Continuing from issues 70 Geoff Allen describes the progressive machining Tony Claridge explains more about motors

feed screw assembly, improved spindle bearings.

induction motors, synchronous motors, reluctance motors. abrasive band and disc machines a health warning, further experiments with CNC, converting to metric, after the exhibition (a wife's view), replacing drill batteries.

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On the editor's bench A pot-pourri of small lathes

Geoff Sheppard

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ornamental turning, new publications The small lathe has a fascinating history some aspects of which widen interest, proliferation after 1918, a are explored by Don Unwin custom-built lathe. A simple dividing head for the Hobbymat Peter Bowes made good use of wet weekend and ended up with MD65 a useful attachment for his lathe external grooves, internal grooves, other Measuring grooves Philip Amos suggests some methods of determining their size shapes, conclusion. A free-lance lathe By W D Urwick reprinted from Model Engineer March 1st 1951 Metalmaster a zero taper machine tool By David Urwick reprinted from Model Engineer 2nd July 1982 The Metalmaster up to date Mick Collins relates the later history of this intriguing machine boring the problems, boring small Lathe projects for beginners (8) boring Harold Hall describes some useful items of tooling diameters, the tools, tailstock die holders, two methods, the larger holder. A universal machine tool for the model by L F Redman reprinted from model engineer 17th March 1938 engineer's workshop a primitive vertical head, a milling table, early drilling methods, using the face plate, am improved face plate, lining up Bob Loader demonstrates that it is possible to press the lathe Drilling in the small lathe drilling work, the drilling process, into service for other duties clamping, clamping round material, using separate drilling machines, other ways and means. Pater Rawlinson describes a modification suitable for a 6 1/2 in An automatic screwcutting stop centre Taiwanese lathe Tom's tips - modifying a Drummond Tom Bartlett recalls some improvements he made to a classic lathe lathe Fireside reading Unimat III lathe accessories by Bob Loader The Murad bormilathe A keyway slotting tool John Payne describes a simply made special purpose tool

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Link up The Manson lathes of Small Machines Inc Cutting metric threads on an Atlas lathe In our next issue gear hobbing, gear shaping, varnishing brass, Warco mill safety interlock - a warning, harnessing technology, a problem solved, no courses for novice turners. Geoff Sheppard Philip Amos takes a wide ranging look at the available methods of forming joints Pater Rawlinson tells how he solved the problem introduction, timber joints, staples, drivescrews, force fits, riveting, tabs and slots, staking, spin riveting, spinning swaging, crimping, clinching, welch plugs, interleaved edges, conclusion. The first ManSon, ManSon accessories, Tony Griffiths describes some interesting small American lathes the ManSon DuoLathe circa 1948, a of post WWII era new company. Norman Hust suggests a solution to a problem encountered by metric threading chart, gear tooth form, many lathe owners new threading chart.

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On the editor's bench

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Permanent mechanical fastenings

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An aid to turning large tubes

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the essential components, the controlling electronics, the mechanical components. Bill Morris continues his description by completing the micrometer calculations, micrometer An autocollimator from the scrap box (2) manufacturing instruction for the component parts thimble, feet, mirror base, mirror holder. method two, keep a store of used Lathe projects for beginners (9) mandrel, tommy bar, the holder Harold Hall describes the completion of the tailstock die holders precision tapers mounting taper, using the holders, adjuster screws, working the screws. The editor pays a brief visit to the 8th national model More space at Harrogate engineering and modelling exhibition Sun Sea and steam Modellers holiday at primrose valley pressure pad, interference fit, increasing a diameter, use a good vice, another method, quadrant bracket, locating and Bob Loader suggests that it is worth looking at alternative ways When in doubt - fabricate locking, fabricating for convenience, of making a component some filing, a raising block for the Unimat, a drastic re-design, dowels again. A self act cross feed for an Adept hand John Crammond suggests a method of upgrading one of the modifications to castings, the new shaper simpler versions components, assembly. A brief look at the Warco 918 lathe Mike Chrisp Gear hobbing on the lathe - an easy way Eric R Rumbo has applied the technique to gear manufacture

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machining the components, imperial or John Chambers describes a lathe tool holding system which A quick-change screwcutting and boring metric increments, standard items incorporates a controlled incremental tool movement and a rapid tool post required, final assembly, tool holders, retraction feature precision drilling. John Garnish suggests an alternative solution to the problem An adapter for the rotary table addressed by David Oxley in MEW 72 an unusual vernier motor, direct current Electro-magnetic devices (9) Tony Claridge now introduces the theory of stepper motors motors. Link up In our next issue salvaging drill batteries, lathe chuck replacement, a key for the 4 jaw chuck, Scribe a line a sincere plea from a newcomer to model engineering, alternative methods, a design for a muffle furnace sought. news of events, model engineering On the editor's bench Geoff Sheppard classes. mirrors, lenses, microscopes, optical Optical instruments in the home centre punch, optical centre finder, laser Philip Amos discusses some aids to better vision workshop pointer, stroboscope, cameras, optical projector, conclusion. An autocollimator from the scrap box (3) Bill Morris concludes his description assembly, using the autocollimator. Dick Stephen suggests that there may be advantages to using Working and using exotic materials materials not usually employed The 71st model engineer exhibition the process, things which affect cutting, cutting with hand tools, lathe tools, Chips with almost everything Bob Loader discusses the forms in which swarf appears milling cutters, practical considerations, my favourite materials. The next project in Harold Hall's series involves the machining Lathe projects for beginners (10) machining cast iron, the jack, screw of a form of material not previously encountered and introduces working with cast iron cutting. cutting threads in the lathe built from stock materials, making a Raymond McMahon construct a machine on which to sharpen The Raymac cutter grinder (1) start, base plate, sliding pivot plate, pivot end mills base, channel slide, side plates. motors, motor mounting plate, belt A powered down-feed for the milling Peter Rawlinson investigates the possibility of adding a powered cover, motor cover, control system, machine quill quill to his milling machine capstan clutch unit. The philosophy of Tom Walshaw Bill Jones correspondence Link up In our next issue An intriguing mechanical device Derek Cooke describes an ingenious mechanism

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Electro-magnetic devices (10)

Tony Claridge explains more things about DC machines

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Scribe a line

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On the editor's bench Awkward drilling Model engineering courses

Geoff Sheppard Philip Amos suggests ways of getting around the problem

how the power relates to the dimensions, the basic equations of machine behaviour, motor connections, controlling speed, dc generators, some other magnetic devices. recycled rotary table another source, gear shaping, modifying a Drummond, machine tools and cars, the contribution of Messrs Urwick Radford and Cleeve, dividing on the Hobbymat MD65, screwcutting coarse threads by hand, a historic lathe, advice to a 'lone hand', Reeves 2000 - an update. the model engineer exhibition, calling North Hykeham. free space, very limited access, shoulders, small chuck, pin chuck, pin vices, drill bit extension, special cases.

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direct reading thermocouple, attachment by spot welding, tempilaq temperature Temperature measurement Dyson Watkins surveys a couple of methods indicator paints and Tempstik, infra red pyrometer. Taming spray drift Derek Brown suggests some simple methods other bits and pieces. the superfine adjuster, pivot block, The Raymac cutter grinder (2) Raymond McMahon continues his description micrometer sleeve, dovetail clamp, balance springs. end plate, bearing housing, 'align' power Fitting power drive to a Senior 'E' milling Shelly Curtis describes how he fitted a commercially available feed, limit switch, electrical, summary, machine table table power feed unit to his milling machine footnote. using the single point tool, calculating infeed, setting the tool, using chasers, taps as chasers, the common factors, Lathe projects for beginners (11) screw To complete the small screw jack Harold Hall produces a couple tumbler reverse, setting up, lathe speed, cutting of threaded items over-run groove, the half nut, thread dial indicator, cutting the thread, internal threads, imperial pitches, screw jack assembly, faceplate work. Giles Parkes decided to modify his Worden tool and cutter Updating the Worden mk 1 grinder Link up primer, how much to bend, jigs, first get Bill Morris demonstrates that it is possible to construct one such your tubing, lapping, calibrating, small On the level item with relatively little difficulty angle generator, construction, using the generator, graduations.

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We visit a master engine builder In our next issue A self-centring vice Electro-magnetic devices (11) toys for children of all ages Scribe a line On the editor's bench Limits and fits tolerances and surface finish Free-wheel hobbing a worm wheel Trade counter The Raymac cutter grinder (3)

Brian Parkins Peter Rawlinson describes a simple but useful addition to his workshop Tony Claridge concludes his series a circular linear motor, eddy current brake and induction motor rotor, another electromagnetic gun, an electromagnetic balance, the torque reaction poser. help for the newcomer, after-sales service, elevating head lathes. HSE document, what's in a name, Ron Drake steps down at Blackgates, au revoir. fits, systems, tolerances, interference fits, surface finish, conclusion. design aspects, worm and hob, wormwheel. circular dovetail, degree setting ring, collet head, spindle collet holder, cutter support, optional indexing, optional lever attachment. two wheel knurling tool, faceplate work.

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Geoff Sheppard Philip Amos describes the systems by which physical features of machined parts may be specified and how these may be related to home workshop machining You really can produce useable worm wheels without a precision hobbing machine Bill Morris tells how

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Raymond McMahon

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Harold Hall has designed this two-way knurling tool in such a Lathe projects for beginners (12) getting way that it provides a number of opportunities for face plate to grips with the faceplate work Metalwork in the middle of nowhere Trevor Marlow offers a few suggestions Controlling spray drift a postscript Len Billinge A facing and boring head Link up In our next issue Renovating a machine vice Victor Elsendoorn describes two methods Ted Wale talks us through the manufacture

function and purpose, drawings, manufacture.

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A tailstock turret

Peter Rawlinson describes a time saver

the welding process, the replacement process, surface grinding, painting, conclusion. safety first, the tool head, the smaller components, assembly, locating the tool positions, tool holders.

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Scribe a line

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On the editor's bench Laser alignment of a mill/drill head Formit a 3-in-1 sheet metal forming tool Quorn variations (1)

Dave Fenner Peter Rawlinson described an answer to a common problem Peter McQueen reviews this recent addition to the home workshop H J Cash presents some adaptations and procedures for the evergreen cutter grinder

the Drummond lathe, rotary tables yes another recycled source, when is a bargain not a bargain, a cheap aid to better vision, taps and stratagems, learning the hard way, a mysterious lack of clearances, the CES gear hobbing machine, gear hobbing in the lathe, never throw anything away. a historical reflection, attitudes to safety, it's that time again. overview, background, laser and electrics, target arrangement, parts manufacture, setup.

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setting system, cup wheel technique, operating notes, end teeth. leadscrew, backplate, slide, final Ted Wale concludes his description of the lathe accessory which machining and assembly, completing the A facing and boring head is based on a design by Edgar Westbury machining, final assembly, overall setup, conclusion. Philip Amos describes his modified version of a worthwhile introduction, design, manufacture, An improved thin piece vice accessory conclusion. how is TIG different, what are the variations, why is AC necessary for Al and Mg, what advantages does TIG offer, what sort of TIG welders are available,, first steps in technique, the Electric arc welding techniques tungsten Trevor Marlow reviews the use of TIG welding within the home importance of surface tension, fine inert gas workshop control of current, pulsed TIG welding, slope up and slope down, square wave, preflow and postflow, backfilling, using your TIG apparatus as an intense heat source. Quick tips Seasonal tip the grinding head, the spindle, pre=loading bearings, spindle pulley The Raymac cutter grinder (2) Raymond McMahon continues his description wheel, assembly, pillar and base, motor and mountings, electrics, using the Raymac. arm spacers, swivel pieces, adjuster Lathe projects for beginners (12) stud, assembly, the adjusting knob, Harold Hall completes the construction of a knurling tool knurling (really part 13) knurling the method, milling/drilling spindle.

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Trade counter

Richard and Quinton Bartlett, the midlands exhibition at Castle, plans are in progress at Hemingway overview, basic principles, switches, resistor colour code, important formulae, more on switches, micro switches, reed switches, simple switch circuits, relays, some useful relay circuits, notes for experimenters.

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Electronics in the model engineers workshop (1)

Mike Feather starts this new series

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Link up In our next issue Scribe a line Simple ideas are often the best On the editor's bench workshop tidy for short lengths of bar, a tailstock drill pad Dave Fenner changes aboard, on boilers and testing, advance notice, quick tips, on an unhappy note, society structure, and a final plea. production schedule, bearing clamp nuts, body, spindle, bearing adjuster tube. background, inspiration, basics, size and fit, fabrication, operation, conclusion. disc wheel technique, operating notes, constructional changes. how much precision, supplier details and ideal equipment, grinding parting tools.

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Lathe projects for beginners (14) mill drill Harold Hall builds on skills introduced previously spindle Suction fence (for a woodworking table saw) Repairing lathe slide nuts Quorn variations (2) In our next issue Link up Quick tips Trade counter Plate rolls and end rolls Improving the Peatol tailstock Ted Wale describes a useful accessory Don Unwin shares his experiences H J Cosh concludes his description of modifications and techniques

Cross drilling shafts Softcover International. Myford Ltd Peter Rawlinson presents a redesign Tony Jeffree describes his modifications to a well known lathe modifications, construction notes, materials. introduction, extending the lever, locking knobs, micrometer set-over adjuster, operation. theory of DC motors, power control with a variable resistor, transistor basics, controlling power and bi-polar transistors, transistor switch, FETs, SCRs, motor direction control, power supplies, power control chips, 24v 50W DC motor control using L298 chip.

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Electronics in the model engineers workshop (2)

Mike Feather leads us into aspects of DC motor control

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The Raymac cutter grinder (3)

Raymond McMahon suggests some alternative uses

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Measuring hardness

Philip Amos reviews the history methods and systems of measurement

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Scribe a line

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On the editor's bench

Dave Fenner's commentary

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Lathe projects for beginners (15) Trade counter

Completing the Milling Spindle MACOR machinable glass ceramic, record tools Ltd, Rotagrip catalogue, vehicle wiring products. A multiple toolpost approach

Tool post and cross slide drilling spindle, slotting attachment, dividing attachment, wheel dresser, cutter support finger, setting pins, setting up, centre finding, dressing the grinding wheel, sharpening cutters. Mohs scale, metals, Brinell, Scleroscope, Rockwell, Vickers diamond pyramid test, comparison of methods, other tests, methods for the home workshop, conclusion. later information on HSE publications, spray drift, elevating head lathes, what's in a name, the Griggs lathe, laser alignment, basic tools for radius turning. global warming or cooling, cold fluids I the workshop, unsung heroes REMAP, extra mural activities, broken bolt removal. collet chuck body, collet, assembly, drive arrangement, pulleys, using the spindle, materials.

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Easy changing of lathe tools.

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Give yourself the edge.

Drill sharpening methods reviewed, and an unusual technique described

background, introduction, the adopted system, indexing detent plunger, turret, allocation of tools, comment, shims, storage, conclusion.; recoverable or not?, can you re-heat treat?, which quench medium, storage discipline, coatings and carbide, various devices, refresh rather than resharpen, totally manual - by hand and by eye.

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Laser centre finder. Errors in taper turning due to incorrect tool height The 71st model engineer exhibition.

Some exhibits and results from Sandown Park rationale, general construction and application, dismantling the NM2 morticing machine, to stay or not to stay, the base, the bed, column extenders, vertical feed.

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36 38 A cabinet stand for a Myford ML7 Next issue

A low cost self build mill from stock parts

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An alternative route to success

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Electronics in the model engineer's workshop

AC. Power Control

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Grind-all A precision indicator stand Link up Scribe a line

A description of an unusual accessory Incorporating unusual feature for fine adjustment Reader's Sales and Wants Reader to reader

introduction, diode power control, safety considerations, SCR (thyristor) power control, controlling AC power with triacs, rate effects and RFI, opto-isolated triac switching, techniques for varying AC power burst fire control, phase trigger control, making printed circuit boards. introduction, construction, operation, amateur considerations. general arrangement, locking spindles, base and column, blocks, differential screw, rod carrier and attachments. more switching considerations, metalwork in the middle of a colliery, keeping your cool, workshop H&S. small scale train spotting, model rail Scotland 2002, back in the workshop, Myford ML7 review, readers response quick tips, corrections, issue 77 self centring vice, issue 80 measuring hardness, forward planning, MEW index. vertical feed, X/Y table feeds, column bushes, spindle and bearing, operating the mill. background, safety, construction, welding, operation. background, manufacture, operation. taper and chuck body, collet closing ring.

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On the editors bench

Dave Fenner's commentary

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Compumill. Grinding on a shaper Traverse stops Lathe projects for the beginner (16) Trade counter Reader Visit Variable frequency inverters Quick quill stop

Concluding the low cost self build machine An attachment to give basic surface grinding on a shaper Accessories for a rotary table Getting started on a milling chuck Trycut and Testfoam, MEW index, white metal, Warco, Chronos. We visit the workshop of a motorsport enthusiast One reader offers his experience A time saving accessory for the mill

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Screw threads are not just for fastening

An overview of types and applications

now the bad news, wiring a motor in Delta, speed control, about the waveform, switching speed and noise, cooling, circuits. introduction, manufacture. a useful reference book, square, cutting square threads, Acme, cutting Acme threads, Buttress, round or button, vee threads for measuring and moving, cutting vee threads, measuring threads, multi-start threads.

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Easychange quadrant arm

Take the pain out of changewheel changing

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Secrets of successful coil winding

The essence of miniature magnetos

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A winch from scrap material

Heavy lifting made easy

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Electronics in the model engineer's workshop (4)

Bench power supplies

introduction, background and description, construction, quadrant arm preparation, quadrant arm - milling the slots, quadrant arm - milling the edges, boss, stud assembly, stud retaining clip, completion, reference. introduction, initial trials (and tribulations), theory on primary wire size, solving the secondary, coil winder considerations, operation and tension control, interleaving and insulation aspects. introduction, kilograms, watts and all that, construction notes, the control unit, cautionary notes. introduction, the basic requirements of a power supply, fixed voltage regulators, fixed voltage three terminal regulators, variable voltage three terminal regulators, switch mode power supplies, project: a versatile bench power supply. the alternative designs for rolls, more information on the L298 chip, comments on exhibition categories, electromagnetic effects and old gramophone records. a cautionary tale, technology marching ever forward, nostalgia near Nevis. introduction, basic information, toolpost holders, basic system, the grinding fixture, references.

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Link up

Reader's sales and wants

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Scribe a line

Reader to reader

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On the Editor's bench A grinding fixture

Dave Fenner's commentary To give accurate lathe tool angles

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Musing about stainless steels

Metallurgy for the layman

a fascinating material, so: why doesn't it rust?, what are the "alternative, largely forgotten hypothesis" for stainlessness?, is "stainlessness" special to these "chromium in iron" alloys?, when is it stainless? When is it not?, carbon the cause of generations of problems, why there is more than one kind of stainless, five primary categories? what are those categories?, what is "Ferritic stainless"?, what is "Martensitic stainless"?, what is "Austenitic stainless"?, what is "Duplex stainless"?, what is "precipitation hardening stainless"?, these identities, ferritic, austenitic and so on: what do they come from?, this ferritic structure can I visualise it?, what about the austenitic structure can I visualise that?, what about the martensitic structure can I visualise that?, can I visualise the precipitation hardening structure?

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Quick tip Trade counter Next issue Lathe projects for beginners (17)

An alternative use for a calculator New items from suppliers collets, holders, collet locating peg, "C" spanner, the completed kit, put to the test. spindle speed, increasing cutting speed, speed reduction, reduction gearbox description and operation, making the epicyclic reduction gear, the upper assembly, the lower assembly, final assembly. introduction, description, some general advice, manufacturing notes, operation. introduction, design, construction, conclusion. a second project, a third project, conclusion, footnotes.

Completing the Milling chuck

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Developing the Compumill theme

Adding a speed reduction gearbox

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MEW index A hand pipe bender Another finger plate Link up Plastic storage crates in the workshop

The index for Issues 69 to 80 to remove or copy To produce neat bends and continuous coils A useful workholding device for small parts Reader's Sales and Wants More items in less space courtesy of the supermarket

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Electronics in the model engineer's workshop (5)

Servo and Stepper Systems

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Scribe a line

Reader to Reader

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On the editor's bench

Dave Fenner's commentary

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Milling projects for beginners (1)

Getting started in milling

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Nickel plating

For dimensional recovery and appearance

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Taming a wandering head Link up Next issue

A modification for a mill/drill Reader's sales and wants

clarification, servomotors and stepper motors, analogue proportional control, digital proportional control, other servomotor circuits, stepper motors, variable reluctance stepper motors, permanent magnet stepper motors, unipolar stepper motors, bipolar stepper motors, identifying motor types, stepper motor drive circuits, generating the phase sequence, load current regulation, a practical 4-phase unipolar motor drive circuit. suction fences and vacuum cleaners, an electronic query, information wanted, coolant comment, a threadform query, toolposts, fingers and elastoplasts, an interference (won't) fit, elevating head lathes and other queried oddities, choosing a lathe. on exhibitions past, and yet to come, retirement homes and workshops, more extra mural activities. milling cutter chuck, milling vice, milling cutters, measuring equipment remaining essential items, tee-nuts, making the tee nuts, up and down milling, machine speed, machining commences, words of warning, finishing off, screws, studs and washers. background, the DIY kit, the tanks, the power supply, plating the parts, conclusion. introduction, deficiencies, solutions, design, manufacture, flexibility, conclusion.

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Musing about stainless

Metallurgical oddities

how can I tell one piece of stainless from another, stabilised, are you sure, a valuable material at high temperature and a pitfall, rubbed up the wrong way, it came apart in my hand, how do I examine my stainless steel to see if I have SCC problems, straight out of the stores .. straight into the skip, how do I examine my stainless to see if I have these pitting problems, how do I avoid pitting on cherished surfaces, strange failure of threaded components, you mentioned magnets. What are the magnets for, tube wall defects, it shouldn't be stainless but it is, brushes with disaster, finish that fillet. Close that crevice, smutty talk, it seems now not to be as springy as I seem to remember, things that go bump in the night, trouble down below, and in closing. carriages, design layouts, making the inserts, in use, conclusion. introduction, machining the castings, about the assembly of the vertical slide, the end result. assembling parts using screws, surface plate substitute. having fun, principles, parameters, plunger, anvil, body, cap, springs and things, a post script.

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Lurking under the editor's bench A grinding fixture A vertical swivelling slide Quick tips Hahn and Kolb gap gauge Workshop equipment at Harrogate Trade counter

Useful tools or just rusty metal? Correctly ground lathe tools made easy Machined from castings

Teutonic intricacy A visit to the exhibition in Yorkshire New items from suppliers

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Reader to reader

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On the editor's bench Dividing on the Myford Super Seven 7 (1)

Dave Fenner John Britain offers two solutions to headstock dividing

a spark of interest, spurred into action and repair, more repairs, sharpening small drills, metal hardness, free for uplift, pyramid versus pinch rolls, what is it. location, and back to the workshop, Donnington exhibition, a return to normal. Bullwheel dividing, and on to other numbers, notes for beginners.

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Milling for beginners (2) an angle plate

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Drummond half nut replacement The Chester craftsman lathe

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A hydraulic addition to a toggle press

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Developing the Compumill theme (2)

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A small roller box Variable ratio rack and pinion steering Collet chuck for the Myford lathe Mill head repositioning Link up In our next issue A tale of two read-outs (1) DRO Raymac cutter grinder update

introduction, cylindrical square, first face, rough and finish machining, second Harold Hall describes the stages involved in machining an angle face, ends, edges, finish machining, end plate mill versus face cutters, finishing touches. Mr H McNair describes his technique for revitalising an older overview, manufacturing operations. machine delivery, assembly and installation, more Mike Haughton describes his purchase on installation, testing and use, later additions, minor gripes. first a toggle press, then the need for Forced with a pressing need for more force John Crammond more grunt, and an instant two ton found the answer in simple hydraulics upgrade. introduction, the fastest options for 1/8 shank cutters (up to 32000), a note on bonding, the fast option for 1/4 6mm shank cutters (up to 22000), the epicyclic gearbox option used as a Richard Bartlett introduces options for high cutter speeds speed multiplier 4:1, components suitable for light milling or engraving required for speed step up conversion (assuming 12mm to 15mm mod on input shaft is done), change speed in fast mode, inverting the gearbox to change from multiplier to reducer, note, final points. Peter Rawlinson borrows from industry practice ideal for turning a small scale design, operating notes, long slender components construction notes. Philip Amos sheds light on an apparently simple yet deceptively Bishop concept, helical gears, complex mechanism manufacture, conclusion. Dyson Watkins presents a design to enhance milling operations body, collet holder, cone centre, final using commercially available collets assembly. Harry J Cosh suggests a straightforward method and adds a method, hand wheel modification, handwheel modification experiments with lasers.

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Trade counter

Barry Harrison talks us through the process of selection fitting decision process, fitting arrangements, and using industrial level equipment and then on to the lathe. Raymond McMahon describes a modification to his cutter grinder Combined Tilgear catalogue, Myford spares support, and another step forward in hot melt adhesives, plastic gears small motors and more, workshop comfort, take a closer look at magnifiers on the lathe, starter kits from Minicraft, recent developments from Softcover International, new catalogue from Pico, new owner from Woking Precision.

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Scribe a line Quick tips On the Editor's Bench Machining Morse taper adapters Dave Fenner's commentary

vacuum suction, the way it used to be, a mill/drill mod, some sort of clamp, on storage and moveable machinery, advice sought on gas firing. international boat show, variable speed drives, in the workshop, DRO developments, out and about. the clamp bars, Tee nuts and other uses, secure clamping, parallels, parallel how.

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Milling Projects for beginners (3) Link Up Motor speed control Simple tools simple methods

Clamp bars and parallels Readers sales and wants The humble washing machine is a ready source of useful parts Chisels and saws

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A tale of two readouts (2) Next Issue Retrofitting ballscrews to a Wabeco mill

Operation and advantages of DRO systems

chisels, safety considerations when using a chisel, saws, hacksaw, junior saw, coping saw, short cuts. minor limitations, initial effects, absolute or incremental, and so to lathe, other benefits, which way to look. background, the alternatives and options, nut brackets, adapting the ball screws, alignment and backlash, conclusion. background, first considerations, parting off tools, tool positioning, tool shaping, trial, conclusion, appendix - chattering. the dead centre, method of operation, vibration, lubrication, end plunge grinding. die holder, retaining cap, morse taper shank, sliding tube, key, spring plungers, assembly and use. the human limitation, the two handed solution, backplate, arm, bolts, machining the angle holes, operation. the collection, applications, not a chuck but still useful. use of the vertical adjuster, eliminate backlash and endfloat in the Z-axis, use of counterbalance for the vertical head, fit a linear positional indicator to the Zaxis.

A straightforward improvement to accuracy and longevity

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Parting off on the Quorn

Blade geometry and how to obtain it

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Rotary grinding

A simple and easily made accessory

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Tailstock floating dieholder

Accurate threads on inaccurate lathes

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Angle milling fixture Chucks how many?

A useful set up aid A collection described

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Enhancements to Compumill (3)

Downfeed refinement and low cost DRO

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Rodent rules A brief note on steel specifications An outline for beginners An outline for beginners

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Scribe a line Model Engineer Exhibition 2002 On the editor's bench

Reader to reader Entry form and notes Dave Fenner

the mouse PCB, the optical switches, example as an angular encoder, making slotted disks, using a mechanical saw. the 1983 system, steels for the amateur workshop. hardness tester, what is it - the answer, milling advice, and continuing on coolant, retirement complexes and workshops. gripes at officialdom, drawings standards and attitude, wrong method right result, the model engineer exhibition, and finally. material, production planning, the boring head, the turned items, final assembly. first impressions, getting to grips, up and running, dimensional checks, conclusions, footnote. millenicuts, using the files, draw filing, getting things square, breaking up a surface, slots, using a fence, holding awkward shapes, things to remember. material and facilities, method, turning, milling, conclusion. design, fabrication, use, detail, sequence, conclusion and caution. cutter grinding details, the grinding unit, using the grinding unit.

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Milling projects for beginners (4) The BH600-G the little big lathe from Warco Simple tools simple methods or hand tools for beginners (2) A filing rest in a hurry from scrap A milling machine extension A gantry crane An engraver cutter grinder Link up In our next issue Enhancements to Compumill - budget DRO A tale of two read outs (3)

Harold Hall describes construction of a precision boring head Raymond McMahon

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Bob Loader continues his examination of basic techniques by considering the humble file Dave Fenner makes more swarf Adrian Kruger describes his solution to machine stretching Philip Amos offers a moving and handling solution for those involved in heavyweight projects Doug Ball examines the geometry of engraving cutters and offers an accessory for sharpening them

Richard Bartlett considers design solutions to the linear to angular translation Barry Harrison concludes his arrangements for fitting DRO scales to his Myford Super Seven 7 DIY waterslide transfers, part off par excellence, and from engine wise, Badger range three airbrush kits, new machine mart catalogue, air dusters from Kenro, Chronos new catalogues. Dave Fenner

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frictional translator, rack and pinion translator, calibration, helical translator, testing the units in X Y Z configuration, making a very simple linear DRO. the components, assembly to the lathe, conclusion.

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Trade counter

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Two days in the life of an editor

the midlands model engineering exhibition, a morning at Myford.

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On the Editor's bench

Dave Fenner

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Gearcutting some trials and tribulations Link up

Brian Perkins offers the benefits of his experience

large scale quick fix, confusing to the enemy, still in business, gas firing, galling avoidance, screwcutting stop and spline technique, caveat factotum, explosive remedy, belt changing aid. an apology, ME exhibition Sandown park, motor speed control, real world engineering, in the workshop. a source of advice, calculations, cutting teeth, the Hydra and it's problems, the penny drops.

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search engines, refining the search, Getting engineering information from the advanced search logic, links (hyperlink), Mike Haughton uses the internet as a free source of information internet webcrawlers, email, groups, auction sites. Useful workshop tools by Stan Bray, Unimat III lathe Fireside reading accessories Bob Loader Peter Rawlinson describes a simple accessory to facilitate A spring pump centre manufacture, operation. tapping in the lathe and reduces tap breakage construction, tailstock modification, Modification to a Unimat tailstock M Rhodes describes a lever locking arrangement assembly. Trade counter manufacture, turned items, assembly, Milling projects for beginners (5) Harold Hall describes a dividing head and next. Dick Stephen describes how he enhanced his Wabeco CNC mill so why change anything, hardware and Adding CNC to your milling machine (1) with driver and software changes software. Quick tips design, machine tools and achievable Tool height gauge Philip Amos offers a simple design for lathe tool height setting accuracy, manufacture, checking, conclusion. integrated approach, motor types and Vasilii Zakharov expands on his previous article MEW 86 and safety notes, the Hotpoint option, More information on motor speed control considers Hotpoint equipment selecting parts, concluding safety observations. wobblestick, indicator, deep holes, making a reamer, other tribulations, The Mikrokinescope Mick Collins builds an alternative to a DTI plunger rod, base fulcrum, scale, plunger limit stops, and then to the sticky part, final setting. A simple roller screw drive John Jardine outlines a cut price alternative to ballscrews concept and construction, setting. Improvements to the Warco BH600-G concept, fitting, visor modifications, Ray McMahon suggests an improvement to provide a clutch lathe conclusion. The 72nd model engineer exhibition at Sandown Park

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Scribe a line On the Editor's Bench Shim Tool Model Rail Scotland Milling Projects for Beginners (6) Workbench Additions (1) Link Up A Review of Threaded Fasteners and locking methods On Round Belts and Shelving Trade Counter Reader Survey Scan2Cad Next Issue Adding CNC to your milling Machine (2) Putting it together and making it work Dave Fenner's commentary How to make neat holes in thin metal A grinding rest A variety of accessories for woodworking convenience Readers' sales and wants

screw threads, bevel gears, motor failure. REMAP at Sandown, tales from the shop floor, in the workshop briefly, reader survey and trends. background, punches, the die and punch guide, heat treatment, the die. manufacture, assembly. wobble saw, saw flip stop, router handle, router adapter, first experiences.

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configurations, externally threaded components, head recesses, setscrews, An in-depth look at heads, threads, nuts, and locking techniques studs, nuts, lock washers, locking methods, conclusion. background, method, simple metal Technique for joining round polyurethane belts shelving. New items from suppliers To help us learn more about you, the readers, and cater accordingly rasters and vectors, converting raster to First hand experience of using this raster to vector software vector, working with text. getting it all together, connecting up the Gecko drive units, the software, CNC Pro programming. outline, background, new design, rotary table, construction using Corian, workpiece mounting, golden section, summary. workshop practice series 33. small is beautiful, delicate butchery, trying it out, a specific application: rotary indexer for lathe spindle, a short diversion, making the encoder disc, note on accuracy of the original mouse injection mouldings, assembly. the alternatives, slot cutting, shouldn't work but does. background, construction, finish, in use.

89 89

43 45

A New Design of Oval Chuck Fireside Reading

A method for machining ellipses making clocks

89

46

Rodent Rules

Mouse electronics applied to rotary division

89 89

50 52

Four Jaw Chuck Repair A Handy Indicator Mounting

A practical alternative method An up, up, and away DTI - Myford Super Seven 7

89

54

Scribe A Line

90

11

On the Editor's Bench

Dave Fenner's commentary

90 90 90 90 90 90

12 17 18 20 25 25

Milling Projects for Beginners (7) Internal Boring Bar A Magnetic Picker Upper Fitting Slip Dials to a Mill/Drill Link Up Next Issue

Accessories to enhance the versatility of the grinding rest Easily made with replaceable tips A cleaner, easier way to lift ferrous swarf and filings A straightforward improvement to save time and frustration Readers' sales and wants

suppliers, Warco BH600, gas burners, drawing standards, motor speed control, Granville lathes, hand tools. learning something new every day, a correction, miniaturisation taken to extremes, free service from SAGA, engineering at the college of North West London, bikes at Ingliston. the accessories, important safety requirements. tool holder, tool tip. description, design considerations. assessment, design, detail, down feed, conclusion.

90

26

Workbench Additions (2)

Woodworking aids and accessories

bench clamps, Elektra Beckum saw adaption, dust suction connector, height setting gauge, hold fast bosses, acrylic infill discs, tenon cutter guide, standardisation of Tee slots, band saw, sander, table saw, new saw fence, featherboard adapter.

90

30

Oxyacetylene Welding (1)

Maybe out of favour for industrial production, but versatile, and available for the amateur

why oxyacetylene, is the welding of thin steels difficult with oxyacetylene, when to gas weld and when not to gas weld, and what about brazing, rusted solid, making the most of what we've got, will it work in a field, best for big jobs or small jobs, a cut above the rest, minimising the costs of processing the oxyacetylene capability, hazards in using oxyacetylene welding/brazing apparatus, lighting up time, but there is a minor problem, easy exercises to develop your welding skills, what about the thicker stuff, and the really thin stuff, filler techniques for steels, some things are easy some things are not, identification of the parent materials as the basis for selection of fillers and fluxes, to flux or not to flux that is the question, cleanliness is next to godliness, brazing and the oxyfuel torch .. a marriage made in heaven, a few cutting remarks, destruction and distress, cutting to a pattern, keep in mind that .., so the conclusion at the end of the day is. the Sparey dividing device, the Radford approach, modifications. marriage of duplex to Quorn, jig for fourfacet drill grinding, the sharpening process, construction, offset squares, chuck adapter. base plate and block assembly, Lammas style toolposts, larger tools and parting tools, tool height gauge, other accessories. parting tool techniques, screw thread and helix angle, drawings standards and attitude, the internet, electric shock, drill sharpening, life with a small lathe. in the workshop, future project.

90 90 90

36 40 41

Dividing on the Myford Super Seven 7 (2) Trade Counter Drill grinding with the Quorn

Additional methods, equipment, and improvements outlined New items from suppliers Several attachments and systems considered

90

48

Some Thoughts on Quick Change Tooling

which have evolved over many years in the workshop

90 91

54 11

Scribe a line On the Editor's Bench

Reader to reader Dave Fenner's commentary

91 91 91 91

12 14 15 20

A New Approach to Making Form Relieved Gear Cutters Link Up Milling Projects for Beginners (8) A Smelting and Heat Treatment Furnace

Cutter tooth relief without complex accessories Readers' sales and wants Details of an end mill sharpening fixture Not to be confused with underfloor heating, this design puts serious foundry capacity in the garage

background, materials and concept, manufacture,.

91

24

Friction

A review of theory, use, and avoidance

fuel choice, site safety, pit construction, the furnace, control system, thermocouples, operation. background, general theory, detail considerations, belt friction, machine controls, balls and rollers, lubrication, bearing lubrication, air lubrication, extreme load bearings, friction modifiers, conclusions. why conquest, what's in a name, so what needs improving, top slide who needs it, the versatile tool post, no free lunch, a leadscrew handwheel, declutching the leadscrew, disengagement gear, in use, unexpected bonus, parting thoughts, future development, contact. more thoughts about flames, different flames from different mixtures, flame stability and gas pressure, an attack of the bends, filler, fluxes and solders, which flux, brazing downsides, cutting out the problems, other benefits, all major credit cards accepted.

91

30

Next issue

91

31

Improving the Conquest

Enhancements to a budget lathe

91

38

Oxyacetylene Welding (2)

A deeper examination of a number of topics

91 91 91

42 43 44

Trade Counter Fireside Reading A Cabinet for a Small Lathe

New items from suppliers The Taig Lathe Simply made, giving storage for tools and other items. Unimat 3. the materials, the Unimat comes home, the framework, drawers, drawer fronts. construction, the bed, the slide, dividing head, the cutting head, pulley, tensioning spring, general notes, additional parts. sharpening end mills, cutting an ellipse, joining belts, CADintosh, Star lathe, tool hardening, Douglas Diffra steering gear.

91

47

Dux Wheel Engine

A gearcutting device for clock making enthusiasts

91

54

Scribe a line

Reader to reader

92

11

On the Editor's Bench

Dave Fenner's commentary

92

12

Milling Projects for Beginners (9)

Using the grinding rest and end mill sharpening fixture

92

15

Table Router Height Adjuster

Accurate height control for woodworking

Harrogate exhibition, a day out for two wheel enthusiasts, remap yearbook 2003, dates for your diary, link up. setting the angles, sharpening end mills and slot drills end teeth, helical cutter edges, an aside on technique, centre punch, other uses, safety, postscript re screws, studs and washers, conclusion. before you start, work on the router, modifying the table saw, mounting plate and support rings, mounting bar, sliding assembly components, toothed belt system, assembly. finning, piston rings, valves and guides, cams, serrations and splines, bits and pieces. operation, the building process. background, limitation, solution, operation. lateral thinking, measurement, action, trials, result, conclusion. versatility, precision, operating modes, features, the future. background, initial efforts and frustration, mark 2 injector and heated block, additional equipment, multi-size clamp, preheating device, mould design, mould material, runners and gates, internal diameters of finished components, draft, air release, design and machining, materials/temperature, tolerance/shrinkage, ball end cutters, sources of raw material, heating/temperature control, examples, health and safety, improvements. design, material, stress relief, machining, heat treatment and grinding, rollers, jig bored version, operation. commercial equipment, in search of improvement, operation. modification procedure, the future.

92 92 92 92 92 92

15 20 24 28 29 30

Next issue More Trials and Tribulations Universal Cutter Grinder (1) The "Piddington" Toolholder Correcting a Leaning Tower Divisionmaster Reviewed A techniques masterclass Built without castings Now available commercially No not Pisa, but improving mill/drill vertical An easy answer to accurate indexing

92

32

Plastic Injection Moulding for the Amateur Workshop

A practical approach to making plastic parts

92 92 92 92

38 42 44 46

Toolmakers Sine Bars Cutting Sheet Modification of Black and Decker Wood Turning Lathe Harrogate 10th Anniversary

Make easy work of accurate angles Vertical milling attachment used horizontally Adapted to operate without the power drill Workshop equipment exhibits reviewed

92 92 92 92

50 51 52 52

My Friends the Little Men Trade Counter Modifications to a Clarke Bench Drill Link Up

Unseen workshop assistants New items from suppliers Enables light milling and improves Readers' sales and wants

specific examples, and they say the camera never lies. construction, in use. helix angle, Warco BH-600, CL300M lathe, gas welding, internet, CAD packages, hacksaw castings, print screen key, oval pan head, Twin vertical miller. training at SMEE, and at Dudley college, back in the workshop, reader survey, model engineer exhibition 2003. function, heath and safety, equipment needed, a master cube, preparing the grinder, 1-2-3 blocks and Vee blocks, a two inch sine bar, and then to the Grindex, method of operation as follows: background, construction, experience so far. background, wiring diagrams, schematics, design method, diagrams compared, diag 5 features, fail safe, fuse protection, switching in the neutral supply line, essential interlocking, layout of operator controls, good circuit design, golden rule, connection overloads, an insight only, auto control, no volt release, overload reset, the use of electronics. the slide, the frame assembly, the motor support, adjustable tooth rest, electrical circuit, safety, conclusion. what do you get, what do you not get, setting up, the lathe, turning work held in the chuck, screwcutting, good points, and not so good points, conclusions. screwdrivers, handles for files, punches, clamps, tap wrenches, squares, some extra for the lathe, tool holders for throw away tips, an improved boring tool, a crutch centre, a chip guard, a better face plate.

92

53

Scribe a line

Reader to reader

93

11

On the Editor's Bench

Dave Fenner's commentary

93

12

The Grindex

A DIY version of an grinding accessory well known to toolmakers

93

19

Adaptor for Vertex HV6 Rotary Table

To achieve repeatable concentricity

93

20

Circuit Design

Explanation of diagrams and guidance on machine electrical diagrams

93

26

Universal Cutter Grinder (2)

No castings, just stock materials

93

32

A Beginner's Lathe?

Initial experiences with a Warco Mini

93

36

Simply Made but Useful Tools

Quality tooling without the expense

93 93 93 93 93 93

42 45 45 46 48 49

Reader Visit Trade Counter Fireside reading Revolving Spindle Polishing for the Amateur workshop Next Issue A Co-ordinate Table for the Milling Machine

workshop and machinery, completed projects, special tooling, lathe We visit the workshop of a modelmaker and motorcycle restorer accessories, making life easier, current project, a policeman's lot New items from suppliers Metalwork Tools and Techniques Stan Bray purpose, technique, safety, process, the Improving fit and finish wheels in order, bar form compounds, and calico mops. A straightforward aid to positioning drilling construction, summary. aid to aligning vice on miller, friction, oxy-acetylene welding, washing machine motors, Chester Conquest lathe, form tools, cleanliness, taper roller bearing. reader survey, another machine in the workshop, thunder in the glens, model engineer exhibition. main fabrication, bushes, spindle, pipe vice clamp, bracket. leading edge to cutting edge, birth of the super seven, super seven plus and connoisseur. decision time, colour, spindle nose adaptor, cabinet, electronic variable speed inverter housing, larger capacity headstock, drive motor and controls, long cross slide, tailstock, standard equipment supplied with the lathe, the oil gun, use and impression. rationale, design considerations, grinder spindle, mounting the grinder, inner and outer flanges, the wheels, mounting the wheels, mounting the grinder, direction of rotation, mounting the rest, guarding, using the set up. remedy, comment. background, construction, operation.

93

50

Scribe a line

Reader to reader

93 94 94 94

54 11 12 19

Model Engineer Exhibition Entry Form On the Editor's Bench Dave Fenner's commentary

Construction of a Pipe Bending Machine Based on industrial technique (1) The Seven Dynasty Myford Super Seven 7 a historical note

94

20

The Connoisseur Lathe

Latest incarnation of the Super Seven reviewed

94

26

A Tool and Cutter Grinding Head

Easy conversion for high precision

94 94 94

32 32 33

Modification to a Mill/Drill Link Up A Quiet Lathe

To avoid quill jamming Readers' sales and wants Revised fine feed drive

94

34

Washer Tool

Punching from sheet rather than parting off

94

37

Ornamental turning for model engineers The horizontal cutting frame described

94 94 94 94 94 94

40 42 42 44 47 48

Keeping Rust at Bay Trepanning in the lathe Next Issue Bristol Exhibition 2003 Trade Counter A Poor Man's Bandsaw

Switch on to corrosion protection Bigger holes less swarf

background, washer tool, making the tool, making the washers, fly press, die manufacture, making split dies, cutting clearance, conclusion. history and background, the horizontal cutting frame, square shank and sector plate, frame, cutting spindles, pulley system, eccentric chuck. the heater, the control electronics, the power supply, heater circuit description. background, existing tooling and a modification, initial experience, further thoughts.

Workshop equipment reviewed New items from suppliers No power, just elbow grease and a delicate touch background, serendipity strikes, design and manufacture, in use. injection moulding, CAD, vertical alignment, patents, vertical milling machines, friction, oval chuck, microscope making, Newall DRO, furnace.

94

50

Scribe a line

Reader to reader

94 94 95 95 95

53 54 11 12 14

A Note on Dog Clutches Model Engineer Exhibition Entry Form On the Editor's Bench

Odd numbers for easy machining a local commendation, MEW index, other reading, the model engineer exhibition, sad news from Australia. why so few, doing it your way, appropriate finish. the new control board, the deskCNC software. protracted evolution, the work head casting, the change gear quadrant, the mandrel, vertical slide and various parts, operation and set-up. new depth stop, longitudinal stop, subsequent variations, conclusion. unpacking, bench test, bolting on, controls, spindle speeds/inverter flexibility, permutations and combinations, preparatory paperwork, cutting material, use of clutch, overall, it sells itself.

Dave Fenner's commentary

Judging Tools and Workshop It's not all down to spit and polish Appliances Desk CNC - a Windows based controller Recent advances in hands off machining for CNC A Hobbing Attachment for the Lathe Accurate gears made easy A straightforward upgrade to improve convenience and repeatability

95

16

95

20

Travel Stops for a Drill/Mill

95

24

Newton Tesla CL750 Inverter Drive Review

Latest vari-speed drive put through its paces

95

26

Construction of a Pipe Bending Machine Using both external and internal constraint (2)

barslides, headstock and tailstock, assembly of bars headstock and tailstock, headstock sleeve, bending spindle, pipe vices, finishing and painting, tooling, support pads, vice jaws, bullet head arbors, formers, grooves, bending operations, conversion to opposite mode, conclusion.

95 95 95

33 37 38

M. E. W. Index Trade Counter Mk. 3 Wire Eroder (1)

Index for issues 81 to 92 to remove or copy New items from suppliers From holes to profiling history and background, technology and design, sourcing wire, two spool arrangement, transmission evolution, keyway and distortion. a quick recap, omissions, screw cutting filling in the blanks, operation experience, cross slide adjustment, forward/reverse selector, chuck backplate threads, thread indicator and cleaning personal protection, tailstock adjustment, accessories added to the lathe, adaptors, keyless chuck, milling collet chuck, screwed shank tooling, ball turning attachment, conclusions.

95

42

Chester Craftsman Lathe - a Progress Report

Further experience on this popular machine

95 95 95

47 47 48

Link Up Next Issue The Midlands Model Engineering Exhibition

Readers' sales and wants An overview of some workshop related items MEW index, Tiplap boring tool grinder, gear cutters, removing taper, blueing steel, CL300MM electronics, cutting long threads, micrometer bed stop, injection moulding, latex gloves, anti-scale paint. in the workshop, added website facility, training courses at SMEE model engineer exhibition.

95

50

Scribe a line

Reader to reader

95 96

54 11

Model Engineer Exhibition Entry Form On the Editor's Bench Dave Fenner's commentary

96

12

Project for the Shaper

Cutting metal and keeping fit

96

18

Surface Mount Soldering

Technique for miniature electronics

96

22

Mk3 Wire Eroder (2)

Mechanical construction

shapers, adjustable angle plate, tooling and accessories, manufacture, clapper box, machining the edges, machining the bosses, finish machining, boring the bosses, other shaper applications, shaper in the workshop. types of component, resistors and capacitors, semiconductors (transistors and integrated circuits), vision, manipulation aids, actually doing it, an alternative technique for the desperately small stuff, soldering a complete board and dealing with small leg spacing, desoldering components, antistatic precautions, health and safety. a brief aside on the avoidance of scrap, choice of material, Y and Z axis motion parts, spools, spool carriers, main framework and gearbox, forward and reverse pulley. modification, new parts, operation. Gerald Wingrove blue sky brainstorming, further evolution. overall design, construction, closing words. professional approach, woodworking alternative, experience of use, metalwork application. raison d'tre, design and construction, electrics and filtration. relax, searching services, too many hits - try images or groups, other search engines, engines, directories, and metacrawlers, payment for listings and visits, why can't I find it on the web, copyright, online auctions, web favourites, conclusions.

96 96 96 96 96 96 96

28 29 29 30 32 35 36

Drawbar and Extractor for the Warco Mini Mill/Drill Trade Counter Fireside Reading Half nut quick release mechanism for Myford A CNC Wheel Cutting Engine Gluefilm Blastbox

to do away with the mallet New items from suppliers The complete car modeller A redesigned autofeed trip Clock wheel teeth made easy An alternative workholding solution Easily constructed for grit blasting

96

38

A further helping of Getting Engineering Sound advice for better search targeting Information from The Internet

96

41

Next Issue

96 96

42 46

A Set of Steadies for a Logan Lathe The 73rd Model Engineer Exhibition

Replacing lost accessories A brief look at workshop equipment

background, general considerations, the fixed steadies, assembling and welding, the travelling steady. motor source and modification, bronze bush, mounting plate, mounting spacers, motor unit mounting bushes, modification to the Hobbymat KT leadscrew, the shaft and nut, the clutch, the clutch activating fork, assembly, electrical connections. Newall DRO, sine bars, patents, DRO, long threads, removing taper, quiet lathe, Orac CNC lathe, mill/drill lower slide cover, CL300M electrics, knurling. on the grapevine, development in progress, out and about, course and club at south Kent college. the machine, the accessories, initial setting up, the drilling operation, safe working, speed selection, hole size accuracy the projects, tapping guide, screw holding fixture. precision reproducibility and accuracy, the injured veteran, mature and experienced, the novice, are the measuring surfaces flat, are the measuring surfaces parallel, calibration of the micrometer screw. background, steel blocks, cross bar, assembly. the supplier, the instruction sheet, does it sharpen perfectly, why can't I get it exactly right, how does it work, how much clearance, choosing an abrasive, making your own wishbone, adjustments, and finally should faults and failures happen.

96

48

Table Drive for a Small Mill

Low cost approach to autofeed

96

51

Scribe a line

Reader to reader

97

11

On the Editor's Bench

Dave Fenner's commentary

97

12

Drilling Projects (1)

A tapping guide and screw fixture

97

16

How's Mike

Assessing the accuracy of micrometers

97

20

Improved Access to the Minicraft MB850 A simple modification for enhanced convenience Lathe

97

22

Musing about ... the Wishbone

and a DIY version to sharpen small drills

97 97 97

27 27 28

Link Up Next Issue Mk. 3 Wire Eroder (3)

Readers' sales and wants principle of vertical movement, gears and pulleys, clutches and brakes, small parts, tank.

Completing the mechanical construction

97 97 97

34 39 40

Keyway cutter (1) Trade Counter Fireside Reading

Go easier on your lathe with this device for internal keyways New items from suppliers lathe work a complete course, atmospheric forge and heat treat oven

background, consideration of broaches, back to single tooth, arbor, driver, cage, angular orientation, tongue and screw.

97

41

Going Round The (South) Bend

and a quick change tool system

97 97 97

48 51 52

The Chester 626 Turret Mill Bench Project Engraving Roman Numerals

Assembly and first impressions Taking a lesson from industry Using home-made copy

97

54

Scribe a line

Reader to reader

98

11

On the Editor's Bench

Dave Fenner's commentary

98

12

Machine Tool Building Using Epoxy Resins

Restoring accuracy and lost metal

98 98 98 98

16 21 22 23

Drilling Projects (2) Improving a Le Count Mandrel Next Issue Keyway cutter (2)

Making sash clamps Revised version for improved grip

design and performance requirements, tool holding system, toolbit regrinding, setting for screwcutting, rigidity of the toolbit, accommodation for a range of rake angles, some remarks of cutting process, the drawings, fabrication, assembly of a toolblock, assembly of the toolpost, set-up for cylindrical turning, tool grinding, the toolpost in use, conclusion. background, delivery, installation, imperfections, experience to date. problem and solution, description. background, the project in hand, geometry, method, unforeseen problems, other application. knurling, releasing a taper, travel stops, chuck removal, floor crane, mini lathes, manual vs. CNC, dragons blood, shell milling cutter. is life too short, articles by Philip Amos, out and about, a tale of two taps, just rewards. historical perspective, friction and damping, low friction plastic for sliding purposes, plastic resins for location, uses in model engineering, lathes, milling machines, summary. manufacture, assembly and fitting, jaw assemblies. reworking, concept, manufacture, conclusion. ratchet, pawls, blade, main body, adapters, power driving worm and wormwheels, next steps. background, which machine, the machine in pieces, delivery, small mod and little niggles, overall.

Self feed device for internal keyways

98

28

The X-3 Milling Machine

First impressions

98

30

Mk3 Wire Eroder (4)

Electronic controls

98 98 98

35 38 40

Accessories for a Centec Enhancing the Peatol/Taig Toolpost

DTI holder and work stop Examination of two commercial items from America

Ornamental hulling for Model Engineers The Eccentric Chuck (2) A Simple Prismatic Centre Finding Microscope Trade Counter Improve accuracy and speed in setting up New items from suppliers

98 98

44 47

spark eroder PC board, control circuit, safety notes, board and negative, exposure, developing, etching the board, drilling holes, precautions, population. oh woe is me, there has to be a better way, a dial gauge holder, no room at the top use a work stop. the flipper, the Kebo QC toolpost. answers to queries, the eccentric chuck, general description, description modern type, construction modern type. background, the prism, the spacer and side plates, tubes and lenses, assembly calibration, operation. the tools, opening up, different materials different methods, other shaping methods, fine surface finish, a simple scribing block, simple construction, a simple rule stand, an emergency radius gauge, post script. background and function, construction, rear bracket, saddle bracket, profile plate, operation, a word on geometric accuracy. patents, CL300M electrics, drawbars, mini lathe tailstock, Myford ML7 change wheel gearing software, logan steadies spare parts, out and about, further education courses, drilling safety, that's not model engineering, in the workshop. clamping screw, final assembly, cross vice alternative, material specs and sizes. background, tools and materials, marking off the form, cutting the form, reaming the dowel holes, the screw holes, assembly, conclusion. background and philosophy, design and manufacture. mechanics of this device, use of the device, postscript.

98

48

What No Power!

Experimenting with elbow grease

98

52

Profile Turning Device

A versatile approach to contours

98 98 99

54 55 11

Scribe a line Link Up On the Editor's Bench

Reader to reader Readers' sales and wants Dave Fenner's commentary

99

12

Drilling Projects (3)

Completing the sash clamps

99

14

Centre Square

Easily made marking out accessory

99 99

17 18

A Simple Tapping Attachment A Quicker Approach to Ball Handle Turning

No frills approach to vertical alignment With geared infeed

99 99 99

20 22 23

A Mending Job Next Issue Improving a Budget Drilling Vice

Experiments in soldering cast iron

oh those compliments, problem assessment, preliminary trial, location jig, grinding and heating, success. background, main body and fixed jaw, moving jaw, location using spotting screws, stepped jaws and clamping holes. electronics, safety, power system, new electrics, external wiring, two cases, wiring, motors, conclusion. materials required, machining sequence. background, flats, discs, rods, tube, conclusion. background, bearing mounting box, motor mounting, final assembly, conclusion. background, construction, final assembly, measurement procedure. construction, footnotes. platinum chloride for bluing steel, dragons blood, browning process, Chester 3M, knurling, drilling project, half nut release for the ML7. centennial issue, missing identity. Good news for watchmakers, courses at Northbrook college. Stan Bray, the start of MEW, Harold Hall, accidental outcome, changes over time, Geoff Sheppard, out of retirement into MEW, technology for the amateur, and the future. The compact lave by Stan Bray, Milling a complete course by Harold Hall.

Silk purse from sow's ear?

99 99 99 99 99 99 99 99 99

26 32 33 34 38 42 44 48 51

Mk 3 Wire Eroder (5) Mini Lathe Accessories (1) Link Up Coping with Thin Things A Three Speed Scroll Saw Trade Counter Dial Gauge Internal Caliper March 2004 A Quarter Inch Square Toolholder for the Hobbymat Scribe a line

Electronics, electrics and testing Improved gear cover retention Readers' sales and wants Various methods considered Improved versatility from a single speed unit New items from suppliers For more accurate bore measurement Latest industrial technology A simple, adaptable design

99

52

Reader to reader

100

11

On the Editor's Bench

Dave Fenner's commentary

100

12

Blasts From the Past

Comment from previous editors

100

14

Fireside Reading The Production of High Quality Printed Circuit Boards

100

15

It really doesn't need an industrial set up

PCB, printed circuit board software, design, cleaning, iron on resist, etching, etching components other than PCBs, conclusion, health and safety.

100

18

Holes on a PCD (the mathematical method) Next Issue TIG Welding: Controlling the current

No rotary table? Then use basic trig

background, hole generation, the formula, a curved slot, using a programmable calculator, using a computer, multiple calculations, adding logic. background and rationale, how it works, the circuit explained, motor matters, the pedal unit, setting up, and finally. background, material dictates design, a brief diversion, mark II miniature version, tilting variant. early days, insulated and well lit, first lathe, power source, starting afresh, house move, current accommodation, and equipment, projects. construction conventional type of eccentric chuck.

100 100

22 23

DIY foot pedal control

100

26

Milling Sub-Tables

Aids to setting up for milling

100 100 100 100 100 100

30 34 35 39 42 44

My Workshop Link Up Ornamental Turning for Model Engineers (3) Trade Counter Cleaning Ball Screw Assemblies Scan2Cad V7.2

The steps forward (and back) towards comfortable working Readers sales and wants The conventional eccentric chuck Arc Euro Trade, Folkestone Engineering Supplies, Camden Miniature Steam, Warren Machine Tools, Hemingway Kits, Newton Tesla (electric Drives) Limited. Removing the swarf and restoring accuracy Latest version reviewed

100

46

New Lathes for Old

Factory refurbishment at Myford

100

52

Scribe a Line

Reader to reader

101 101

11 12

On the Editor's Bench Rotary table (1)

Dave Fenner's commentary Useful accessory built from castings

the problem, dismantling procedure, reassembly. purpose, rasters and vectors, instructions and procedures, OCR facility, conclusion. history, initial examination, re-machining, the saddle, headstock, tailstock, top slide, reassembly, conclusion. Harold Halls drilling project, displaying drawings in the workshop, drive belt renewal problems, plastics identification char, knurling pliers, scientific instrument protective lacquer, tailstock morse prevent arbor from turning, B&Q stepped wedges, a poem. out and about, real world engineering, evening and daytime classes, 74th model engineer exhibition, a correction. general description, manufacture.

101

16

Improving the Chester Champion Mill

Modifications described

101

20

Metal Spinning

Complex shapes from flat sheet

101 101

26 31

A Speed Increaser for your Milling Machine Trade Counter

For improved finish and more effective use of carbide cutters New items from suppliers

preparation, wedge block assemblies, reader mounting plate, reader mounting, swarf guard, final assembly, table, saddle, removing the saddle, spindle, general. terminology, procedure, a complication, annealing, beginners metal, pallet size, problems due to technique, setting up, blank size, parting off, finishing, conclusion. rationale, the construction, materials required, experience to date, stop press. background, unplanned, problems to overcome, help, MEW link up, motor mounting, switchgear and wiring, pulleys and belts, the main 1in arbor, the table and ways, gearbox, paint job, stops, tee nuts and a test run, vice squad, horizontal and vertical, after some use, conclusion, comments, manuals and drawings. introduction, time for action, too hot to handle, and for my next trick, explanation, and a post script. the cross-slide, plate sizes, rear tool post, stops. variable speed inverter, why threephase, what is three-phase, what are the options, change the motors, install a VSD, phase converters, other issues, power availability and protection devices, acoustic noise, customer support, installation. the base, rocker, post, clamp, sleeve, spindle, clamping nut, adjusting screw, set screw, springs, service, a last word. etching technique, knurling, bandsaw blade tracking, taper tooling, trigonometrical aide, atlas lathe, moving machine tools.

101

32

Refurbishing a Centec 2A Horizontal Milling Machine

Small but capable and now restored

101 101

37 38

Bizarre Alchemy Accessories for a Taiwanese lathe

and a strange experimental outcome Additions to give accuracy and versatility benefits

101

42

Three Phase Power Solutions

from a single phase supply, the options discussed

101 101

48 50

Next Issue A Scribing Block Easy to make tool for scribing and measuring

101 101

52 53

Scribe a Line Link Up

Reader to reader Readers' sales and wants

102

11

On the Editor's Bench

Dave Fenner's commentary

model engineering in Bangor, and next the information police, in the workshop, 74th model engineer exhibition. 5c collets and accessories, emergency collets, Myford collets, ER collets, Clarkson collet tapping collet, home made collet, R8 collets, CDBX 1, single and double angel collet, multisize and multibore collets. background, components required, setting up and operation, dividing with an ML10. table, cutting the Tee slots, cover plate, worm wheel, cover plate drilling, eccentric spindle, handwheel, graduation ring, worm spindle, remaining parts and operations, assembly, worthwhile, the larger table. Stan Bray the tailstock, design considerations, manufacturing, the lead screw, the clamp and bearing block, body casting, assembly and operation. rationale, selecting the ball screws, materials required, selecting the stepper motors, slideway friction, dismantling the machine, correcting minor imperfections. for use with saw and file.

102

12

Collets and Collet Chucks

For speed and accuracy

102

17

Keyway and Plane Cutting System using Hand operated low cost facility an ML10 Lathe

102

20

Rotary table (2)

Concluding construction of the CES kit

102 102 102

26 26 27

Trade Counter Fireside Reading Tailstock Modification for a Clarke Metalworker

New items from suppliers Milling A straightforward improvement to a budget machine

102 102 102 102 102 102

30 34 35 36 39 42

Retrofitting the X3 Milling Machine (1) Dressing Screws Next Issue Springtime At Harrogate Four Way Tool Post Lathe Tool Height Gauge

Conversion for CNC operation Easy ways to cut to length A look around the workshop equipment on display With integral tool angle Avoid contortions with an optical approach

102

44

Toolmakers Clamps

A project aimed at new recruits to the hobby

102

49

Backplates and Faceplates for D1-3 Lathes

A DIY approach to making these expensive items

background, basic design, materials and construction, usage and tips, conclusion. background, better mouse trap, remote gauging, setting four jaw, conclusion. materials, item 1, avoiding damaged threads, tapping, item 3, item 4, without the lathe, assembling item 4, drilling the pin hole, machining the angles, adding the bracket, drilling the bracket, assembly, simplified version, conclusion. making two gauges, holes for camlock studs, getting studs.

102 102 102 102 102 103

52 53 54 54 55 11

Moving 3/4 Ton Lathe Single Handed Scribe a Line Issue 100 Competition Winners Link Up MEX Entry Form On the Editor's Bench

An approach to machine relocation Reader to reader making gear wheels, making PCBs, knurling, drill sharpening, speed increaser, thirteen leaf pinion.

Readers sales and wants For the 74th Model Engineer Exhibition Dave Fenner's commentary issue 100 subscription winners, free software, in the workshop, model engineer and exhibition. applications, conversion methods, stability, conversion methods (2), appearance, getting to work, the species, wood for carving, obtaining your timber, finishing, adhesives, PVA, extramite, epoxy resin, design, the task in hand, a router, a final comment. general arrangement, detail and dimensions, chuck drive shaft, ram tube, motor modifications, motor mount and slit clamp, pivot pin, operating levers, assembly and adjustment. no 2 Morse taper support, die holder, sliding tube, key, spring plungers, retaining cap, collet and cap, collet, collet adaptor, collet milling jig, locking ring (centralising) assembly and use. requirement, method, usage, other sizes. fitting the ball screws, the screw rods, fitting the ball nuts, fitting the Y axis screw, fitting the X axis screw, fitting the Z axis screw, fitting the Z axis stepper motor, attaching the X and Y axis motors. background, modification, results and assessment, conclusion. why jigs, sophisticated or simple, working with castings, bodges, lash ups. simple changewheel, and for larger numbers, clinometer, microstop attachments, some afterthoughts.

103

12

Wood in the metalworking workshop

An insight into selection, working and finishing

103

17

A High Speed Tailstock Drilling Attachment for the ML7 Next issue

Small drills are best run fast

103

19

103

20

Floating Toolholder

For tapping, reaming etc. even with an inaccurate tailstock

103

25

An Alternative Method Of Making Tee Bolts And Studs

With a large element of recycling

103

26

Retrofitting the X3 Milling Machine (2)

Mechanical modification for CNC operation

103 103 103 103

32 34 36 38

VMC Slow Speeds The Beginner's Guide to Jigs, Lash-ups and Bodges Trade Counter Accessories for a Taiwanese Lathe (2)

26 rpm and ultra low cost A practical approach from down under New items from suppliers Gadgets for dividing

103

42

DIY Air-Turbines for PCB's. Engraving and Internal Grinding etc. Abrasive cutting discs in the home workshop The Midlands Model Engineering Exhibition Scribe a Line Link Up Mex Entry Form On the Editor's Bench Holders for ER Collets In Car Hoist

Alternative approach to high cutter speeds

103 103

46 50

Towards precision grinding, without a grinder A brief overview of workshop equipment

background, brushless motor, turbines, building, body including spider, vacuum belts, machine mount, spindle, assembly, testing, other uses, addenda. improvisation for tough jobs, safety first, making an arbor, mounting the work, powered spindles, conclusion.

103 103 103 104 104 104

52 53 54 11 12 16

Reader to reader Readers sales and wants for the 74th Model Engineer Exhibition Dave Fenner's commentary. Low cost route to better concentricity Built for one purpose but useful for others.

moving heavy machinery, Atlas lathes, crankshaft straightening, tailstock modification, Taylor chuck, three phase converters.

104

18

Taps and Dies, Choosing and Using

There's more than one way of skinning the cat, or cutting a thread.

74th model engineer exhibition, a correction, in the workshop, model engineering classes. background, the body, the closing gap. the problem, a solution, important safety note, the electric hoist, electrics, initial failure, hoist fabrication, lifting problems, mark two steel work, in use. background, internal threads, tap forms, tap materials, tap accuracy, availability, what to obtain, external threads, tapping, the torque factor, tapping drill size, choosing the drill size, core diameter, mechanical aids to accurate tapping, cutting lubricant, blunt taps, external threads, mechanical aids to accurate external threads, under power, other possibilities, other tap forms, finish, machine tapping, machine cutting of external threads. an overview, mode 1 absolute DRO, mode 2 relative DRO, mode 3, what is required, macro commands, building and testing from the basic kit, building.

104 104 104

25 26 29

Trade Counter Comp-U-Guide Next Issue

New items from suppliers Programmable DRO system

104

30

Retrofitting the X-3 Milling Machine (3)

With an added electronic handwheel.

104

37

An Auto Feed Stop for a Chester Craftsman Lathe

Added electrical safety feature

104

43

A Simplified Spark Erosion Machine

For hard material and broken taps

104

46

Worden Modification

Gets the dust under control

104

50

Supplier Visit - Simply CNC

Builder of CNC milling packages

104 104 105

52 54 11

Scribe a Line Link Up On the Editor's bench

Reader to reader Reader's sales and wants Dave Fenner's commentary

wiring up the stepper motors, assembling the stepper motor drive unit, materials required for electronics, the assembly manual control unit, final comments. disaster, removing the carriage gibs, removing the carriage, removing the apron, spare parts, modifications and rebuilding, an electrical emergency stop, mounting block for the rear shears, rewiring the lathe, in conclusion, warning. background and philosophy, construction and operation, electrical considerations, performance, conclusion. background, guard, side plates, support pillars, pillar spacers, side plate straps, making the guard, cover plates, assembly, and finally. background, mechanical details, demonstration and software, high speed spindle, conclusion. knurling, Taylor chucks, chuck key dilemma, dressing screws, Startrite, creeping authoritarianism, Metalworker tailstock, variable speed drive box. new electrical regulations, in the workshop. design considerations, base, real column, head assembly, the turned items, assembly using, an assembly problem, a manufacturing consideration, an alternative. just a touch of nostalgia, an expert instructor, types of scrapers, three square, half round, the technique of flat scraping, sharpening, making a start, the sting in the tail, reasons for scraping, finishing, things to remember. background, disassembly, resetting.

105

12

Tapping Stand

Vertical guidance with pitch control

105

18

You'd Like It Flat - Scrape ft!

Beginner's guide to the black (more correctly blue) art

105

22

Micrometers for South paws

Put the numbers where you can see them

105

24

Temporary Restraint

A compendium of devices

105

30

Adjustable Saddle Stop for Myford Seven 7 Inconclusive experiments 74th Model Engineer Exhibition at Sandown Park Long Bolt Box Camp-U-Guide (2) Trade Counter Powered Top Slide A Technique for Finishing 4-Stroke Valves Chuck Lock For Screw-On Lathe Chucks

Neat accessory for improved repeatability

105 105 105 105 105 105 105 105

35 36 40 44 46 48 50 52

Process trials and tribulations An overview of workshop equipment exhibits Combination tool for quantity production Using the system New items from suppliers For an even finish on a taper New use for that diamond lap An added safety measure

introduction, definition, operating means, gravity operation, spring operation, magnetic latch, sliding latch, roller latch, toggle, ratchet, conclusion. rationale, design concept, manufacture of main components, small parts, mounting and assembly, using the saddle stop. background, casting method, welding method.

back to the beginning, manufacture, operation. mode 1 DRO, mode 2 preset, macro routines. the raison d'tre, what's in the box, putting it together, attachment, control electrics. the problem, the solution. hidden opportunity, machining, brazing, operation, footnote. Clarke metalworker tailstock, bandsaw problem, H&S and nanny state, straightening Briggs and Stratton cranks, flying chuck key, machining Lignum Vitae. index, rip off Britain, age and infinity not a barrier, training at the society of model and experimental engineers, in the workshop. background, the light duty boring head, construction, arbor, a few notes on taper turning, large and small bullets, body, slider, leadscrew, key, leadscrew collar, final assembly. notation and sign convention, setting angles, bent bar solution. background, manufacture, hardening and tempering, more detailed explanation. cell failure, recovery technique.

105

54

Scribe a Line

Reader to reader

106

11

On the Editor's bench

Dave Fenner's commentary

106

12

Tow Heads Better Than One? (1)

This first one for light duty boring

106 106 106

18 20 22

Drill Grinding With The Quorn Tool And Cutter Grinder Tee Slot Cutter "Zapping" Ni-cads

Simple accessory makes for added convenience Saving cash and making non-standards Delivering the electrical kiss of life

106 106 106 106 106 106 106 106

24 26 27 28 29 30 33 37

The Beginners Guide To The Black Arts - a treatise on "best value" Of Workshop Acquisition Toolroom Tips Out And About Getting To Grips With A Griptru Next Issue Compuguide 3 MEW Index Trade Counter Working with "virtual jigs" Index for issues 93 to 104 to remove or copy New items from Suppliers On counterboring and countersinking A quick look at a couple of shows Advice on achieving optimum precision

auctions, dealers, local works, boot sales and rallies, junk shops, club sales, summary. counterboring, countersinking, screws. accuracy in context, traditional fitting, enter the Griptru. machining to CAD data, mode 3 using programmable functions, first example, plan for cutting, second example.

106

38

TIG Welding of aluminium and it's alloys The pros and cons of AC. Welding in the Home Workshop (1)

money well spent to thrown away, what do you get for all that extra cost, are ac machines difficult to use, stand back and what do you see, despite all that there must be positives, the pleasure factor, are repaired items fir for service, and to cap it all no breakfast, which is the best TIG for my workshop, why such caution about investing in AC TIG. the history, the construction, the body, the objective holder, the side arm, the arbor, the prism mounting, objective lens mount, making the graticule, scribing the circles, anodising the microscope, assembling and centring the microscope. rationale, construction, use. background, solutions, construction, operation. Star drilling machine, ER collet holders, demagnetiser, leaky fuel tank, tapping drills percentage depth of engagement, three phase on single phase supply, American tool post, ER collet holder, WEE directive, in-car hoist, speed increaser, chuck key.

106

44

The Centring Microscope

New Kit from Hemingway

106 106

50 51

A Collet Slitting Jig for the Lathe Another Penny Finally Drops

A short cut for clockmakers Improved convenience in parting off

106

52

Scribe a Line

Reader to reader

106 107

52 11

Link Up On the Editor's Bench

Readers sales and wants Dave Fenner's commentary REMAP 2005 yearbook, in the workshop, new projects. problems with marking and drilling, scribers, make it visible, use every possible aid, aids for centre punching, why use a centre punch, drill construction, drill modifications, backing off the rake, long series drills, home made long series drills, core drills, some improvisations, drilling oversize, flat bottoming, sharpening, some of the pioneers, hole boxing, and example of boxing, button boring, setting the buttons. heavy duty boring head, construction notes, body, head, leadscrew nut, gig strip, leadscrew location details, leadscrew, locking collar, washer, leadscrew collar, dial, final assembly. the construction process. background, construction. background, making a holder. background, base unit, intermediate slide, top slide, toolpost, stylus, depth adjusting screw, spring, spring locator, locking screw, gib strip, locking plate, clamp, cross bar, height bar, template holder, assembly, using the attachment. workshop practice series 36 getting it together. Centreline cracking can I avoid it, success or failure can hinge on detail, choosing your filler materials, the welding and the alloys miscellany, proceed at a cracking pace, a few closing thoughts. initial components, makeshift mill table, reassemble top make more parts, saddle off and on once more, rack and pinion.

107

12

Drilling Holes In The Right Place

Accuracy without sophisticated equipment

107

18

Two Heads Better Than One? (2)

The heavy duty version

107 107 107

24 26 28

A Kinematically Mounted Indicator Stand For repeatable measurement for a South Bend Lathe Indexing Handwheel For Myford Lathes Zeroing feature for the leadscrew wheel Tipped Slotting Tool Carbide benefits without cost

107

30

A Copying Attachment for the Warco 300/2 Lathe/Mill

For tapers, profiles, and repeat work.

107 107

37 37

Trade counter Fireside Reading

New items from suppliers Photo Etching

107

38

TIG welding of aluminium and its alloys in the Home Workshop (2)

AC. welding, is it worthwhile?

107 107

43 44

Next Issue Unimat 3 Split Nut Lead Screw Clutch Improved convenience for a popular machine

107

49

Some Ideas on Tool Storage.

Quarts into pint pots?

107

52

Scribe a Line

Reader to reader

background, taps dies tapwrenches and dieholders, change wheel storage rack, a saw and cutter rack. Pendreighs gearbox, Chester craftsman, turboCAD, tap forms, single point thread cutting, spark plug electrodes, bearing information, scraping, Clark metalworker tailstock, Tom Senior major feednuts, Taylor chucks. Three phase from single phase, Bull wheel tooth count, in the workshop, Matchmaker - the saga continues. an introduction, cutter chucks, vertical slide, tee slotted cross slide, machine vice, work piece clamps, limited capacity, drilling machine, cutters, saddle stop, the milling process, some brief comments worth bearing in mind, the series to come. using the boring heads, cutting tool options, cutting tool geometry, top rake, lead angle and tip radius, practical recommendations. historic difficulties, current industrial practice, DIY or outsourcing, similarity to PCB, design and artwork production, making the masks. the origin, the tool, machining, thread protection back to the machining, in use. background, turnaround. background, electronic alternative, heavy duty and mk II versions, Vero board version, board construction, accuracy and options, conclusion. background, the body, long slot, sliding jaw, screw retaining plate, jaw bottom plate, screw, comments.

107 108

55 11

Link Up On the Editor's Bench

Readers' sales and wants. Dave Fenner's commentary

108

12

The Lathe Only Workshop (1)

Introducing a new series for those with one key machine

108

17

Two Heads are Better Than One (3)

Hints and tips for operation and tooling

108

20

Sheet Metal Etching (1)

An alternative approach to delicate components

108 108 108

26 28 30

Tailstock Off Centre Tool Stent Modifications Gear Hobbing Without Change Gears

For taper work without disturbing the lathe setting Alterations to well known tool and cutter grinder Any number of teeth up to 999

108

35

Machine vice for the Myford

A useful accessory with fabricated construction Myford, Warco, Arc Euro Trade, D M Machining services, Eternal Tools polishing kit, Chester (UK), Engineers Tool Room, Jean Burhouse, Reeves 2000 press release.

108

38

Trade Counter

108

40

Fireside Reading

Hand Scraping, machine shop essentials questions and answers by Frank Marlow, model engine mechanics by Gordon Cornell, Stirling and hot air engines by Roy Darlington and Keith Strong, the complete car modeller by Gerald Wingrove. philosophy and theory, grinder layout, setting, grinding the drill, the critical situation with the clearance angle, results of grinding experiments, test summary. background, simple addition, lower bracket, bracket assembly, head rework, top bracket and bush, operation and evaluation. the industrial approach, the DIY alternative, blueing, tooling, a 'silly' tailpiece. background, lathe application, drill application. background and bargain hunting, checking and testing, mounting and using. tin coated Dormer drills, chuck screws, regulations, motor stator demagnetiser, NETTO< reaming tips, screw threads, care of ni-cad cells, engravers wax, replacement cross slide, lignum vitae, Viceroy 5in lathe manual, chuck keys in chuck, winding handles and stepper motors. Northern showroom, more data from Colin Usher, from paper engines to paper cars, and then the workshop police, Midlands model engineering exhibition, 75th model engineer exhibition.

108

41

Next Issue

108

42

Drill Grinder (1)

What's in a point and how to achieve it

108

47

Round with Dovetail Advantages

An improvement for round column machines

108 108 108

50 51 52

Toolroom Tips (2) Two Capstan Handles Precise manual control

A Cheap Quality Universal Motor Speed Furthering the best traditions of recycling Controller

108

53

Scribe a Line

Reader to reader

108

55

Link Up

Readers' sales and wants.

109

11

On the Editors Bench

Dave Fenner's commentary

109

12

CNC for Free (well almost)

Low cost computer controlled mill

109

17

The Lathe Only Workshop (2)

A grinding rest produced on the lathe

background, the complete CNC package, CAD, DXF to G code converter, simulation, software drivers, electronics to drive the stepper motors, power supplies, other software, the milling machine, construction, master utilities program, connections for master program, the next machine, conclusion. common design feature, problem overcome, manufacture, rectangular bar parts, base angle, the dovetails, turning operations, assembly, using the rest, end mills, an important lesson. The amateurs Lathe by L H Sparey, Model Engineers Handbook, Tubal Cane. moisture content, cautionary note, the microwave alternative, results. exposure, developing, etching, removing the resist, metal thickness and quality, storage, computer design, use of layers, equipment the final stages. an overview of the grinder, notes on building methods, notes on drawings, assembling the grinder housing. planning, help the professionals, boxed and packing, moving the immovable, placement, lashings, hand tools first, pulling down the roof, post script. background, design manual and ICE program, program purpose, program basics and principles, program overview, data details, outputs tables graphs, examples tuned pipe effects, conclusions. ML7 cross slide lock, shear scraping. setting up, jaw operation, brace type key, concept, bent bar key, manufacture, conclusion.

109 109 109

25 25 26

Trade Counter Fireside Reading Microwave Timber Seasoning

TasDevil laser line scanner, Arc Euro trade, www.lathes.co.uk.

A culinary technique for cabinetmakers

109

28

Sheet Metal Etching (2)

Fragile parts and no cutting forces

109

35

Drill Grinder (2)

Continues with the construction of the machine

109

41

Moving Workshops

More involved than moving house

109

45

ICE Program Review

A design and analysis tool for two strokes

109 109

48 50

Myford Seven 7 Cross Slide Lock and Shear Scraping Facilitating The Use Of the Four Jaw Chuck

Useful accessory and a technique for restoring accuracy Time saving tips and gadgets

109

52

Scribe a Line

Reader to reader

110

11

On the Editors Bench

Dave Fenner's commentary

110

12

Lathe Only Workshop (3) - modified Vice In the finest traditions of silk purse

110

15

Modifications to the X3 Milling Machine

Belt drive transmission

110

18

A gear Cutting Attachment for the Lathe Milling head for use with Myford

110 110

24 27

Tail Stock Drilling Centre Drill Grinder (3)

An aid to accurate cross drilling Concluding drawings

L H Sparey gearbox design wanted, Crossness pumping station, bullwheel/backgear on super 7 plus and sigma lathes, Myford ML7 additions, centring microscope, in the workshop, Chipmaster topslide renovation, The Model Engineer exhibition 29-31 December, a correction issue 108 electronic gear hobber, college courses at Stafford and Leicester. rationale, sliding surfaces, grooves, moving jawkeep plate, jaws, postscript. replacing the gear drive with an HTD belt, background, making and fitting HTD pulleys, making pulleys other methods, general calculations for pulleys. background, end housings, body, bearing adjuster nuts, spindle, drive pulley/flywheel, bearing retaining flanges, jockey pulleys, setting up and use. achieving accuracy, cutting the vees, clamp screw holes, use. the reason, wider application, first thoughts, second thoughts, one step forward two steps back, initial operation, the electronics, bipolar driver, control box, conduit box, component parts, operation. the eccentric cutting frame, a simpler design,. a couple of definitions, recipe for disaster, recovery techniques, milling machine application.

110

28

Tailstock Power System

Cut down on wrist ache

110 110 110 110

34 38 40 43

Ornamental Turning For the Model Engineer (4) Tool Room Tips (3) Harrogate 2005 Trade Counter

A look at the eccentric cutting frame Clangers and cover ups An overview of workshop equipment exhibition accessories for Chronos, CNC mill from Warco, new distributor for DivisionMaster products.

110

44

An Introduction to Aluminium and it's Alloys (1)

Guidance on the material, casting and furnaces

background, an insight, the types and identities of alloys, alloy selection and method of casting, the reuse of scrap, alternatives to scrap, aluminium melting furnaces,, choice of fuel, metallurgical considerations, basic gas fired furnace design, small furnaces. manufacture. health and safety, chemical milling, bagpipe museum, model engine mechanics, checking cross holes for concentricity, competent person, CE marking, encoders, retrofit CNC to milling machine. in the workshop, building a case for Stuart triple expansion engine, mew from Alan Monday, index, ready made board for 555, apologies 75th model engineer exhibition, dates for the diary, correction beam deflection MEW109 P49. summary, digital calipers and scales, capacitance, inside a typical Chinese scale, a Centec 2a horizontal mill, scale modifications, Shimatech DRO 350, assembling the DR)-350, the case, cables plugs and sockets, the power supply testing the DRO and individual scales. angle plate alternative, casting, finish machining. the modifications, bearing blocks, main bearing bar, worm shaft, motor mount, swinging latch and clamping plate, assembly and adjustment, final words. design, construction, base plate, attachment to the lathe bed, other makes of lathe, once more to the base plate, guide bar, an alternative guide bar, yet again the base plate, graduating the base plate.

110

50

A Quick Change Toolpost for the Unimat A time saving attachment suitable for smaller lathes 3

110

52

Scribe a Line

Reader to reader

111

11

On the Editor's Bench

Dave Fenner's commentary

111

12

A Self-Build DRO for Chinese Scales (1) Budget box digital readout with on board intelligence

111

17

The Lathe Only Workshop (4) A CNC Headstock Dividing Attachment for the ML7

Machining a small angle plate

111

20

Modifying a classic design

111

24

Taper Turning Attachment (1)

For accurate shallow angle tapers

111

30

A Plain Spindle Head For The X3

Is a quill feed really necessary?

making the head, having the head cast, fabricating the head out of mild steel plate, belt and head cover, making the spindle housing, making the spindle, making the draw bar, attach the spindle housing to the head, fitting the motor. small scale liquid metal hazards, refractory installation preparations, furnace base, furnace body, refractory installation, furnace base, furnace body, furnace lid, surplus refractory, refectory drying and heatup procedure, temperature measurement, liquid metal working tools, handling tools, workshop ventilation and fume removal, personal protection, large scale liquid metal hazards, liquid metal treatment prior to casting, flux treatment, degaussing, other treatments, conclusions, purchasing notes.

111

36

An Introduction To Aluminium And Its Alloys (2)

Furnace construction, tools and metal treatment

111 111 111

41 42 46

Trade Counter Low Voltage Power Hacksaw (1) Machining Ball Handles By Generating On The Mill

dividing by Harold hall, arc euro trade, machine-DRO.co.uk, Chronos, motors direct. Low cost and simple construction An alternative approach to creating spherical surfaces. concept, frame, blade mountings, swinging arm, motor mounting. background, setting out and setting up, boring head adjustment, further thoughts and other applications. the mental prompt, equipment to hand, first thoughts, second thoughts, modifications, first use, home build, control, safety. centring microscope, Coventry die head tail stock mounted, Cleeve accessories, compensating pendulum, DIY CNC milling, moving workshops, powered cross and topslide, Boost phase converter, Myford Seven 7 shear scraping. move to tem issues, in the workshop, time and toys, the many shades of stainless, travel to Sandown, replies to phone calls etc, hacksaw video.

111 111

48 50

Resistance Soft Soldering A Day Out at Leamington Spa

A different take on a basic art. The Midlands Model Engineering Exhibition.

111

52

Scribe a Line

Reader to reader

112

11

On the Editor's Bench

Dave Fenner's commentary

112 112

12 17

The Lathe Only Workshop (5) A small vice Friction Dial Handwheels for the Unimat Home conversion for easy zero setting 3

manufacture, assembly index dials, handwheels, handles. Raison d'tre, development process, webcam centring unit - requirements, software, hardware, the graticule, focussing the camera, constructing the camera unit, adjusting and securing the camera, finale centring of the unit, general points, other applications of webcam in the workshop. one stage further, description, results, conclusion. construction. mounting the scales on the mill, scale guards, mounting the DRO on the mill, replacing the batteries and ground loops, a comparison with a Newall Microsyn, in summary, what's next. base, stop, vice, mounting and painting, connecting up, a few afterthoughts. Background, geared approach, modification and construction, back gear assembly, quick tip on speed measurement. prompted to buy, vertical digital scale, DRO, work experience, delivery. history, early home workshops, the lathe, techniques, present status, relation to industry, the future, priorities, conclusion. recess for guide bar adjusting screw, adjusting screw and housing, slide, alternative construction, slide attachment details, other lathes, cross slide feed screw disconnection, guide bar clamping nuts, assembly, alternative thoughts, alternative construction.

112

18

Webcams in the Workshop

Centring and seeing the impossible

112 112 112

23 24 27

Next issue Multi-facet Sharpening of larger drills Power-file Holding Fixture A neat jig for 4/6 facet sharpening Frees both hands for improved control

112

28

A Self-Build DRO for Chinese scales (2) An intelligent readout at budget price

112

32

Low Voltage Power Hacksaw (2)

Cheap and simple for home construction

112

36

A Back-Gear for the Mill-Drill Chester Lux Geared Head Milling Machine Home workshop Technology

Space saving speed reduction system to a Chester Champion

112

38

First impressions of this versatile machine

112

40

A historical perspective

112

42

Taper Turning Attachments (2)

Long small angle cuts made easy for a Smart and Brown lathe

112

47

Drilling Flat Sided Holes

Yes and with a rotating tool

112

50

Lathe or Machining Centre

Multifuctionality of latest equipment digital handwheel from Arc Euro Trade, winter offers from Tilgear, New products from Engineers Toolroom, cheap ballscrews. Reader to reader Dave Fenner's Commentary

background, method 1, constructing the bit, method 2, construction of the wobble bit. company background, sliding head the basics, machine developments, software advances, latest machine - Star SV32, results so far.

112 112 113

52 52 11

Trade Counter Scribe a Line On the Editor's Bench Lathe Only Workshop (6) Cross Drilling Jig Mini Vice Next Issue Louvre Tool 75th Model Engineer Exhibition at Sandown Park

113 113 113 113

12 17 19 20

Versatile tooling item from Hemingway Gripping stuff for small scale parts

CE, aluminium and it's alloys, workshop police. magazine ownership, in the workshop, heating, unconventional tooling sources, Remap at Sandown. body, the vee groove, bush holder assembly, miscellaneous turned parts, in use. jaws, adjusting screw, Tommy bar, Tommy bar caps, guide rods, post. background, press requirements, pressing jobs, other forms of power, alternative methods, size, manufacture, hardening, mounting, use.

Air flow with style from this press tool.

113

24

A brief look at workshop equipment background, introduction, linear transmission, bell crank, ropes, cordage, wire rope, chain, block and tackle, Bowden cable, linear to rotary transmission, crank and conrod, scotch yoke, eccentrics and cams, rack and pinion, screw and nut, misalignment, double slider or Oldham coupling, rubber block coupling, disc coupling, gear coupling, chain coupling, flexible tube coupling.

113

28

Getting Power Around Corners (1)

Transmission techniques reviewed.

113

33

Broadband Internet Access

With faster connection now available

113

35

Fireside Reading

Book review

113

36

X3 - CNC - Further Options

Variations on the theme

113

42

Musing about ...a problem to die for!

Caring for those cutting edges

113 113 113 113

44 46 51 52

Lath Aids Dispenser Base

Getting the coolant where you want it.

Power Feed for Naerok 350 Mill-Drill (1) A proven design for power traverse Trade counter Taper Setting Tool for Chipmaster miniature live centre, new mill from Warco, machine DRO, Divisionmaster. For accurate top slide adjustment.

a fall off in performance, asymmetric DSL, contention ratio, internet speed freak, large on-line catalogues, emails, screen dumps and digital photography, videos and software downloads, Yahoo interest groups, golden oldies, Skype, broadband safety, in conclusion. making simple model steam engines, Stan Bray. leadscrew mods, motor mounts, choices of motor and drivers, installing the power supply, installing the motor drivers, driving the mill, performance, heavy tests, final comments. a sense of foreboding, cause and consequence, even worse, just sometimes, caring for what you've got, it's widget time. design of the new base, machining, assembly, conclusion. modifications to the machine, drive motor, gear ratios, materials, backplate, bearings, idler backplate, guide pins.

113

54

Scribe a Line

Reader to reader

114

11

On the Editor's Bench

Dave Fenner's commentary

114

12

Cylindrical Grinding Attachment

Extend the versatility of a tool and cutter grinder

114

18

Lathe Only Workshop (7)

Making the small Vee block from Woking Precision

background, concept, accuracy, repeatability, construction, inspection. boring with a D drill, expansion coefficient for SS, compensated pendulum, bagpipes, etching, ML7 screwcutting gearbox, shaft encoders, Slocombe drill, resistance soldering, 555 pcb. real world engineering, calling all authors, in the workshop, do I really need one, a correction, generating spheres, windscreen wiper motors. background, spindle, spindle body, headstock, countershaft, spacers, pulleys, base plate, motor support, belt guard, using the grinding headstock. preliminary work, finish machining faces, machining the vees, matched pair.

114

21

Getting Power Around Corners

Power transmission methods

significant misalignment, intentional misalignment, rotary transmission, rope drive, line shafting, flat belting, round belting, synthetic round belting, vee belts, toothed belt, chain drives, conveyors, spur gears, helical gears, rack and pinion, bevel gears, spiral bevel gears, hypoid gears, worm and wheel, the differential, intermittent rotation, non-mechanical means, electric, pneumatic, steam, hydraulic, conclusion. toolroom and heat treatment, hints and tips, lathe tips, marking out tips, scraping tips, drilling tips, milling tips, storage and bench work tips. operating lever, drive-shaft gearbox, gear train, telescopic shaft, drive shaft, the controller, conclusion. the design process, preparing the panel, cover sheet, assembly, other possibilities, results. recommendations and caveats on technique, final observations. background, and old iron, going nuts, steady on now, better boring, easy dividing. necessity is the mother, modifying the calculator, operation, other calculators. tapping, screw cutting. background, bearing block, lock plunger, cam spindle, lock handle. background, special nuts, nuts. anti-rust self-regulation heaters, flatsided holes, webcams in the workshop, in the workshop, fencing, pulse jet, more nonsense from Euroland, industrial practice. jaws, jaw plate, adapter.

114

28

Reflections & Things

Hints and tips for novices and experts

114

32

Power Feed For Naerok 350 Mill-Drill (2) Powered table traverse for this popular machine

114 114 114 114 114 114 114 114 114 114 114 115 115

38 40 41 42 45 46 48 51 54 55 55 11 12

Nice, Neat Control Panels An Alternative Route To Milling Light Alloy Next Issue

Adding a finishing touch Without an expensive milling machine

Chucks Away, And Steady As She Goes Advice on workholding, a simple steady, and dividing. Trade Counter A Cheap And Simple Turns Counter Tool Room Tips (4) Tailstock Lock For The Prazimat Lathe A modification for the Chester DB8 centre the Scribe line Link Up On the Editor's Bench ultrasonic cleaner, Clarke engineering, Tilgear. Keep track when coil winding On cutting threads Avoid playing "Hunt the spanner" with this neat improvement To speed up chuck changes Reader to reader Readers' sales and wants Dave Fenner's commentary

Lathe Only Workshop (8) Five Inch Two First of two articles covering this Hemingway kit Jaw Chuck

115

17

Creating a Home Foundry

- for aluminium casting

115

20

Simple And Sometimes Primitive Heat Treatment

Hardening, tempering and annealing made easy

115 115 115

24 27 28

Angle Setter Trade Counter Grinding and Making Lathe Tools

A measuring/setting tool to reach the parts others cannot. machine mart, engine wise, routoutCNC. not as difficult s you might think

search for furnace, moulding box, other tools, safety, making a start, success. a little knowledge, the effect of heat on steels, hardening technique, ways of judging temperature, by colour, by scale, quenching, tempering, steamboats toaster, heat sources, heating devices, blow torches, cooks blow torch, gas stove, plumbers blowlamp, case hardening, softening, blueing and oil blacking. general design, manufacture, in use. hollow ground angles, simple tool rest, grinding and honing, and for tiny tools, brazed tip carbide tools. general design, bracket, thimble, barrel, threaded insert, graduating thimble, and barrel, assembly. background, kit supplied, safety devices, fitting, experience. Harold Hall background, description, in use, construction notes, body items, tool holder, adjustment nut, clamp, cam, handle, spanner, assembly. the convention al type, the head, spindle, the pulley, the shank, leadscrew, the end-plate, the micrometer head, screw and clamp, nut. a smelly, messy job, manufacture, operation. anatomy of a PIC, peripheral devices, PIC 16F84, PIC 16F877, development and support, circuit design, PCB layouts. metric counterbores, D drills, icosahedrons, taper setting gadget, condensation and digital scales, DRO, mill mount for magnetic base. out and about, pre 65 trial, in the workshop, motorcycle lifts, pulsejet manufacture. body, using the faceplate, jaw slides, jaw screw, gland, drilling for jaw screw, assembly.

115 115 115 115

30 34 35 36

Saddle Stop for the Myford Fitting an Electronic Speed Control to a Warco 6in. Lathe. Fireside Reading Quick Change Tool Post

An essential accessory for repeatable length control. Newton Tesla inverter drive package for the BH600 Tool and Cutter sharpening A straightforward design for home construction

115

42

Ornamental Turning For Model Engineers (5) A Recirculating Cleaner For Airbrushes RevMaster - A Simple Tachometer (1)

Eccentric cutting frame described

115 115

48 49

A near zero cost device to conveniently economise on thinners to give an accurate indication of spindle speed.

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54

Scribe a Line

Reader to reader

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11

On the Editor's Bench

Dave Fenner's commentary

116

12

Lathe Only Workshop (8)

Completing the Two Jaw chuck (part 2)

116

17

An All Steel Workshop

Self built to professional standard

116

22

A Low Cost CNC Dividing Head

Headstock indexing with Routout software

116

26

RevMaster - A Simple Tachometer (2)

Accurate spindle speed indication

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30 32 39

Vertical Spindle Alignment Table. Needle scaler Making Chuck Jaws

for spot on re-setting of tilting heads Not just for rust removal Process demystified

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42

Shape

Geometric symbols, tolerance, and measurement

finding the right materials, designing and planning, the foundations, erecting the framework, cladding, cutting the panels, fitting the windows, the doors, fitting out. background, mounting the hardware, the electronics, the software, next steps, costs. etching the PCBs, drilling and populating the boards, final assembly, mounting the rev counter on a mill, choosing a sensor and measuring range. raison d'tre, cost cutting design, use, postscript. in normal use, and now for the fascinating bit, and yet further benefit. background, check measurement, jaw blank and slots, cutting teeth, fixture details, and finally. diametric tolerances, symbols, manufacture, measuring equipment, specifics, straightness, squareness, flatness, parallelism, angularity, roundness, concentricity, profile, conclusion.

116 116

44 45

Trade Counter Tailstock Adjuster

exhibitors at Harrogate, Routout CNC, engineers tool room, Arc Euro Trade, Chester UK, Warco, Chronos, Rust Away from Enginewise. Put away that hammer Chester Conquest lathe, attachment, background, variation on a theme. personal beginnings, craftsmen of old, how did they do, self-contained standard, circular scales, eccentricity, precision polygon, soft grinding, lapping, calibrating the polygon, calibrating a circular table, degradation of workmanship. getting power round corners, use of calculator, cold damp workshops, D bit, cross drilling, Peerless Model PL-18480, twist drill stiffness, Drummond round bed lathe, workshop condensation and low temperatures, counterbore bits. B. Terry Aspin

116

46

Dividing The Circle

to a higher order of precision

116

53

Scribe a Line

Reader to reader

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55

Fireside Reading

The backyard foundry

117

11

On the Editor's Bench Lathe Only Workshop (9) -Retractable Tool Holder Sensitive Drill Feed Display Frame

Dave Fenner's commentary

117 117 117

12 16 22

The GHT design from Hemingway Delicate touch on a big machine Organise and view those drawings

in the workshop, motorcycle lift, a correction, RevMaster PCB, into the 21st century. the tool slide, the body, bridge piece, gib strip, the tool slide, the turned items, final assembly, conclusion. Startrite drill, background, application, construction, in use. concept, preparing the drawings, concluding construction. common faults when sawing, ways and means, hacksaws as roughing tools, beware of the set, more hacksaw devices, other useful saws, junior saw, coping saw, razor saw, jab saw, beware of imitations, reminders.

117

24

A Plain Man's Guide to Saws and Sawing

Valuable advice for beginners

117

29

Trade counter

Chronos laser, Tracy tools to the rescue, welders warehouse, Tilgear catalogue. history, concept and power unit, milling cutters, drills, making the flexible drive carrier, vertical support, baseplate, bed guide plate, assembly of items, holder, holder backplate, guide pins, final assembly, using it.

117

30

Sharpening with Diamond Discs

Clean and simple

117

35

The World Comes To Harrogate

Workshop equipment at the recent exhibition DRO Chinese scales, spherosyn and microsyn, site visit, scale adjustment and calibration, scale head manufacture, digital display units, scale mounting, evaluation of competitors scales, repair and service, incremental and absolute, conclusion. Myford ML7, design considerations, a stage further. Warco 220, background, design, conclusion, operation, appendix.

117

38

Visit to Newall Measurement Systems

A peek behind the scenes at this premier British manufacturer

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40 44

Lathe Spider Self-Releasing Mandrel Handle

to hold thin work squarely No shock loads on the headstock bearings

117

46

Bending Tools

for use in the humble fly press

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51

A Simple Spark Erosion Machine

Remove taps or cut holes in hard material

117

53

Scribe a Line

Reader to reader

background, basics of bending, working out the developed length, DL, elastic plastic deformation, grain direction, minimum bend line radius, spring back, simple bending tools, precision bending tools, 90 degree bend tool, the punch, the die, base plate, guide plate end stop and spigot, assembly. background, initial design, mark two, further development, circuit details, conclusion. power feed for the RDM350, low cost dividing head, counterbores, Bridgeport modifications, preventing rust, motorcycle lift, stainless steel expansion rates. out and about Lathalmond and Glamis, in the workshop, Griptru chuck replacement jaws, variable pitch worms. workpiece shape, clamp sizes, in use, fixed jaw, impossible tasks, lightweight Tee slots, a marking out device. euphoria diminishes, the internet and MEW to the rescue, adjusting the micrometer, caution. background, Clarke CL300M, symptom and cause, procedure, postscript. lower minimum headstock speed, rotary forward/reverse switch. model marine steam Stan Bray, tools to make life easier Peter Rawlinson, electromechanical building blocks for the model engineer Pat Addy. base spacer and table, clamp frames, vee blocks, backstop frame, backstop clamp plate, flipper arm, other parts, assembly, using it. background, design considerations, first purchase, construction, pulleys, leadscrew extension, stepper motor, motor mount and guard, marking out.

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55 11

Next Issue On the Editor's Bench Dave Fenner's commentary

118

12

Low Profile Work piece Clamps

Staying out of the cutter path

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18

Fixing A Moore & Wright Micro 2000 Modification To A Quick Change Tool Post Improvements To The Clarke CL500M (1) Fireside Reading

Restoring lost accuracy

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20 22

Easy change for added convenience Upgrading a budget machine

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27

Recent publications

118 118

28 33

Drill Sharpener Attachment MEW Index

for four facet grinding Index for Issues 105 to 116 to remove or copy

118

37

More Power at Your Elbow (1)

Adding power traverse to the popular Wabeco mill

118 118

42 46

Myford VM-E CNC Retrofit (1) Trade counter

CNC conversion for this larger milling machine Warco new products, souther springs and pressings, MEW index in DOS format, L S Caine electronic services, Chronos laser centre. DIY version of professional kit

background, ballscrew selection, fitting the Y axis screw, fitting the X axis.

118 118 118

48 52 53

Co-Axial Centring Gauge Next issue Scribe a Line

background, the grey cells are stirred, ensuring accuracy, assembly and test, operation, legitimacy. making chuck jaws, mystery device, mods to Myford stand, Guildford College courses, Chester champion mill, lathe tailstock mods, motorcycle lifts. castings, lever locking topslide, motorcycle lift safety, fine surface finish, website davefenner.co.uk, in the workshop. the locking arrangement, advantages, cross slide requirements. conically shaped drill flanks, practical considerations. the supply, voltage/current, DC supplies, basic circuits, choice of values, two speed motor, voltages in a loop, power, importance of the power consumed, capacitance, inductance, electricity generation, back to inductors, inductors and capacitors compared.

Reader to reader

119

11

On the Editor's Bench

Dave Fenner's commentary

119 119

12 18

A Lever Locking Topslide (1) Drill Grinding with the Quorn Tool and Cutter Grinder

Swivels, slides and retracts Reproducing as new performance.

119

22

Basic Electrical Theory (1)

Starting with Ohm's law

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26

Trade Counter

Myford collets available again, brass sections from Folkestone, Pro machine tools, higher performance from Loctite, Arc Euro Trade. Three further modifications discussed. finer self-acting feed, left hand screwcutting modification, calibrated hand wheel on mill drill head, conclusions and work. the story so far, choices, comparisons, getting the best price, delivery and installation, in use first impressions, manuals, toolbox, the x-axis power feed, Newall Digipac 2-axis DRO, after some use, belts and speeds, panning and tramming the head, the quill, R8 tooling, milling chucks, lubrication, guards, Tee nuts and clamps, conclusion.

119

30

Improvements To The Clarke CL500M (2)

119

35

Review of the Chester 626 Mill

Considerations after a year or so of ownership

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40 43 44

More Power at Your Elbow (2) Next Issue Myford VM-E CNC Retrofit (2)

Wabeco Power traverse by stepper drive

overall design considerations, oscillator circuit, hand held control unit, connecting the units. finding the best z axis approach, fitting the z axis, machining the ball screws, go on admit it, two incidental improvements, conclusion. background, adding angle, sacrificial block, further modification, experience. drill grinder, gib strip, motorcycle lift, deep hole drilling, lathe bed heaters, workshop condensation. a correction MEW index, out and about, temporary closure, editor required, model engineer exhibition, in the workshop, stripping a 77 Triumph Bonneville. AC power, voltage values, impedance, power in an AC circuit, power factor correction, AC to AC conversion, AC to DC conversion, resulting voltage, zener diodes. motor mount and couplings, leadscrew modifications, feed nuts, reassembling the axes, results. in the beginning, how to get started with eBay, search keywords, who is selling, registering as a buyer, meet the seller, PayPal or plastic, registering as an eBay seller, charges, ,cost eBay charges fall on the seller, fraud, other ways of shopping online, free cycle. enter the modern standards, snags and problems, the new standard, line standards, rules, the vernier system, end standards, balls blocks and rollers, micrometers, many different micrometers, special micrometers, getting the feel right, digital read-outs, DRO, a modification, measuring by comparison.

Tackling the Z- axis

119 119 119

49 52 54

Really Short Work with a Band Saw Scribe a Line Model Engineer Exhibition

Getting a grip of small offcuts. Reader to reader Entry form

120

11

On the Editor's Bench

Dave Fenner's commentary

120

12

Basic Electrical Theory (2)

AC. power for beginners.

120 120

15 16

Next Issue Taig/Peatol mill CNC conversion (1) Mechanical modifications

120

19

Buying Engineering Stuff on eBay

A starter guide to internet trading

120

22

The Business of Measuring

Systems, standards and equipment

120

26

The Bristol Model Engineering And Hobbies Exhibition 2006 Renovating A Myford Super Seven 7 Lathe (1)

A brief look at the workshop equipment on show synopsis, acquisition, problems requiring remedial work, raising blocks, coolant tray, tailstock, grease nipples, swing head, missing topslide, lathe carriage, lathe mandrel, backgear broken tooth. top slide arrangement, screwcutting retract, toolpost, making it, annulus, cross slide. precision bending, the curling operation, first stage tool, the hinge closing tool, machining forms, the combination tool, conclusion. relieving end teeth end mills and slot drills, reforming end teeth slot drills, gashing end mills, relieving flutes end mills and slot drills, surface grinding, lathe tooling, cylindrical grinding, conclusion. design, machining the slide frames, adjustable stop, operation. advantage of home made tool bits, concluding footnotes.

120

28

Work on a sorely abused example

120

33

A Lever Locking Topslide (2)

Further design points and initial advice on manufacture

120

38

Curling Tools

Continuing with presswork

120

42

Some Thoughts On Cutter Grinding

Attachments, modifications and methodology for the Clarkson

120 120 120 120

45 50 52 53 54

A Pair of Comparators (1) Tungsten Carbide Tool Tips For The Home Workshop Trade Counter Scribe a Line 76th Model Engineer Exhibition

Accurate bore measurement made easy Home brewed brazed tip tooling. Chronos laser centre finder, working precision models joins Hemmingway kits, new catalogue from Arc Euro Trade. Reader to reader Entry form and guidance notes

Tribology and the appropriate choice of friction parts. xmas approaches, midlands exhibition, successor required, correction and omission, MEW 119 555 pin out, in the workshop, Myford changewheel, bending exhaust pipe, nickel plating, exhibition all change. New website. background, construction, wiring, hindsight, safety notes. logic, binary numbers, transistors, thyristors, LEDs, light sensitive devices, other electronic devices, electric motors, induction motors, commutator motors, AC/DC commutator motors, speed control, available power, the internet, a final comment.

121

11

On the Editor's Bench

Dave Fenner's commentary

121

12

A Nine Inch Disc Sander

A useful machine at near zero cost

121

16

Basic Electrical Theory 3

Beginner's guide to logic, electronic components and motors

121

21

CentreCam (1)

Using a webcam for precision centring and measuring.

121

25

Taig/Peatol Mill CNC Conversion (2)

Adding computer control to this popular machine.

121

33

Plans Index

121 121

34 37

Pinstriping American Style A Pair of Comparators (2)

Brushing up on lining out Second instalment covering external measurement.

preparation, basic design, motivation, CentreCam software, in use, conclusion. size is important, torque, how much torque is enough?, torque calculations, the stepper drive, drive system enclosure, power supply, drive LEDs, drive power wiring, motor socket connections, signal connections, DeskCNC board, closing comments. locomotives, LBSC locomotives, miscellaneous steam engines, petrol engines, traction engines, clocks, workshop equipment. some history, pinstriping UK, the course, conclusions. the outside comparator, manufacture, operation, saving money. the tailstock body, tailstock barrel, countershaft cone pulley, 2-step motor pulley, lathe bed, 60t backgear assembly or bull wheel, 17/53th backgear cluster, cross slide assembly, cross slide body, cross slide feed screw assembly. checks, machining the bracket, machining the table, conclusion. annulus centre pad, stirrup lever and eccentric, swarf guard, screwcutting retract, Myford seven 7 top slide. R8 fix, Polly model honing kit, MEW 8 missing, Warco mill mods, ultrasonic cleaner, workshop dehumidifier and humidistat, Warco lathe (Clarke CL500M) speed changing. in the workshop, BUMA cylinder boring, disc skimming, wheel lacing, corrections engineering plans handbook, Remap, new website. background, manufacturing, assembly.

121

40

Renovating A Myford Super Seven 7 Lathe (2)

using a variety of repair techniques

121 121 121

46 47 48

Correcting an Out of Square Drill Press Table Next issue A Lever Locking Topslide (3)

Accuracy improvement on a budget offering.

Concluding the description of this ingenious accessory.

121

53

Scribe a Line

Reader to reader

122 122

11 12

On The Editor's Bench Large Rear Tool Post

Dave Fenner's commentary Constructing this useful accessory from the Hemingway range

122

17

A Small Router Table

Ideal for occasional woodwork

122 122

22 26

Feedscrew Traverse for the Worden A Novel Hygrometer

Added facility for this popular grinder Check up on your workshop humidity

122

27

A New Angle on Bending

The Warco Magnum - from concept to production

122

30

Gear Cutting Using CNC

Let the computer do the legwork

fine height adjustment, router base plates, polycarbonate, the router table top, circle-cutting jig, starting pin, guide bushings, a router fence, fence checks, feather boards, read all about it, final thoughts. background, construction, using the fine feed, and finally. background, the principle, the timber, manufacture, finishing. sheet metal folder, bending forming blocks, flypress, bend roll and shear machines, Magnum bender specification, machine construction, bending bars, Magnum bender operation, taking the bender to market. materials required, construction, spindle, mandrels, worm mounting plate, worm mounting plate, worm bearing assembly, attaching the stepper motor, the shroud, using the dividing head to cut wheels, Gcode programming. background, the lighting problem, possible solutions, LED illumination, resistor values, construction, in use, measurement accuracy, height gauge block, conclusions. top slide feedscrew, top slide assembly, carriage assembly, lathe motor single phase and rotary switch, motorising assembly and headstock belt guard, headstock it's removal and replacement, lathe tray, carbon arc brazing. Christopher Vine design criteria, solution, assembly.

122

34

Next Issue

122

35

CentreCam: More on Web Cams (2)

Positioning and measuring now with illumination

122

38

Renovating A Myford Super Seven 7 (3) Work includes the headstock, carriage, and a new tray

122 122 122 122

44 45 46 50

Trade Counter Fireside Reading Adjustable Grinding Tooth Rest Workshop Equipment at Leamington Spa

Warco, Tracy tools, Chester, Arc Euro Trade. How (not) to paint a locomotive For improved convenience and accuracy in tool grinding Exhibits at the Midlands Exhibition

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53

Scribe a Line

Reader to Reader

123

11

On the Editor's Bench

Dave Fenner's commentary

ink jet continuous ink supply, PayPal or plastic, Chester UK 626 mill, motorcycle lift, homeworkshop.org.uk information, 12v cordless drill power, nautical mile and metre confusion, Myford VMB setting up. a warm welcome to the new editor, and a partial farewell, in the workshop, oil blacking, model engineer exhibition, publication schedule. ER collets, the collet chuck, manufacture, lathe collet body, between centres test bar, closing ring. shapes and angles, clearance angles, rake angles, favourite shapes, side cutter, turning and facing, square nosed rougher, radius turning and facing tool, parting off or grooving, screw cutting, combination n facing chamfering, materials, high speed steel, carbon tool steel, tipped tools, locking screw, sharpening the tools, an improvisation, sharpening techniques, hones and stones. the device, other push clamps, wedge, double wedge, chuck removal, sash clamps, flooring cramp, machinists jack, bottle jack, hand pump kit, conclusion. background, wood butchery, initial thoughts, design considerations, construction.

123

12

ER32 collet chuck for the lathe

Useful accessory for precision turning.

123

16

Turning Tools for Beginners

Basic essentials for tyro turners

123

22

The Quoin and other Pushers.

Compressive devices reviewed

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25 27

A Clamp-on straight edge Next Issue

Simple accessory aimed at woodworkers

123

28

Renovating a Myford Super Seven 7 (4) Concluding the rebuild

123

34

Did you know...? (1)

Technology transfer from a goldsmith

123

38

Shaping up to a Cross Slide

with tips on the use of the shaper

123

44

Machining Large Radiuses on the Lathe Quick set up leading to quality results

raising blocks, cabinet stand, electrical wiring and switches, quick change gearbox, unexplained phenomena, graduated dial for the tailstock handwheel, adjustable height tool holders, a detent for the bull wheel for graduating purposes, minor modifications to the gearbox, realigning the tension spring for the changewheel guard backplate, roller and plunger assembly for the belt guard, redundant volume in the cabinet stand, finishing lathe on its cabinet stand, a final point to check. the basic processes, the tools, the rolling mill, draw-plates, the piercing saw, using the tools, making wire, making tube. background, first find some cast iron, safety first, cutting tools, roughing, the dovetail, seat for topslide, graduating, topslide base, mounting the feednut, gib, a back tool post. the raison d'tre, solution, method, further thoughts. the origin of the project, the need for a slim line lathe dog, the main body, drive leg, clamping screw, clamping pad, assembly and finishing touches.

123

46

A Slim Lathe Dog

gets closer to the chuck

123

51

London Model Engineering Exhibition 2007 Evaluating Capacitors

Workshop equipment on display background, preliminary safety note, equipment, method, preliminary test, actual capacitor test, a note on electrolytic capacitors.

123

52

Straightforward route to determining capacitance College engineering supply, Arc Euro Trade, New products from Warco, Engineers Tool Room. Reader to reader

123 123

54 55

Trade Counter Scribe a Line

124

11

The Editor's Bench

Dave Clark's commentary

rotating Jacobs chuck, tube bending, sharpening twist drills. a hard act to follow, business as usual, future articles, in the editors workshop, missing references, error correction MEW 121 Taig CNC conversion.

124

12

Unimat Vertical Alignment Guide

Improved accuracy when milling

the guide bar, the half nut the release lever, modifying the head casting, the feed screw, locking lever. two options, likely to wonder, screwcutting ruled out, manufacture, the body, the bushes, using the holder. making chain, making a draw-bench, a few words about soldering. background, faceplate availability, plenty of access, adaptor design considerations, the register end, the fixing holes, the faceplate end, fitting the faceplate, checking for true running, final thoughts. background, the chuck discovered, making the chuck, examples of use, centring a tool edge, repeatability, stuck fingers. power hacksaw machines, fixed jaws, fitting the jaws, moving jaw, sawing small work pieces, support screw, extended jaw, sawing large work pieces. background, new floor needed, forming ribs, restoring flatness, finishing touches. background, process, production considerations.

124 124

16 18

A Guided Die Holder Did You Know (2)

Keep your threads straight Chain making for the beginner

124

21

A Faceplate For Uncle George

Adapting a Clarke faceplate to a Hobbymat MD65

124

24

The Super Glue Chuck

A replacement for the wax chuck

124

26

Modifications to a Clarke Bandsaw

Cutting metal the long and the short of it

124 124 124 124

30 32 34 36

A Metal bashing Masterclass Thermal Drilling Headstock Dividing On The Myford Series Seven 7 Lathes Replacement Belts

Sheet metal for the car enthusiast Drilling and forming a hole with heat An unusual method of mounting the Myford dividing attachment 0-rings make economic belts

124

37

Holding And Clamping Awkward Shapes How to hold that difficult component

Unimat SL, Unimat 3, Toyo, Sakai, Record, Manix Ml-210. working on large diameters, reverse jaws are useful, accurate lining up, saddle boring, using built in datums, the faceplate datum, the tool post as a datum.

124

42

Pneumatics

A beginners guide to compressed air systems

124 124 124 124

49 50 51 52

A visit To The Toolbox Simple Trepanning Next Issue Trade Counter

Dave Clark visits a second hand tool shop Save time by trepanning instead of turning Folkestone engineering supplies, Pro Machine tools, Tilgear, Myford, Bede tools and machinery, Tracy tools.

the composition of air, the gas laws, absolute and gauge pressures, compressors, home workshop DIY air compressors, air treatment, inlet filters, coolers, filters and water traps, air driers, lubricators secondary air treatment, relief valves, pressure regulators, pressure gauges and regulators service units, measuring airflow rate, tubes and fittings, uses of compressed air, air tools, valves, multi-port valves, construction, spool or slide valves, actuators cylinders, actuators rotary, actuators grippers, logic controllers, paint spraying, vacuum. various tools, the main display, a worldwide service.

124

54

Scribe A Line

Reader to reader

125

11

On The Editor's Bench

Dave Clark's commentary

125

12

Dividing In The Workshop

A comprehensive Look At Dividing

125

19

An Automatic Carriage Stop For The Prazimat Lathe

An Automatic Feed Stop

Ron Burt, 12v drill, amusing terms, drilling square holes, readers tips, boring heads, borrowing and lending, glass cutter, clamping bolts, soluble oil, blackening metal, small boring tools, tee nuts and studs. increase in number of issues, model plans service, ME and MEW workshop website, buying items on eBay, Harrogate exhibition, new life for old model aircraft engines, wheel rebuilding, readers tips wanted, future articles. the mathematics, how many holes, division plate errors minimised, making the divisions, the bullwheel, mandrel mounted gear, backplate dividing, dividing heads, some more mathematics, some applications, gear cutting, dial cutting, backlash, holes on a PCD, rotary tables, another method. the pivot block, the trigger, the bracket, the stop, pillars, pin.

125

21

Simple Taper Turning

Accurate Angles On The Lathe

125

24

Wheel Building DIY Style

New spokes For A Triumph Bonneville

125

27

Hydraulics

A beginners Guide

125

34

Myford VMC-E CNC Conversion (3)

The Benefits Of Hindsight

125

36

Making Cycloidal Pinion Cutters

Gear Cutting for Clockmakers

clock gauge holder, the sine-bar, auxiliary tailstock, calculations, preparation and setting up for taper turning. background, preparatory work, jigs, dismantling brake disc, back to the wheel. differences from air, basic hydraulics, pressure drop, mechanical advantage and simple cylinders, brake systems, disc brakes, mobile plant hydraulics, control valves, solenoid valves, hydraulic pumps gear types, vane types, piston motors, pump control, actuation cylinders, hydraulic motors, the pressure intensifier, effects of temperature, cavitation, effects of pressure, pneumatic/hydraulic systems, hydraulic pipe flexible hoses and fittings, in summary. postscript. background getting into clocks, from involute hobs to cycloidal cutters, definitions, an example, radiusing the tool tip, cutter blanks, the relieving fixture, clearance angles, how much setover, forming the cutter teeth, hardening and tempering, cutting speeds. the relay, construction details. simple turning, ovality, a small taper, lapping the piston, perfectly square, hardening and tempering, easier to hold. simple to use.

125 125 125 125 125 125 125

43 44 45 49 50 51 52

Electrical Safety in the Home Workshop A Simple Footswitch A Soldering Iron Controller Protect Your Soldering Bits A New Life for Old Model Aircraft Engines A Profile Copier for the Unimat 3 Next issue Trade Counter Fireside Reading Cylinder And Piston Renovation Simple Profile Turning Aldi, Machine Mart, on the move, WNT (UK) Ltd, socket sets from Chronos, Digi-Key corporation, variable speed drives. Electric Motors

125

53

Scribe A Line

Reader to reader

Jim Cox, second edition. MEW concept from Stan Bray, drill sharpening, MEW 123 cover picture, Clare milling collets, mods to Malcolm Leafe's clamp, evaluating capacitors, 12v cordless drill.

126

11

On the Editor's Bench

126

12

A Miniature Boring Head

A tool for small machines

health and safety physical mechanical and electrical, Ted's foot switch, updated contributors notes, long hair and baggy clothes, loose wire, the good old days, safety in the home workshop, readers tips, 12 issues a year. manufacture, the topping jig, the body, faceplate, balancing the faceplate, assembly, being put to use, method for smaller machines, a final thought. engraving tools, the tri-facet engraving cutter, the spring loaded engraving tool, construction, using the DeskCNC line fonts, drawing the dial, dials with Arabic numerals, engraving the dial, the engraving tool path. background, design criteria and process, operation, manufacture, reservoir and damper tubes, piston and rod, rod ends, needle valve body, needle, base end cap, top end cap, base angle bracket, top bracket, pivot pins, tie bars, assembly, reinforcement bar, adding oil, conclusion. Hobbymat BFE mill/drill, the new scale, the bracket, the screw, the nut, finishing touch. background, DRO linear scale selection, cross slide linear scale, lathe bed saddle linear scale, avoiding drilling and tapping, console connections, conclusions. it worked first time, a smooth clean passage.

126

17

Engraving with CNC

A precision engraving tool

126

23

Bandsaw Damper

Get longer life from your blades

126

30

A Hobbymat Milling Aid

A precision measuring attachment

126

32

Digital Readout For A Myford Seven 7 Lathe

A new life for an old ML7 lathe

126 126 126 126 126 126 126 126

36 37 38 39 40 42 44 46

A Steam Port Alignment Gauge A Unimat 3 Mandrel Handle A Visit To Penny Farthing Tools A Simple 90 Deg. Press Fine Angle Adjustment for the Unimat 3 The 2007 Bournemouth Model Engineer Exhibition The Harrogate Exhibition Next Issue

An unusual tool to ease drilling alignment A simple Unimat attachment A Wiltshire tool shop Bending made easy A Topslide attachment

126

50

Trade Counter

Pinstripe and Kustom Graphics magazine, Myford Seven 7 series splash back, J&L industrial, model engine builder magazine, Stuart models, Chronos, Rite Time publishing, "items" mail order ltd, Plastic Parts centre, Northern Tool and equipment, J.M.W clocks. MEW 124 super glue chuck, MEW 122 router table, borrower/lender, MEW 123 rotating Jacobs chuck, model engineering course, health and safety, MEW 123 capacitor testing and threephase motors, loose clothing and long hair, electrical safety, readers tips, tap lubricant, removing swarf, MEW 124 boring tool tip, smaller low profile clamp, small bar chuck. in the editors workshop, Tom Senior mill, Myford ML7-R, ME and MEW website, 2007 Model Engineer exhibition, Harold Hall, Cherry Hill, the greatest collection of models under one roof, subscriptions, scribe a line. the purpose of the workshop, the major items, minor machines, the workshop, in the house, in the garage, purpose built, location, insulation, condensation, roofing. design considerations, column assembly, drive assembly, spindle assembly, mounting assembly, large collet chuck, making the column assembly, top and bottom plates, leadscrew, slider blocks. the cause of it all, getting rid of rust, internet searches, in practice, experiment, how does it work. initial trials, design, construction, conical spigot, base plate, swing plate, tool block, adjuster slide, fulcrum block and pivot rod end, pivot post, other parts, assembly, operation.

126

52

Scribe a Line

127

11

Dave Clark's Commentary

on the editors bench

127

12

The Metalworkers Workshop (1)

Setting up a home workshop

127

16

A Lathe Mounted Milling Head (1)

A useful accessory for the lathe

127 127

22 23

Unimat 3 Milling Head Depth Stop Electrolytic Rust Removal

Drill holes to a set depth Reclaim old tooling

127

25

A Ball Turning Attachment

Turning very small ball ends

127

30

A Tale of Two Toolposts

Making a quick change toolpost

127

36

Using the Warco Magnum Bender

Bending sheet metal

background, manufacture system A, system C, tool holders, making the block, other parts. complex components, the starting point, an angular measuring device, channel cross sections, one possible criticism, making shackles, wrong first time. background, dust control, table control, accessories, common work slide, the slitting saw jig, drill grinding jig, alternative drill jig, vertical slide, second lathe tool holder, radius table. Malcolm Stride

127

39

Living with the Worden

Improve your cutter grinder

127 127 127

50 51 51

Trade Counter Fireside Reading Next issue

Warco Magnum bender, The Warco catalogue. Miniature Internal Combustion Engines

127

52

Scribe a Line

motorcycle restoration, gremlins, the mix of articles, REMAP Scotland, REMAP Berkshire, motorcycles on the cover, safety and little engines, lapping model aircraft engines, model aircraft engines and spark erosion, motorcycling, dividing in the workshop and engraving with CNC, router table fence, motorbike wheels, MEW wall charts, motorcycles variable frequency supplies and aircraft engines, a revolving chuck, cleaning up after silver soldering, realigning a centre drill, multi-purpose machine, dressed b razed joins in copper, quick tips, editors' tips, carbon brazing. MEW complaints, large and small, CNC conversions and machining, new contributors, letters and readers tips, MEW 127, extra special subscribers offer, the ME and MEW website, advertisers, evening classes.

128

11

On The Editor's Bench

Dave Clark's commentary

128

12

The Metalworkers Workshop (2)

Fitting out the workshop

the benches, storage, electrical power, some pointers, supply source, length of cable, the workshops own consumer unit, earthling, installation, lighting, heating. spindle mounting bracket, leadscrew operating handle, drive assembly pulleys, drive input spindle, pulleys continued, spindle assembly. background, base and clamp blocks, support arm, locking lever and washer, support pillar, clamp collar, locking screw, tool rest, tool rest post, having a go, result. DRO, background, the objectives, some possibilities that were considered, making the bed swarf guard, grater cross axis travel, longitudinal scale, cross scale, digital scales mode of operation, the scale end plates, performance and benefits. background, farmed out, in house, cutting devices, cutting trials, design, construction, the block, the shank, conclusion. background, the Myford ML7 collet system, the project takes shape, making a start, collet closing nut, making the collets, making the double collet blank, slitting the collet, considerations for collet with small bores, silver steel and hardening.

128

17

A Lathe Mounted Milling Head (2)

Continuing the construction

128

24

A Quick Change Hand Turning Rest

An easily made accessory

128

29

Adding Digital Readouts to a Mill/Drill

Economical accuracy improvements to your mill

128

34

Cutting Circles in Thin Sheet

A simple tool for cutting circles

128

37 Making Two Morse Taper Collets

Improve your work holding

128 128 128

42 45 46

Unimat 3 Auto Feed Belt Looper A Simple Electronic Edge Finder Next Issue

More improvements to the Unimat An easy-to-make setting aid

using an LED and battery.

128

50

Trade Counter

Myford series 7 manual, GLR catalogue, Mallard metal packs, Blackgates Engineering, Polly model engineering, Camden miniature steam services, Proops brothers ltd, the college engineering supply, Milton Keynes metals. the Darex drill doctor, health and safety and the home workshop, article suitability, health and safety police, safety and family involvement, scribe a line format article suitability and safety, Tom Senior mill, drilling square holes, bending polycarbonate sheet, micrometer stand.

128

52

Scribe a Line

129

11

On The Editor's Bench

Dave Clark's commentary

the third Friday, workshop practice books, the model engineer exhibition, MEW contributors, readers letters and tips, in the editors workshop, Axminster workbenches, Clarkson tool and cutter grinder. going metric, drill sizes, thread systems, calibrated equipment, metric measuring equipment, material specifications, free cutting, general purpose, lead content, not available, known specification, non ferrous metals, project planning, tolerances, made to fit, a list of materials, man-hours, avoid tool changes, most useful item, computer aided design, unfinished project. the spindle continued, large collet chuck assembly, assembly, design changes, belt guards. fitting the stop, design no 1, design no 2. DRO, Myford Super Seven 7. background, the body, slide, feed screw bracket, feed screw, feed nut, hand wheel, spring end plate, cam spindle, handle, final thoughts.

129

12

The Metalworkers Workshop (3)

Planning the work

129 129 129 129 129

16 21 23 24 28

A Lathe Mounted Milling Head (3) Two Unimat 3 Saddle Stops Fine Tuning a Digital Readout A Retracting Screw Cutting Tool Holder A Practical Use of CNC Machining

Finishing the construction Turn accurately to length Ensuring correct alignment Design for a small lathe Simple profile milling

129 129

31 33

Axminster Power Tools Double Bench Station The Clockmaker's Workshop

Assembling flat pack workbenches Making a simple clock stand

what's available, assembly, the bench top, drawers and shelves, conclusions. background, a useful exercise, an old tool, material for files, sizes and shapes, small and versatile, rough or smooth, single or double cut, special types, time savers, safe edge or not so safe, picking off blemishes, keep them clean, be safe, ways and means, filing techniques, old files never die they get recycled. the definition, metallurgy of brazing, solidus and liquidus, the six steps, design the joint, cleaning the components, fluxing the joint, assembly, heating, post-braze cleaning.

129

34

Fitters Little Helpers

Files for the workshop

129

39

A Closer Look at Silver Soldering

Do you know how to do it?

129 129 129 129 129

42 47 48 49 50

The Guildford Model Engineer Exhibition A great day out Using Veroboard as a Riveting Guide Accurate setting out for rivets Top Slide Modification for the Warco A useful lathe Improvement WM180 Next Issue Tag Gortons live steam workshop, bearings for Harold Halls Trade Counter milling head, Noggin End metals. Fireside Reading

background, the locating disc, clamping plate, hexagon head bolts.

129

51

129

52

Scribe a Line

Ultimate sheet metal fabrication and advanced sheet metal fabrication by Timothy Remus, the car modellers handbook and slot car handbook. new contributors and criticism of articles, feedback on MEW, MEW 127 carbon brazing, cross drilling, MEW front cover, keeping clean in the workshop, the metalworkers shop, taper turning MEW 125, dividing MEW 125, combined roller bender shear, the Quorn MEW 125, Shellac, disc sander MEW 121, metal splinters, raw material supplies, foot switch safety, small unidentified lathe, Aureole and Avia micrometer study, editors tips, stub drills, countersinking holes.

130

11

On The Editor's Bench

Dave Clark's commentary

the model engineer exhibition, the variety of articles, Harold Hall and new contributors, longevity, size matters, 2 1/2in gauge, SMEE model engineer training courses, lather tool grinding. file types, tooth sizes, needle files, scrapers, scraper applications, sharpening scrapers, spanners, hexagon wrenches, measuring and marking out equipment, measuring angles, marking out, methods, hand stamps. background, 'Tina' the kit, value for money, particularly the milling head, jigs and fixtures, rotary table, locating diameter, concentric bores, machining a radius, machine vices, capable of machining steel, angle plate, slitting saw, connecting rod, different methods, the step method, using a spreadsheet. background, the body, fixed jaw, moving jaw, toggle, washer, pin, knob, finishing off, further thoughts. background, safety, general notes and modifications, construction, using the lift. the driving force, craft skills preserved, marking out, the number of crossings, templates, cutting out, filing jigs, choice of files, finishing off.

130

12

The Metalworkers Workshop (4)

Basic Workshop Hand Tools

130

16

Using The Lathe Mounted Milling Head (1)

Machining components

130 130

22 26

A Miniature Pin Type Precision Vice A Motorcycle Lifting Bench

Work holding made easy Cut out the backache

130

30

An Introduction To Crossing Out

Clock making in the home workshop

130 130

33 37

MEW Index Tailstock Drilling Depth Measurement

Index for issues 117 to 128 Demountable accuracy from a digital vernier DRO, Myford Super Seven 7, the development process construction, in use.

130

39

Anodising in the Workshop

Protecting and dying aluminium

before we begin, what is anodising, the principle, what we have to do, anodising in practice, safety first, electrical contact, sufficient cross section, the AAA rule, regulated power supply, current density, rinsing, applying the dye, sealing, what can be anodised, hard versus not so hard, sealing, what can be anodised, hard versus not so hard. the intermediate plate, camlock backplate.

130 130 130 130

45 47 49 50

The 2007 Model Engineer Exhibition ER25 Collet Chuck for a Camlock D1-3 Mount Next Issue Trade Counter

Tools on display at Ascot Improve the accuracy of your lathe Allendale Electronics, Myford Ltd. gears and gear cutting by Ivan Law, the amateurs workshop by Ian Bradley, model engineers workshop projects by Harold Hall, how (not) to paint a locomotive by Christopher Vine. silly mistakes, foot switch safety, removing broken taps and steel bolts from non-ferrous metals, model engineers exhibition, electrolytic derusting, Darex drill doctor, anodising in the home workshop, Baird mechanical television, use of CNC in the home workshop, readers tips, soluble oil problems, useful vice modification, cross drilling, cutting oil dispenser, two Morse taper collets. one the move new phone number, MEW availability, newsagent orders, overseas subscriptions, Sjef Pijls calling all Dutch and Belgium readers, incorrect photo MEW 128 P14. micrometers, vernier callipers, height gauges, height gauges, dial type measuring instruments, digital versions, slip gauges, sine bars, hole gauges, precision spirit level, parallels, surface plate, Vee blocks.

130

51

Fireside Reading

130

53

Scribe a Line

131

11

The Editor's Bench

Dave Clark's Commentary

131

12

The Metalworkers Workshop (5)

Precision tools

131

18

Using The Lathe Mounted Milling Head (2)

Machining components

131

23

A Useless Gift Put To Use

Making a collet chuck

using the cross slide table, flywheel, drilling, cylinder assembly, high speed, the plinth, setting the spindle perpendicular, some final thoughts, minor changes, minor modification. the body, nose, geared nut, pinion, the keys, stud and nut, moment of truth. background, module cutter, single point cutter, tooth form, theoretical cutter dimensions, making the cutter, cutting the wheel, conclusions. introduction, preparation, rough milling the outside radius, the inside radius, turning the outside radius, the inside radius, the threaded holes and the slot. background, tools required, the DRO package, fittings for the Tom Senior VS Major mk1, fitting the DRO support bracket, fitting the cables, caution, fitting the scales, x-axis scale, y-axis scale, zaxis scale, validation, functionality, conclusions. construction, the base, the grinder, swing arm stand, swing arm, work holding carriage, other components, setting-up, in use, testing, with hindsight, conclusion. placing the order, tanalised bearers, the door fittings, windows. what it's all about, get to work, finishing an fettling.

131

26

Gear Cutting

Using a multi tooth cutter

131

30

One way To Make An Awkward Shaped Machining an unusual component Object

131

33

Fitting A Digital Readout To A Tom Senior VS Major Mill

Improve the accuracy of your machine

131

38

A Swing Arm Work Holder For Surface Grinding Next Issue A Shed To Far

An unusual surface grinder

131 131 131 131 131

44 45 46 47 51

Buying a wooden workshop

A Detent For A Vertex BSO Improving a dividing head Low Temperature Repairs To Light Alloy Repairing model aircraft crankcases Components The Clockmaker's Workshop Making a screw head polishing tool

131

52

Scribe a Line

know that spanner and making radius turning tools, home workshop condensation, time for praise, single cut files, cheap DRO readouts, live chucks and rev counters, gunmetal grey paint, enjoyable articles, small stationary engines, types of article, the HSE and the home workshop, Mike Hurley's best tip, Clarkson autolock holders, star letter MEW 129, safety and other rantings, removing broken taps sheared bolts etc, anodising in the home workshop.

132

11

On The Editor's Bench

Dave Clark's commentary

on the move settled at last, future articles, broadband and scribe a line, workshop charts, Dave Fenner and the C3 lathe, issue 133 the Christmas edition, Bob Loader, new contributors still required, small tools. saddle stop, tapping guides, universal joints, distance gauges, grinding rest, back stop, faceplate balancing fixture, the electrics, electronic and the workshop, digital readouts, DRO, CAD/CAM longevity, CAD for drawing only, machine installation, hygiene/safety, hand creams, physical protection. increased traverse, digital readout DRO, minor modifications, if ever.

132

12

The Metalworking Workshop (6)

Home made tools and accessories

132

20

Lathe Milling Head Additions

Adding a digital readout

132

21

Alternative Work Holding For The Worden

A height adjustable tool holding attachment

132 132 132

29 31 34

A Workshop Catch-all Converting A Gas Only MIG Welder To Gas Or No Gas The Midlands Model Engineering Exhibition 2007-10-26

Stop losing small pads Improvements to a budget welder Tools on display in the Midlands

background, side plates, guide bars, side block, spacer block, side cheeks, parallel arms, sub assembly, bracket and lifting screw, housing, subassembly, bracket and lifting screw, feed-screw assembly, housing, space and table plate, stop screw and support bars, setting scale, bracket piece, tool holder body, lathe tool holder, tooth rest, index ratchet, cam plate, tap cam followers, angle disc, handle, conclusion. background, lean to sew, Calico and stuff, out with the iron, don't get knotted, walk away safely. the basic welder, the strip down, the conversion.

132

37

A Tool And Cutter Grinder From The Junk Box (1)

Making do with scrap components

132

45

A Swing Clear Boring And Threading Tool Holder

An old device renewed

132

48

Home Made Cutting Tools

Budget tooling for the workshop

133

11

On The Editor's Bench

Dave Clark's commentary

wheel head body and end caps, retaining nuts, shaft assembly, bearing retaining caps, wheel head bracket and slide adjustment, the wheel head slide, motor bracket, compound work head, top slide, main slide, capstan hand wheel, slide stop, jockey block, collet tube, guard, the collets, lathe tool attachment, diamond wheel dresser. the boring tools, recycling, the retracting version, screwcutting, boring. materials, mild steel and even brass, silver steel or carbon steel gauge plate, high tensile bolts, high speed steel, tungsten carbide, tool geometry, examples from the toolbox, milling and drilling tools, press tools, hand tools, conclusion. 2007, 2008, future articles, the model engineer exhibition.

133

12

The Metalworkers Workshop (7)

Harold Hall introduces the lathe (part 1)

the lathe only user, the size of the lathe, the speed range, controls, drive clutch, top slide, screwcutting, saddle half nut, thread dial indicator, powered cross slide feed, milling head, accessories, cutters, replaceable tip cutters, permanently tipped cutters, high speed steel (HSS) cutters, which type, tool holders. gear ratio, disengaging the worm wheel, table locks and end stops, using the rotary table, mounting the workpiece, vertical use, hole boring, the machining process. background and description, delivery, initial impressions, procedural summary, strip down, examination and reassembly. background, using the tool, final touches, versatility, put to use. background, the current project, making the tool, using the tool. background, motor problems, lessons learned, problems with the index collars, options, make totally new aluminium index collars, the new collars. background, adapter, throwaway, cutters, making your own FC3 adapter, this is the procedure I adopted. background, steel or wood, general design, drip tray, cutting material, cleaning, welded up, protection, and next. background, design, the caveats, lifting frame stress check, main frame, construction.

133

18

Using A Rotary Table In The Home Workshop

Harold Hall goes round in circles

133

24

The C3 Mini Lathe (1)

Dave Fenner looks at this versatile lathe

133 133

30 33

Graduating To Quicker Scales A Boring Solution To Spherical Turning

Jim Whetren Scribes Lines David Haythornthwaite tries his hand at ball turning

133

36

Living In Harmony With Tom

Eric Clark makes the most of his Tom Senior mill

133 133 133

38 39 40

Increasing The Versatility MEW Caption Competition UK result A New Bench For The Myford Series Seven 7 Lathe

Of The Clarkson Autolock Chuck

Dave Fenner gives his lathe some support

133 133 133 133 133

45 47 48 49 50

An Elevating Barrow Next Issue Chuck Storage Fireside Reading Trade Counter

Dave Fenner raises and lowers his work

John Slater keeps his chucks in good order CNC milling in model construction vol 1,2,3 TurboCAD Deluxe 14

Christopher Selig

133

51

Scribe A Line

Win a book for best letter and best tip

alternative uses for Myford kits, rotary table and errors MEW 130, gas-no gas MIG conversion, availability of electronic spares, small i/c engine design for beginners, Ta Shing lathe request, Clarkson autolock holders, the metalworkers workshop - machine layout, grey paint, gear cutting MEW 131, disc sander motor, future articles, Mike Hurley's recommended flux and chemical dangers, soldering zinc and condensation, stub drills and spot drills, wax lubricant, applying coolant.

134

11

On The Editor's Bench

Dave Clark's commentary

134

12

The Metalworkers Workshop (8)

Harold Hall introduces the lathe (Part 2)

134

18

Thread Cutting Using Tip Tools

Harold Hall's screwcutting tips

new year, copyright theft, in the workshop, CNC mill, new contributors, MEW availability. work holders, faceplates, jawed chucks, backplates, collet chucks, range held, closing method, dead length systems, collets holders, are collets worthwhile, must haves, drill chicks, centres, catch plate and lathe dog, tailstock die holders, steadies, knurling tools, saddle stop, other accessories, Keats angle plate, non-turning operations boring, dividing. the process, using indexable tipped tooling, the tips, the holders, handling, making your own holder, using the tipped tools, a word of warning, where to purchase. getting started tooling up turning, sharpening, drilling, measuring, accessories, work holding and tool holding, brief digression, two M6 nuts, saddle/carriage stop, brief digression, getting started safety, a first exercise, observations after initial experience.

134

22

The C3 Mini Lathe (2)

Getting started, tooling up

134

28

A New Bench For The Myford Series Seven 7 Lathe (2)

Dave Fenner attempts woodworking

134

32

A Toothed Belt Drive For The Unimat 3

Maurice Rhodes cuts his teeth on a Unimat

134 134 134 134 134 134

36 38 41 42 50 51

Keeping It Clean A Poor Man's Linisher Next Issue A Tool And Cutter Grinder From The Junk Box Trade Counter Fireside Reading

John Slater puts most of us to shame Jim Whetren goes shopping

philosophy, drawer slides, cutting, biscuit jointing, carcase assembly, top drawers, knobs, tidying up, further drawers and storage, change of direction. a positive drive, Unimat SL belts, the toothed belt, the cutters, a salvaged wheel, a tempering tip, make a gauge, concentricity, tensioning the belt, fitting the new drive, speed control, mounting the control box. fitted covers, leather protection, hidden attachment. stop, spacer, mounting plate, fence, mounting, assembly.

Part 2 the drawings Burnell models, model engineering supplies (Romford). so-cal speed shop's how to build hot rod chassis by Timothy Remus, how to build an old school bobber by Kevin Baas. ideas for future issues, a couple of points about MEW 127, toolpost article MEW 127, electrolytic rust remover MEW 127, residual current breakers and earth leakage breakers, spherical turning and CNC cutter grinding, work piece lubrication, gunmetal grey paint, gas no gas MIG, grinding wheel problems MEW 133, criticism of articles, health and safety MEW 133, MEW 133 cover and future content, Harold Hall's milling head, unusual toolmakers clamp, readers tips, chaos on the headstock cover, workshop layout MEW133, soldering zinc MEW133, screen capture program, non appearance of free ads, MEW index on the web, grinding wheel dressing problem MEW133 scribe a line, 3 phase from capacitors, boring cutter sharpening, Dormer drill grinder information required. the front cover, the first 12 months, the next 12 months.

134

52

Scribe A Line

Win a book for best letter and best tip

135

11

On The Editor's Bench

Dave Clark's commentary

135

12

The Metalworkers Workshop (9)

Harold Hall introduces the drilling machine

135

16

Toolmakers Clamps

Harold Hall shows how to use them

135

21

The C3 Mini Lathe (3)

Dave Fenner improves this versatile lathe

135

27

Broaching Internal Keyways

Mike Haughton makes his own broaches

135

30

A Look At Number Stamping

Jim Whetren finishes a dial

135

33

Making A Large Fixed Steady For The Myford Series Seven 7

Dyson Watkins casts his mould

which drilling machine, controls, accessories, drills, countersinks, counterbores, vice, compound table, other accessories, using the drill, next issue. toolmakers parallel clamps, setting, setting a clamp, limitations, used for milling, used for drilling, other uses, non standard clamps, manufacture, metric materials, how many. apron cover, four jaw chuck centring for beginners, plunger body, taper plug, plunger and spring, a brief digression on parting off, plunger knob, a brief digression on knurling, spacers, thumb nuts, mounting plates, finishing touches. not high speed steel, precision ground flat stock, broach tooth form, a broach machining fixture, hardening and tempering, bushes, key steel, multiple keyways, conclusion. background, punch holder, the punches, work holder, VDH micro drum, cleaning up. the wooden pattern, the moulding set up, casting preparations, machining and casting, milling the slot for the swing clamp, swing clamp bolt, milling the finger location slots, making the fingers, finger retaining nuts, the steel hinge plate, steady mounting plate, thumbscrew. background, the past, powerful almost silent, what's needed, dead power tools, powerful magnets, getting down to it, bearing tube, winding time, losing count, back to the lathe, now to the tricky bit, making the body, don't panic, the cooling holes, fitting the magnets, test fit the components.

135

40

Brushless Outrunner Electric Motors

John Rutter winds his own

135

48

Next Issue

135 135 135 135

49 50 52 53

Set-up And Use Of The Cutter Grinder A Simple Indexing Attachment For The Warco 220 Lathe Fireside Reading Trade Counter

Dyson Watkins offers a few tips Peter Shaw offers easy dividing

a couple of mods, setting up the machine. background, construction, mistakes problems and amendments. steam trains in your garden by Brian Wilson, regulator clock construction by Peter Heimann.

precision oxy welder from down under, Tracy tools has moved, expo drills and tools. outrunner electric motors add on to article, ice program ver. 1.6, condensation in the workshop, future articles, workshop space, Christmas cheer recycled, Harold Hall replies to MEW 134 scribe a line, John Stevenson's comments MEW 133, backwoods three phase, drawing holder, readers tips, c3 quick change toolpost, Myford tailstock swarf guard, a positive response. outrunner electric motors, mew contributors, the practical engineer, machining complicated components, British Seagull outboard motors. turret mills, mill/drills, common features speed control, speed ranges, rotating head, calibrated X Y Z feeds, digital readouts, DRO, traverse stops, power feed, drawbar, the spindle taper, horizontal/vertical attachments, accessories, the cutters, cutters having shanks, indexable cutters, solid cutters, what size cutter, preferred shank, other types of cutter, disk type cutters, holding cutters, boring head. milling in the lathe, modifications, nuts, extension shaft, leadscrew handwheel, graduated collar, leadscrew modification, assembly, tailstock and apron handwheels, and now to milling, sub table, clamps, in use. getting organised, belt sander, a better table, restricted access, the larger tools, more storage, 1950s storage, Worden wonder.

135

54

Scribe A Line

Win a book for best letter and best tip

136

11

On The Editor's Bench

Dave Clark's commentary

136

12

The Metalworkers Workshop (10)

Harold Hall introduces the milling machine

136

18

The C3 Mini Lathe (4)

Dave Fenner makes more improvements

136

24

Revising Workshop Storage (1)

David Piddington Goes Back To Basics

136

29

Tapping Into Scrapyard Resources

Jim Whetren makes a 'George Thomas type' pillar tool

136

33

Insert Tools (1)

Mike Haughton looks at tool materials and inserts

136

37

Vice Squad Clampdown

Jim Whetren advises on using the drilling machine safely

background, finding the material, the pillar, the arms, base, large tool holder, normal tool holder, table and vice, number stamping, heavy hitting, fasteners, locking handles. so why carbide, carbon tool steels, high speed steels, what are carbides, hardness, toughness, so how tough and how hard, CS carbon tool steels, HSS high speed steels, powdered HSS, ultra fine grain carbides, mixed carbides and carbonitrides, coatings, cermets, Si3M4 silicon nitride, Al2O3 aluminium oxide alumina, PCBN polycrystalline cubic boron nitride, PCD polycrystalline diamond, health and safety. background, table support, vice clamping bar, more capacity, recycling, depth stop, depth indication, drilling safety.

136 136 136 136 136

41 43 45 47 49

Some Thoughts About The London 'Richmond' visits the smoke Model Engineering Exhibition A between Centres Boring Bar With Fine Paul Murton makes a boring job easier Adjustment Laying Out A Workshop Michael Green rearranges his machines Making Solid Swarf Next Issue John Slater experiments with trepanning

background, the bar, tool holder, dial, using the boring bar. footprint and extended dimensions. beginners improvers, the sound of the swarf. how to paint your car by Dennis W Parks and David H Jacobs Jr, performance welding by Richard Finch, how to build a cheap sports car by Keith Tanner, how to paint flames by Bruce Coldwell, kustom painting secrets by Jon Kosmski, how to build a cheap hot rod by Dennis W Parks.

136

50

Fireside Reading

136

52

Trade Counter

machine mart catalogue, Actulite task lamp, artist blacksmithing DVD, Myford open day, Arrand flat standing toolmakers clamps and catalogue.

136

54

Scribe A Line

Win a book for best letter and best tip

thread cutting in MEW 134, on the editors bench MEW 132, ER collets, modifications to Warco headstock cover, sawdust in motors, unidentified lathes, Unimat 3 toothed drive, outrunner motor article, model engineers workshop data book, foundries for one offs, MEW 133 cover Dave Fenner's daughter and jewellery, cross slide power feed, Len Masons baby lathe, workshop storage space saving, skip diving, screwcutting.

137

11

On The Editor's Bench

Dave Clark's commentary

137

12

The Metalworkers Workshop (11)

Harold Hall introduces the milling machine part 2

137

18

The C3 Mini Lathe (5)

Dave Fenner makes some more accessories

a younger reader, in the workshop, free ads. minor accessories, the machine vice, angle plates, parallels, Vee blocks, positioning devices, major accessories, dividing heads, 5c fixtures, rotary tables, taking a cut is easy. saddle clamps, positioning against the saddle, cross slide clamping screws, in use, parting off, top plate and body, clamp bolt, support, assembly and set up, in use. out to work, the first job, working it out, carbide tipped tooling, HSS cutting tools, carbide cutters, metric sizes, and finally. the milling machine, the Quorn or the Stent, I considered to following, modifications, double ended, a general guide, the base casting, the motor mounting, a novel motor, cutter guide, the stops, the equipment comprises of:. workpiece materials, ISO carbide grades, insert grade comparisons, insert grade markings, type of work, cutting data, insert cutting performance, tool tip speed, insert edge geometry, conclusions.

137 137

24 29

Revising Workshop Storage (2) The Practical Engineer

David Piddington Goes Back To Basics Experiences from industry

137

31

Making The 'Stent' Tool And Cutter Grinder

Modifications and improvements to this versatile machine

137

36

Insert Tools (2)

Mike Haughton looks at inserts

137

41

Diary Of A CNC Convert

Dave Senior modifies his mill to CNC

background, slow progress, mechanical conversion, electrical conversion, wiring up, problem solving, protected power, using the machine, tool holding, the next phase. background, an original super 7. model engineering use, originally 3 phase, a complete restoration, guarantees of accuracy, Myford to the rescue, a new Hemingway kit, refurbishing the stand, stripping down, a day at Myford, the workshops, milling the bed, surface grinding, the slideway grinder, the saddle, fitting the saddle, shimming the saddle, rack and pinion, headstock and tailstock alignment, Myford records. unidentified lathe, old machinery, backwards three phase MEW 135, Velcro, CNC milling, single cut files, Dormer drill grinder scribe a line MEW 134, Unimat toothed belt, floating reamers, cutter storage, wavy parallels, steam engines on the cover, sand casting, casting aluminium, soft centre replacement, a taper turning trick, weight of round bar, headstock cover modification safety improvement. internet criticism, Clarkson autolock chuck an apology, subscriptions, articles and contributors, in the workshop. grinders, off hand grinder, tool and cutter grinder, surface grinder, belt and disc sanders, motorised saws, horizontal saws. guided centre punch, the body, punch, operation, filing rest, construction, the cradle side plates, rollers, pins, adjuster wheel and nut, pillar, pillar block, clamping screw, angle bracket, base clamp, fixed and travelling steadies, chuck depth stop.

137

46

Rebuilding The Myford Super Seven 7 Lathe (1)

a visit to Myford for a regrind

137

53

Next Issue

137

54

Scribe A Line

Win a book for best letter and best tip

138

11

On The Editor's Bench

Dave Clark's commentary

138

12

The Metalworkers Workshop (12)

Harold Hall investigates grinders and saws

138

16

The C3 Mini Lathe Part 6

Dave Fenner makes a filing attachment and looks at steadies

138

22

Insert Tools (3)

Mike Haughton looks at tool holders

138 138 138

28 33 36

Converting A Myford ML7 Lathe To CNC Tony Jeffree makes a start with the leadscrew Part The Practical Engineer CNC Milling With Mach 3 (1) Experiences from industry An introduction to CNC milling

138

39

Adding A Drive To A Lathe

Linton Wedlock builds a countershaft drive unit

138

41

A Spin On Collets Rebuilding The Myford Super Seven 7 Lathe (2) Draw Plus Next Issue Model Engine Mechanics & ICE 1.6 Fireside Reading A Short Guide To Foundry Supplies & Metal Casting Services

Using ER 32 collets in a spin indexer

ISO external lathe tool holders, turning tool geometry tool holders for automatics, chip breakers, internal turning tools, external and internal screw cutting holders, ISO codes for threading inserts, ISO codes for partial thread cutting inserts, shims (seats or anvils) for threading, my favourite lathe insert systems, parting off, profiling, turning between centres spindles axels etc, threading with inserts. introduction, design decisions, modifying the leadscrew, installing the leadscrew stepper motor, testing the leadscrew drive. installing and aligning a lathe. CNC components, the basics of milling clocking the vice, setting a datum, homing the machine, G codes straight linear moves. drive configuration, frame assembly positioning, al alternative arrangement, belt tensioning, a digression, conclusion. background, the 5C non conforming thread problem, the moment of truth, minor niggles, a new tightening/turning collar, the final touch. apologies, Sino SD56-3V DRO.

138 138 138 138 138 138

46 50 51 52 53 54

Repainting the lathe A simple drawing program Book and program review

CNC programming by Peter Smid, Machinery's handbook, The Hornby book of model railways by Chris Ellis.

138

55

Scribe A Line

Win a book for best letter and best tip

139

11

On The Editor's Bench

Dave Clark's commentary

Sphere Acorn or Halifax, machine vices, brushless motors, grinding wheel dressing, Chinese lathes and mills, gap in speed range of drilling machines, starting a centre drill true. Myford thinking out of the box, subscriptions, back numbers, in the workshop, articles.

139

12

The Metalworkers Workshop (13)

Harold Hall concludes the series with shapers, presses and welders

presses, purpose, bending, punching holes, cropping, force fitting and removing, press types, fly press, arbor presses, toggle presses, hydraulic presses, accessories, punches and dies, bending, installation, need for? Sheet metal machines, welding, electric welding equipment, arc welders, MIG welders (metal inert gas), shaping machines, what are the advantages of a powered shaper, a final comment.

139

17

The C3 Mini Lathe (7)

Dave Fenner makes a drilling attachment, a saw table and a grinding table

139

23

Converting A Myford Lathe To CNC (2)

Tony Jeffree moves on to the cross slide

139

27

The Practical Engineer

Three simple accessories for a Myford

139 139

29 31

CNC Milling With Mach 3 (2) Not Another Toolpost

Tool setting Another add on for a Myford

139

32

Myfords Rule But Not Always

Improvements to the 'George Thomas' dividing head

139

37

Grinding Wheel Selection, Safety And Dressing (1)

The different types of wheels

toolpost powered spindle drive, construction, thumb nut and toolpost nut, using the attachment, saw table attachment, added embellishments, comments after initial applications. introduction, design decisions, constructional details, assembly, cross slide drive performance, next time. Myford series seven 7 bed stop, the support block, main block, a simple chuck back stop, a carriage lock, using the three items. zeroing the machine, setting tool height offsets, tool height setting with G54. Gibraltar toolpost, a casting (or not), match the heights. background, the kit, packing plate, boring and machining the boss, the spindle, tailstock cotters, worms, division plates, drilling the many many holes, boring, micro adjuster, the verdict. anatomy of a grinding wheel, the abrasive, aluminium oxide, silicon carbide, diamond, the size of the cutting grain, the hardness of the bond, the structure, the bond, vitrified, silicate, shellac, resinoid, rubber, marking grinding wheels, difficult choice.

139

41

Insert Tools (4)

Mike Haughton looks at milling tools and tips

milling cutter geometry rake, milling cutter positioning (facing milling), entering angle, face mill tilt angle, ISO nomenclature, milling tool holders, milling inserts, my favourite milling insert systems, face milling cast iron, milling hardened steel, dovetail cutting, power consumption, coolant and lubricants, conclusion. stripping the small bits, reassembling the headstock, the tailstock, unforeseen wear, the Myford open days, unwarranted optimism, excessive backlash, gearbox, motor and clutch, reuniting the lathe with the stand, testing the lathe under power, the electrical installation, on the DRO, fitting the DRO, a minor problem, power cross feed, nearly done. basic plugs, some applications, crossdrilling, turning the plugs, the larger plugs, a tip, storage.

139

46

Rebuilding The Myford Super Seven 7 Lathe (3)

reassembling the lathe

139 139

53 55

Locating Plugs Next Issue

Simple aids to setting up

139

56

Scribe A Line

Win a book for the best letter and best tip

subscription offers, stop press, electrical braking, does anyone speak Chinese scales, the C3 lathe form Arc Euro Trade, free CAD package, alternative CAD, the practical engineer lathe alignment, brushless outrunner motors and castings versus fabrications, an alternative vertical slide for the C3 lathe, keeping chuck threads clean, workshop layout, setting spin index true, mounting vices on milling machines.

140

11

On The Editor's Bench

Dave Clark's commentary

140

12

Making And Using Drill Jigs

Harold Hall discusses these useful tools

140

18

The C3 Mini Lathe (8)

Dave Fenner upgrades the bearings and adds some more accessories

140

26

Making And Using A Saddle Stop

Harold Hall answers a reader's request

140

29

Grinding Wheel Selection, Safety and Dressing (2) A Really Quick Change Tool Post Official Instructions For The Clarkson Autolock Chuck Next Issue

Michel Christiaens concludes his grinding wheel articles

140 140 140

32 38 38

Jim Whetren speeds up his tool changing

the Harrogate exhibition, slight changes to this issue, hark back to the workshop - Dave Fenner writes, articles in this issue, Sieg/Arc Euro Trade KX1 CNC mill. a simple drill bush, more complex requirements, flat plate jigs, two part jigs, larger drill jigs, brushes, hardening and tempering, three drilling jigs, not just a scriber and centre punch job. DRO handwheels, topslide conversion, cross slide conversion, bearing change, brief digression on taper roller bearing adjustment, initial experience, radius turning attachment. boring a blind hole, machining to a step, and in reverse, headed pins or similar, milling on the lathe, calibrated saddle stops, a simple saddle stop, manufacture. take care, truing the wheel, dressing stick, wheel dresser, diamond dresser, the most difficult part. background and evolution, piston, clamping sleeve, locking sleeve, tool holders, parting tool, the smaller lathe. assembly instructions. design, work benches, drawer units, small tool drawer sets, bar stock drawers, mobile units, open shelf units, cupboards and worktop extensions, bandsaw base, toolholder stands. background, swivel base casting, the challenging bit, the spin indexer, a vice, vice adaptor plate, graduation and numbering, indexer Fiducial line. background, more than just lighting, building a system, fuses, transformer details, parts list and costing guide, low voltage power tools, safety warning, lighting conversion.

140

39

Making Workshop Furniture (1)

Stuart Walker shows us his new workshop

140

43

An Outsize Hasty Purchase

Jim Whetren puts a casting to good use

140

49

Low Volt System For The Workshop

Chris Smith reduces his power output

140

52

Harrogate 2008

Dave Fenner reports back KX1 comprehensive review, John Stevenson, the editor's workshop, 'Richmond' rebuilt Super Seven 7, subscription gifts, overseas subscriptions, articles supplied. Sinsheim at Ascot, MEW special Cherry Hill interview, subscriptions, readers free ads, in the workshop, tools at the 2008 Model Engineer Exhibition. sharpening by hand, drill grinding devices, the basic drill grinding jig, using the jig, 180 deg rotation, other forms, reduced helix, point thinning, multi facet drill forms, the disadvantage, editors note Warco jig. introduction, design and construction, manufacture, box angle, short dovetails, swing plate, long dovetail bar, slide assembly, link plate, modifications to the cross slide, clamp plates, operation, first trial. material selection advice - plywood, hinges handles and drawer runners, glues, varnishes and paints, sheet metal, cutting up large sheets of plywood, jointing and assembly, register grooves and screw joints, biscuit jointing, finishing. main base, sub-base, pillar, stud and nut, feed screw and pushrod, bolt, Harrogate purchase, minor problems, the lathe centre height, taking note, setting tools in the front post, setting tools in the back post. drilling the backplate. drilling cycles, the initial Z level, the R level, polar coordinates. fitting the lamps into the holder.

140

58

On The Editor's Bench ... Continued

Dave Clark's commentary

141 141

10 11

Subscription Offer On The Editor's Bench Dave Clark's commentary

141

12

Sharpening Twist Drills (1)

Harold Hall tells you how to keep your drills sharp

141

18

The C3 Mini Lathe (9)

Making a taper turning attachment

141

25

Making Workshop Furniture (2)

Stuart Walker explains the woodworking bit

141

29

A Fine Feed Base For A Drill Grinding Jig Lathe Tool Height Setting The Practical Engineer CNC Milling With Mach 3 (3) Our Youngest Ever Reader Converting Machine Lights To Halogen Lamps

Jim Whetren describes this useful adaptor

141 141 141 141 141

32 34 36 38 39

A simple method of setting lathe tool height How to fit a chuck to a backplate Writing your first program Unless you know different? Chris Smith lights up his machines

141

45

Converting A Myford ML7 To CNC

Tony Jeffree looks at the control electronics

design decisions, safety issues, parts sources, mounting the drive system components, the power supply, drive power and motor socket wiring, step and direction connections, sensor and E-stop wiring, LCD screen platform and drive box mounting, plugging it all together, nest time.

141 141

51 52

Next Issue Trade Counter Arc Euro Trade, Fieldsend Miniature Engineering, Allendale Electronics Ltd, Warco cylinder clamp, the Sieg KX1 CNC mill, Hemingway kits. Modelworks International, MEW on eBay, can you identify this, cheap Chinese machines, tapping with plastic balls, evening class in Kingston, irritated reader and information wanted, saving money, constructive feedback, window cleaning, insert tools, tailstock collision, forward projection of lathe tools, I visited ToysRus today thick rubber matting. Entry form to run your engine Model Engineer and MEW special, 2008 Model Engineer exhibition, Myford will be at exhibition, workshop practice and back issues, Boxford TCL125. the four facet jig, split point geometry, sharpening tools in the workshop. radius turning attachments, new parts, backing, bridge, standoffs, adjuster, handle and push rod, modifications to casting, assembly, a brief aside on fitting threaded parts to tapped holes, tailstock offset centre for taper turning, making the parts, the clamp, swing bar and clamp, adjuster block and screw, backplate, centre, aesthetics, conclusion.

141

56

Scribe a Line

141 142 142

59 10 11

Sinsheim Track Subscription offer On The Editor's Bench

Dave Clark's commentary

142

12

Sharpening Twist Drills (2)

Making a four facet grinding jig

142

15

The C3 Mini Lathe (10)

Improving the radius turning attachment and making an offset taper turning centre

142

20

Retrofitting The Denford Orac CNC Lathe

Converting this CNC lathe to Mach3

introduction, main electrical parts, safety, what to keep, power supply, spindle speed sensor, spindle drive, new inverter. background, mandrel adaptor, tapered plug, worm shaft assembly, worm, collar, spindle, body, bracket, support arm, division plate, body and plate fitting, index arm, index pin, pin housing, knob, assembly and setup. casting media, patterns, split patterns, the centre boss, turn over pattern, core boxes. make a jig, prepare blanks, saw a waste, cut and repeat, a tip.

142

23

A Different Angle On Headstock Dividing Jim Whetren indexes in degrees

142 142 142 142 142 142

29 34 36 39 36 39

Pattern Making For Beginners Sawing Tee Nuts CNC Milling With Mach 3 Part 4 Converting A Myford ML7 To CNC CNC Milling with MACH3 (4) Converting a Myford ML7 to CNC (4)

Dyson Watkins makes some simple patterns Using a simple jig to speed production Simple circles and profiling Tony Jeffree looks at configuring Mach3 Simple circles and profiling Tony Jeffree looks at configuring Mach3

142 142 142 142 142

45 48 50 51 52

Adjustable Dial Indicator Bracket Simple Aids To Tapping Next Issue Fireside Reading Trade Counter

Making a useful swivelling indicator holder Making cheap dedicated tap wrenches Peter's Railway TurboCAD Pro version 15, Allendale Electronics Ltd.

cutter compensation, cancelling compensation. introduction, choosing a PC, installing Mach3, configuring Mach3, ports and pins, motor settings, checking things out. the design, using the bracket, construction, spindle, upper hinge, lower hinge, indicator rod holder, the rods. lathe and drilling machine tap wrenches. Christopher Vine titivation of Chinese machinery, the Stent tool and cutter grinder, drill sharpening 1, drill sharpening 2, keyboards in the workshop, simple can be best Kerry drill press.

142

56

Scribe a Line

143

Subscription offer

143

11

On The Editor's Bench

Dave Clark's commentary

143

12

Know Your Mill

Harold Hall talks about vertical milling

143

17

The C3 Mini Lathe (11)

Making a lever feed for the tailstock

143

20

Retrofitting The Denford Orac CNC Lathe (2)

Fitting a new interface

143

24

Making A CNC Cutter Grinder

Part 1, starting the construction

143

28

Making A Small Rotary Table

Dyson Watkins shows you how

143 143 143 143

31 33 37 40

A chain drilling jig Index For Model Engineers' Workshop Converting a Myford ML7 to CNC (5) High Speed Drilling And Engraving On A CNC Mill Using The Worden Tool And Cutter Grinder Next Issue

An afternoon spent in the workshop Issues 129 to 140 Concluding this interesting series

all change for the better, contacting the editor, 12 or 13 issues a year, dividing article, new model engineering club in Scotland, purchasing from advertisers, Model Engineers Workshop Special, a world first, in the workshop, lathe coolant, evening classes. permitted errors, adjustable head milling machines, the theory, end mill end cutting angles, back cutting, what the standards say, traverse accuracy, the British Standards, setting your milling machine tilting head, a few related thoughts, test pieces, a final thought. anchor plate, pressure block, links, handle arms, lever clock, lever, knob, pivot pins, removable pin, assembly and use. general notes on wiring/refitting, limit switches, software/hardware setup, initial testing, mechanical considerations, in use, suppliers. background, CNC machining, a brief description of the machine, machine construction. base plate, the disc, table, insert, milling Tee slots, Tommy bar holes, Tommy bar, mounting support, Tee nuts, clamp, setting up and use. difficult beginnings, jig description, using the jig, what happens with metal, points of use with metal, hardening, final points. shuttle xpress setup, using the lathe, Mach3 forums, a potential short cut, closing words.

143

41

Jim Whetren makes use of this versatile tool

lathe tools, screw cutting tools, slot drills, end mills, twist drills, radius grinding, wheel dressing, radial grinding, tap sharpening, end mill side teeth, gaining some height adjustment, the future.

143

48

143

49

Trade Counter

Warco coolant system, metal cased verniers from Warco, tool care products from Arc Euro Trade. Sheet Metal Fabrication, Custom Painting, Caroll Smith's nuts bolts fasteners and plumbing handbook, Haynes radio control car manual, beginning AutoCAD 2009, Bearings by Alex Weiss. back article referred to, Boxford CNC, newbie's to the hobby, waterproof keyboards, dimensioning consistency, compliments from down under, Chinese scales, Pinnacle problem, Picador parts, cheap Chinese machines, Warco BH600, CNC milling, subscription gift sorted, another unidentified lathe. the Ascot exhibition, judges volunteers helpers, the model engineer exhibition next year, so where to next year, magazine content, contributors, in the workshop, Simat 101 lathe, 13 issues a year, special issue magazines, the cost of paper.

143

52

Fireside Reading

143

54

Scribe a Line

144

11

On The Editor's Bench

Dave Clark's commentary

144

12

Cutting Complex Pitches With An Imperial Lead Screw

Harold Hall talks about cutting metric threads and worms

metric, using change wheels, metric threads, the mechanics, quick change gearbox, three choices, method three an easier option, worm gears, method one, method two, method three, method 4, required worm pitch, other values, error eliminated, using gear box, designing gear chains. machining to size, gib strip, topslide spigot, leadscrew and nuts, stand offs and mounting details, clamp screws and pads, modification to top slide, swarf guard, conclusion. the tables, gib strips, first assembly.

144

18

The C3 Mini Lathe (12)

Making a long cross slide

144 144

25 28

Making A CNC Cutter Grinder (2) The Bristol Model Engineering and Hobbies Exhibition

Making the tables Linton Wedlock looks at the workshop tools on show

144

29

A Clock Wheel And Pinion Cutting Machine

Charles Woodward describes his silver medal winning machine

background, the design process, the basic requirements, design details, cutter drive train, spindle, handle and screw of the cutter slide, climb milling of pinions, the work head, division plunger, division plates, the tool tray, machine specification. laser levels. assembling the stand, lifting the lathe, general specification, initial impressions, headstock spindle and drive, tailstock, saddle cross slide and top slide, cutting metal. introduction, history, checks before starting, dismantling, the plan, plinth, drip tray, shaper body, motor mount, bolting the big bits together, washing and testing, reassembly, clutch lever improvement, motor mount part 2, assembly last stages, adjusting the slide gibs, tool holder, table Tee slots, tool feed dial, the feed Tee bolt, the finished item.

144

34

A Cheap And Easy Way To Align A Milling Machine Head

An afternoon spent in the workshop

144

35

Chester DB8VS Lathe Review

Dave Fenner looks at this variable speed lathe

144

39

Restoration Of A Shaping Machine

Rebuilding machine tools

144 144 144 144

44 48 50 52

The 2008 Ascot Model Engineering Exhibition Next Issue Trade Counter Fireside Reading

Dave Fenner looks around the UK's premier model engineering exhibition Model works update, Allendale Electronics, Myford collets. how to weld, how to paint your show car, a passion for steam by Marc Horovitz. Cunliffe and Croon horizontal mill, sharpening twist drills, Harold Hall know your mill MEW 143, small rotary table, sharpening twist drills 2, sharpening twist drills 3, hello from the colonies, mobile workshop. Christmas, free adverts, articles required, suggestions wanted, machining videos online http//techtv.mit. edu/file/743/, 13 issues per year, retrofitting the Denford Orac CNC lathe.

144

54

Scribe a Line

144

57

Free Adverts

145

11

On The Editor's Bench

Dave Clark's commentary

145

12

Making And Using Soft Jaws (1)

Harold Hall talks about these useful chuck accessories

purpose, machining the jaws, running true, discs or plugs, holding inside diameters, recording the diameter, hexagonal auxiliary jaws, making hexagon jaws, an easier option, larger wrap around, extending jaw life.

145

17

The C3 Mini Lathe Part 13

Dave Fenner looks at saddle adjustment

introduction, improvement strategies, dismantling and measuring, strategy one, strategy two, strategy three, strategy four, manufacture, the bracket, the taper gib, the adjuster screw, operational experience. operation, some detail, in practice, boring head construction, gear mechanism construction, in use, possibilities, a directly controllable boring head, conclusion. belt pulleys, collet run out, the Grindex, Y axis components. background, a second machine, the X2, real-bull, Weiss/Optimum, features, the machine arrives, lack of foresight, the strip down, removing the head, removing the table, fill of muck, the column, cleaning it all down, reassembling the machine, first impressions, speed control, the downside. a lot of interest, milling in the lathe.

145

21

An Automatic Diameter-Varying Boring Head

Linton Ledlock uses lateral thinking

145

27

Making A CNC Cutter Grinder (3)

John Pace makes the pulley drive trains

145

33

The Weiss WMD25LV Milling Machine

David White looks at this widely available mill

145

38

The Practical Engineer

A look at lathe accessories for building models

145

40

Make Do And Mend

Len Parker shows us his Unimat and accessories

introduction, the Guildford exhibition, the Unimat SL, initial experience, assistance from Foden Motor Works, Rex Tingey and the model engineer, motor failure, improvements and modifications, commercial bits and useful accessories, modifications to the lathe, treadle drive, pillar mount, raising blocks, as supplied, tool post modifications, tailstock, vertical drilling and machine vices, extending the cross slide capability, the tooling, vertical slide, chuck backstop.

145

46

Worden Wheel Height Adjustment

Jim Whetren turns his Worden around

motor mounting, motor guides, vertical guides, drilling the switch box, clamping straps, stop bar, feed nut, feed screw and collar, hand wheel, trial assembly, try out. commercial examples - holders, construction methods, preparatory work, method 1, clanger and recovery, method 2, further reflections.

145

50

Lathe Tool Shanks For Carbide Tips

Dave Fenner makes his own

145 145

53 54

Next Issue Trade Counter

Chester setting equipment, Arc Euro Trade, Jade Products. Chester craftsman down under, drill sharpening, milling a paradox, back numbers of MEW, Ascot exhibition entries, mini lathe tips, chap machine trays. the financial future, more leisure time, woodworking in schools, metrication, increase to 39 issues a year, 5000 value for 3.99, apologies due MEW 145 page 11.

145

56

Scribe a Line

145

58

Free Adverts

146

11

On The Editor's Bench

Dave Clark's commentary

146

12

Making And Using Soft Jaws (2)

Harold Hall shows you how to make your own chuck jaws

146

17

Tarting Up A table

David White improves a Sieg X0 compound table

146

21

An Elegant Centring Tool

John Slater looks at his work centre

making standard soft jaws, the theory, making the jaws, manufacture, a fence is required, machining the jaw teeth, important, machining the side grooves, material, the CNC approach. background, Proxxon, Sieg, problems, start again, additions, odd angles, the gib strip, indents for screws, lapping the ways, clean down well, reassembly, suppliers. background, machining problems, Starrett 65, my design, convenience, in use. slitting saw mandrels, cross slide extension, the indexing head, a paper overlay, the collet holder, the filing rest, a metric machine, the cross slide high speed drill cradle, die holder and extension, drill pad, cross slide drilling and milling spindle, internal radius tool, the external radius tool, associated machine vices and angle plates, mini drill stands, flexible drive, the Potts milling spindle, scroll saw, conclusion, appendix. mounting the grinding head, the vee block, belt assembly. a simple procedure, fitting the digital readout (DRO) scales. background, base, alternative column clamping, table, cutting the fence slots. simple methods, professional methods. cordless pistol drill. www.homews.co.uk introduction, strength and failure, stress strain relationship, welding, metal production, material standards and specifications, a history of BS970, rolled section and plate, identification of steel.

146

24

Make Do And Mend (2)

Len Parker shows us more Unimat accessories

146 146 146 146 146 146 146

31 36 38 42 44 45 46

Making A CNC Cutter Grinder (4) The Practical Engineer A Lathe Saw Table Attachment (1) Bending Tubes A Simple Power Feed System Roller Bearing Drawers An interesting new website from Harold Hall

John Pace continues with the drive trains Fitting an inverter Jim Whetren builds a versatile tool Ken Sprayson takes a look at tube bending Ebbe Normark Sorensen makes a simple workshop aid Ebbe Normark Sorensen utilises wasted space

146

47

Ferrous Metals

John Slater knows his steel

146 146 146

50 51 54

Next Issue The Midlands Model Engineering Exhibition 2008 Trade Counter

'Richmond' makes a Saturday visit metal working lubricants and greases, Tracy Tools, Tilgear, Gemstone faceting machine. lathe tool shanks for carbide tips, starting afresh, gig strip problem, depth of machining knowledge, on the editors bench, scraping information, overseas free adverts and a fraudulent trader, Pinnacle problem in MEW 143 scribe a line, pyrometer required. the future, hard disk failure, CNC cutter grinder, CNC series, subscriptions, model engineer, trade suppliers, rogue trader, the Model Engineer Exhibition, workshop special. hot wire heater, battery charger power source, the bender, method, the result, improved design, heater element, bender in use, materials.

146

56

Scribe a Line

146

58

Free Adverts

147

11

On The Editor's Bench

Dave Clark's commentary

147 147

12 15

Making A Plastic Sheet Bender Practical Engineer (7)

Harold Hall makes a machine guard.

147

16

Low-Cost High Performance Digital RevMike Crossfield improves his machines. Counter

background, lathe and mill, low price, frequency meter module, milling machine rev-counter, electronics, Myford lathe rev-counter, ABS wheel sensor, mounting the sensor, more electronics, a good result. testing the machine. dedicated die holders, workshop storage, non standard dies, pre set die heads, some tolerance, an essential feature, starting the machining. background, single roll tooling, straddle or clamp type tooling, bars and arms, turned parts, operation, radial or face knurling, use of radial tool, cutting type tooling.

147 147

21 24

Making A CNC Cutter Grinder (5) To Die Now! (Better than 'Yesterdie'?) (1)

John Pace concludes this series with a look at programming. David Piddington offers a solution to setting small dies.

147

28

Knurling Tools - Cutting And Crushing

Dave Fenner experiments with knurling tools.

147 147

34 36

Give A Little Lift To Your Mill CNC Milling With MACH3 (5)

Keith Willson makes a simple crane attachment. We look at simple profiling with curves.

147

38

A Lathe Saw Table Attachment (2)

Jim Whetren finishes the rest of the machining

saw arbor, rip fence, cross-cutting fence, tongue, bridge clamp. background, a constant battle, several clamps, construction, handling the bodies, more turning, assembly. background, making the components, motor controller and fan enclosures, removing the motor/gearbox, assembling the belt drive. centre square, odd leg callipers, scribers, surface gauge.

147

42

Cleader's Clamps For Sheet Metal

Harry Kennedy makes some useful clamps

147

45

A Belt Drive For The Sieg Super X1 Milling Machine Next Issue Making Small Tools

David White modifies his pulley arrangement

147 147

49 50

Dave Fenner offers some simple apprentice pieces. trade counter December 2008, free glue, future articles, Dave Fenner's mini lathe book and soft jaws, future articles, pyrometer for old oven, drill sharpening, component protection, email addresses in MEW, chuck adaptor, bending small diameter tubes, faulty Tee nut, the rust fairy, depth of knowledge, know your mill MEW 144, metal spinning and plywood, thin shim, twist drills, James Nasmyth engineer, questions to scribe a line MEW 146, scraping 1, scraping information 2, metric conversion 1, scraping information 2, tube bending, metric conversion 2, metric conversion 3, larger machines overseas and plastic machining, fitting an inverter.

147

53

Scribe a Line

147 148 148 148

60 9 10 16

Free Adverts On The Editor's Bench Building a CNC router (1) To Die Now! (Better than 'Yesterdie'(?) (2) Dave Clark's commentary John Rutter commences construction David Piddington continues making die holders. reader survey, three a month, web site, enforced holiday, Myford open day, Harold Hall. the Z axis. continuing the machining, extended tooling, the smaller die holders, hot from the machine. setting the vice true and square, machining flat and parallel faces from black bar, machining parallel and square from black stock. construction of form tools, simple form tools, making form tools, threading tools, milling cutter examples. the machine, specifications, beginner abuse, coarse feed, essential tools, conclusion.

148

20

An introduction to milling (1)

Donald Brymer offers basic milling advice

148

23

Introducing form tools

Dave Fenner offers some simple solutions David White looks at this entry level machine from Arc Euro Trade

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The Sieg Super X1L review

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A digital facelift for a Warco mill A replacement quill locking handle for a Hobbymat mill Readers Survey 2009 Making a new Myford tailstock barrel A toolpost and spindle grinder

Bob Davis fits a Z axis readout John Noakes improves his quill clamping Win some great prizes

DRO

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A Clarkson Tool and Cutter Grinder (1)

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Buying and renovating used machinery

worse for wear, reaming the bore, the key to accuracy, engraving. Tony Schroder makes a useful tool and refurbishes another background, manufacture of the blades. background, small industrial tool and cutter grinders and drill sharpeners, Mike Haughton describes buying a Clarkson Mk2 tool and cutter other factors, purchase, about Clarkson grinder and spare parts situation, refurbishment of my Mk2. the price argument, what to buy, what to take along, what to check for, buying Mick Whittingham on refurbishing old machines and delivery, how much renovation to do, getting started. Dyson Watkins refurbishes his lathe Workshop projects by Dyson Watkins, the mini lathe by Dave Fenner. computer aided design (CAD), tolerancing, soft jaw availability, CAD dimensions and tolerances, multipart articles, metric and very old contributors, destroying old hard disks, call me Methuselah, MEW 147 letter from Ebbe Sorenson, grinding on the side of a wheel, Dave Fenner and tube bending, sulphuric acid, pyrometer help, tailstock dieholders, metric or imperial, electric etching pen, broken tee nut, about marking out, a challenge, steel and brass supplies, future articles reply to Roger Vane MEW 147. Myford metal preservatives, Warco vee blocks. the model engineer exhibition, the new website www.model-engineer.co.uk, model engineer and free plans, articles in general, surveys, price increase, Harold Hall, 16mm narrow gauge in your garden. the Y cross slide, the X motor mount, the cush drive.

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Fireside reading Next Issue

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Scribe a Line

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52 54

Trade Counter Free Adverts

149

On The Editor's Bench

Dave Clark's commentary.

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Building a CNC router (2)

John Rutter continues construction.

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To Die Now! (Better than 'Yesterdie'?) (3)

David Piddington continues making die holders. background, design philosophy, quick change tool post a brief digression, detent parts. designing by the make do and mend method, adapting the pipe fittings, joining the tees together, filling in the bores, making new accurate bores, boring the main bores, ball handles, the stand, the table and mounting boss, the drilling head, holding taps.

Multi Position Saddle Stop For The MiniDave Fenner improves the C3 small lathe. lathe

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Making A Pillar Tool Without Castings

David Haythornthwaite makes a larger size pillar tool from simple materials.

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Pioneer A Non Compression Internal Combustion Engine

Rudy Kouhoupt DVD review. milling a square block from round stock, calculating the diameter, machining a square on a narrow workpiece, machining a square on a long workpiece. metric threading indicator, applying this to metric threads, metric indicator, choosing the indicator2 gearing, using the indicator2, cutting the 127T indicator plate in the lathe, alternative change gears, cutting multistart threads and patterns 'from the dial', 40T metric indicator, appendix.

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An Introduction To Milling (2)

Donald Brymer Continues his look at basic milling.

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Aids To Screw cutting Metric Threads On An Imperial Lathe

Richard Bartlett makes some homemade thread dial indicators.

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Fitting A Warco Major Milling Machine Into A Confined Space Trade Counter Welding In The Workshop Two Useful Milling Machine Accessories A Sensitive Drilling Attachment Next Issue

Sandy Petrie turns conventional thinking to one side. Warco vee blocks. An introduction to welding, making a simple material support stand. Neil G Heppenstall makes some Vee blocks and positioning bars. Brian Cole saves money by making his own attachment. learning to weld, other useful equipment, support stand project, the base, the main upright, the stand top. positioning bars, acknowledgments.

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A Design For A Cross Drilling Jig

A simple design for home construction.

background, features, construction, vee block, over-arm, work piece clamp, guide bar, stop assembly, stop bar clamp, drill guide, using the jig, conclusion.

149

53

Clarkson Tool And Cutter Grinder (2)

Mike Haughton continues his look at a this versatile cutter grinder

the control cabinet, power cables, RCD tripping, more on using inverters, low voltage lighting, wheel and belt guarding, dust extraction, the grinding department, operator manuals.

150

On The Editor's Bench

Dave Clark's commentary.

supply of Model Engineers Workshop, European and Australian subscriptions, a short holiday, the Harrogate Model Engineer Exhibition, longer than usual lathes, free catalogue MSC/J&L, open evening.

150

10

Workpiece Clamping

Harold Hall looks at clamps and clamping

vices, table clamps, lighter weight clamps, the rules, packing, additional ssupports, compact clamps, stepless clamps, toggle clamps, toolmakers clamps, holding round items, using a part from the assembly being made, low profile clamps. the machine frame. storage. introduction, lapping the ways and gib strips, leadscrew bearing blocks, fixed column, gas strut. horizontal machining of slots and grooves, vertical machining of slots and grooves. material cutting list, shelves, handle, wheels, construction. DRO.

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Building a CNC router (3) To Die Now! (Better than 'Yesterdie'?) (4) X1 Mill Modification

John Rutter continues construction. David Piddington continues making die holders. David White strengthens his mill

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An Introduction To Milling (3) A simple home made vice Making a Welding Trolley A Myford Super Seven 7 Topslide with Digital Readout A Small Compressor

Donald Brymer Continues his look at basic milling. Richard K Wightman makes a simple accessory Jayne Reeve makes another simple welding project Ken Wilson utilises second-hand parts Richard K Wightman utilises second-hand parts

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Introduction to Collets and Collet Chucks Dave Fenner looks at these useful items

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Clarkson Tool And Cutter Grinder (3)

Mike Haughton continues his look at a this versatile cutter grinder

what is a collet, Myford collets, a close approximation, bending the rules, other fixed size (solid) collets, Morse taper, 5C, R8, Clarkson, emergency collets, wide range collets, Crawford multibore, Pratt Burnerd multisize, ER series, double angle collets, depth stops. operator controls, wheels, any old wheel, mounting the wheel, truing and dressing the wheel, a three way 2in vice, cutting off HSS tool bits, twist drill sharpening, thinning the drill web and the drill point.

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Next Issue Trade Counter

Dremel glasses competition. The Metalworkers Data Book by Harold Hall, Build a Plastic Injection Moulding Attachment for a Drill Press by Vincent R Gingery, Building the Tesla Turbine by Vincent R Gingery.

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Fireside Reading

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MEW Subscription Offer an excellent article of soft jaws, depth of information, workshop heating, sheet plastics bender, electric etching pens, etching pens and Clarkson cutter grinders, tolerance, Studer grinder, novice engineers, mechanical disasters, Tommy bars, beating the rust fairy, scraping machine tools, more on metric, sulphuric acid and Merlin engine. model engineering societies, the Myford open day, surveys, model engineer exhibition. swivel joints, bars, additional items, table mount, fixed mount, lathe ,mounting methods. CNC lathe.

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Scribe a Line

151

On The Editor's Bench Dial Indicator/Dial Test Indicator Accessories The Stepperhead Multi-Mode Machine

Dave Clark's commentary.

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10 16

Harold Hall makes some useful setting up aids Alan Jackson describes his gold medal winning lathe

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Choosing and Accessing a Lathe

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To Die Now! (Better than 'Yesterdie'?) (5) Finding the Datum

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An Introduction to Milling (4)

151

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A Metal Mangle Adding a Ball Race to a Mini Lathe Top Slide Z-Axis Modifications to the Super X1L Mill

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Clarkson Tool and Cutter Grinder (4)

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Scribe a Line In Our Next Issue Trade Counter On the Editors bench

size matters, how much, new or second hand, dealer or private sale, spare parts, assessing second hand, headstock, bed, Dave Fenner looks at purchasing new and second-hand tailstock, saddle, cross slide, topslide, machines backlash and wear, changegears, chucks, under power, assessing a bargain, further reading. the under plate, tailstock securing bush, David Piddington continues his look at die holders. under plate gauge, spring components, warning. background, setting up across the table, Dave Fenner sets up his work working from an edge, working from a hole or scribed line. end mills and slot drills, side and face cutters, conventional milling versus climb milling, advantages of Donald Brymer Continues his look at basic milling. conventional milling, advantages of climb milling, disadvantages of climb milling,. design and philosophy, bearings, rolls, side plates, back to the bearings, Dave Fenner makes a precision set of rollers threaded parts, base, gear spindles, handle assembly, assembly. introduction, implementation, second David White makes an improvement to his Mini lathe lathe, pare parts are available. z-axis bearing, implementation, transfer the holes, roller skates, trial assembly, David White modifies his milling machine damping the column, set in stone, bearing part numbers. four facet drill sharpening, six facet drill sharpening, basics of milling cutter design, sharpening the end teeth, Mike Haughton continues his look at this versatile cutter grinder recutting end teeth on end mills, recutting end teeth on centre cutting end mills. pillar tool, compressor, rod poles and perches, PLT interfering with radio amateurs, dehumidifiers, hard work, survey and reamers. restore rust removal gel Dave Clark's commentary. in the workshop, readout on a lathe, another lathe, aquamarine, Williamson engine, new locomotive and vacuum engine series.

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Dial Indicator/Dial Test Indicator Accessories

152

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The Stepperhead Multi-Mode Machine

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16 17 18 20

Building a CNC Router (4) Model Engineer's Workshop Index An Introduction to Milling (5) Headstock and Base Modifications to the Seig Super X1L Milling Machine

152

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A Variable Feed Drive for a Mill/Drill

152

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A Clarkson Tool and Cutter Grinder (5)

152

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First Steps in 3D Design (1)

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Harrogate 2009

fine adjustment unit, non dial indicator uses, base, clamps, mini instrument Harold Hall concludes his look at these useful accessories makers vice, magnify glass stand, machine guard, heavy duty helping hand, references. Headstock, vertical column, bed block, saddle and saddle drive, cross slide, Alan Jackson continues his description of this versatile machine cross slide stepper motor, tailstock, headstock stepper motor. John Rutter concludes the series with a look at the cutter spindle operations Barry Chamberline has updated his MEW index on CD direct indexing, simple indexing, simple Donald Brymer looks at dividing and the dividing head indexing calculations, angular indexing in degrees. fine feed DRO, spindle guard, X1 mill David White adds a fine feed digital readout and a spindle guard base. why add a table feed, the drive dog, milling the dogs, the motor mounting Wilf Baker speeds up production sliding plate, support brackets for motor sliding plate, altering the machine, fitting to the mill/drill and operation. sharpening the flutes, resharpening slitting saws, resharpening side and face cutters, resharpening tee slot and key Mike Houghton looks at sharpening the flutes of milling cutters, slot cutters, resharpening reamers, slitting saws and the face cutters and resharpening lathe tools further notes, making and sharpening and looks at the problems of sharpening carbide tooling on a single point lathe tools, carbide turning tool and cutter grinder. tools, diamond grinding wheels, mounting and dressing diamond wheels, diamond cut-off wheels. the modelling program, computer hardware, the benefits, the negative side, series overview, using truespace, modelling the mouse, useful functions, Linton Wedlock starts a series of articles on an introduction to changing the viewpoint, navigation: an virtual engineering - modelling on a computer. alternative way, modelling with precision, a first model, using libraries, the standard, crankshaft bearing, crankshaft and flywheel, crank, piston, cylinder block. Dave Fenner visits the national model engineering and competition, club stands, trade modelling exhibition at Harrogate. exhibitors, tail pieces.

152

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To Die, Now! (Better that 'Yesterdie'?) (6) Plumb Centre for a Lathe or Mill

David Piddlington concludes his look at dieholders.

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Dave Fenner describes a useful workshop accessory.

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Fireside Reading

152 152 152 153

52 54 55 9

Scribe a Line The Model Engineer Website In Our Next Issue On the editor's bench www.model-engineer.co.uk Dave Clark's commentary.

coupling marking jig, hooks and link, dieholder adapter, boring bar, location key, location key nut + locking clamp nut. background, general design, manufacture, final assembly. how to run a lathe South Bend lathe works, the tricks and secrets of old-time machinists hints and kinks provided by the readers of American Machinist Magazine 1916, forming methods vol 1 forming by section and tube bending forming by press brake, forming methods vol 2 forming by draw bench, power rolls and spinning heat treatment of aluminium alloys. rolling mill, the rust fairy, hard disc failure and rogue traders, metrication, recycling plastic bags, compressor article, shimming lathe tools.

153 153

10 14

Working with the faceplate Sheet metal folder

Harold Hall looks ay setting up work on the faceplate Jayne Reeves makes a simple sheet metal machine Linton Wedlock looks at creating realistic images, further modelling with polyhedrons, and using object axes. Dave Fenner investigates this recently released machine from Warco

153

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First steps in 3D design (2)

153

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The Warco WM18 milling machine

lazy, newish Myford, grinding up turning tools faceplate, to use or not to use, positioning, using the centre finder, using toolmakers buttons, using a fence, fixing, faceplate dogs, references. construction, folder operation. rendering, lighting, object materials, modelling with polyhedrons, ball crank, ball lever, handwheel, lathe centre, object axis, modelling a lathe tool, a graduated collar, a third axes example. lifting, overview, accuracy, in use, criticisms, conclusion.

153

25

An introduction to milling (6)

Donald Brymer continues his look at dividing and dividing head

153

28

A dividing head for the mini lathe

Dave Fenner adds a versatile accessory to the mini lathe

153

34

Choosing and assessing a milling machine

Dave Fenner looks at buying a milling machine

153

39

The Stepperhead multi-node machine (3)

Alan Jackson concludes his look at this versatile machine

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44 45 46

A Clarkson tool and cutter grinder (6) In our next issue Trade counter

Mike Houghton concludes this series by finishing his look at diamond wheels, then looks at solid carbide tooling, "specials" and simple surface grinding on the Clarkson New Warco remote readout, Dremel

differential indexing, principals of differential indexing, indexing plate revolving in the same direction as the indexing crank, indexing plate revolving in the opposite direction as the indexing crank, practical example, determine the movement of the indexing crank, determine the change gear for the movement, determine the direction of plate movement, checking the calculations. background, manufacture, spindle, adjuster nut, spacer and washer, steady bracket, adjuster screw, plunger assembly, plunger support pillar, spacer plate, steady arm, base plate, clamp disc, upstand, operation, further work. catalogue information, machine styles, spindle type, speed range, what to spend, pristine restored or basket case, assessing second hand, transmission and spindle, slideways, three phase machines, other considerations. control panel and computer mounting, computer, stepper motors, rear chip guard, top slide, tool holders, milling head, milling head top slide, mounting table, collet chuck, boring head, operation, milling, conclusion, test samples. resin bonded diamond wheels, solid carbide tools, "specials" and tool making, surface grinding, conclusions.

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Scribe a line

154

On the editor's bench

Dave Clark's commentary.

cutting metric threads, metrication, metrication 2, eBay Asian engineer, eBay Asian engineer 2, is there a good point to aluminium, thank you Warco, stepperhead lathe, small furnaces, dehumidifiers. index for issues 140 to 152, the model engineer website, Warco phone problems, eBay and a cheap engine.

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10 13 16 21 26

Working with the face plate (2) Clip on tool tray for the lathe A dividing head for the mini lathe (2) Harrison M300 - conversion to inverter power source Living with the Stent tool and cutter grinder (1)

Harold Hall continues his look at setting up work on the faceplate Jayne Reeves tidies up Dave Fenner adds division plates and worm drive Kim Wilson goes for a larger lathe Charles Woodward shows us how to use this versatile machine

angle plate, Keats angle plate, adhesive, just screws nuts bolts and washers, balancing, references. construction, welding. worm, spindles, spacer, plate support, body, spindle nut, bracket, sundry items - screwed rod, assembly and operation. references using the machine, attachments. truespace views, drawing 2D shapes, point edit tools, 2D into 3D: the sweep tool, angle plate, tee-slotted table, 2D into 3D: the tip tool, 2D into 3D: the bevel tool, spline shaft, self intersections, crankshafts, bracket, tailstock die-holder, grouping objects, layers.

154

30

First steps in 3D design (3)

Working with 2D shapes and creating straight-sided and bevelled extrusions

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32 35 37 40 41

Index for issues 141 to 152 of MEW A modified Hemingway graduating tool

Stuart Walker makes some scales rivet diameter, positioning and drilling, rivet length, closing, forming, production riveting, hollow and blind rivets, threaded rivets.

A note on rivets, riveting and associated Dave Fenner strikes a blow for riveters everywhere topics An odd solution (calipers and dividers) In our next issue Chris Walter makes a useful tool

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Fireside reading

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Scribe a Line

how airbrushes work by Steven Leahy, airbrushing 101 by Doug Mitchel, welding complete, how to paint your show car by Stefan R Gesterkamp, how to weld by Todd Bridgum, grinding honing and polishing by Stan Bray, building shop by J Randolf Bulgin, a modellers handbook of painting and lining by Ian Rathbone. Tony Claridge - can anyone help with a long memory help?, small furnaces, mini lathe improvements, knurling, is there a good point for aluminium, Brad Amos's paint problem with aluminium, milling article, defiant copy, welding helmets.

155

11

On the editor's bench

Dave Clark's commentary.

155

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Machining internal and external fittings for a lathe's threaded mandrel

Harold Hall looks at duplicating and mirror imaging the lathe's mandrel

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Reaming

Mick Knights discusses reaming in the home workshop

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Quick-set face and angle plate

Harold Hall machines a Hemingway kit

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First steps in 3D design (4)

Introducing truespaces mirror, lathe and macro sweep tools

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How I made my little lathe

Herbert Elffers makes a 2in centre lathe

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Living with the Stent tool and cutter grinder (2)

Charles Woodward shows us how to use this versatile machine

the penny has dropped, more good reasons to subscribe, even more good news for subscribers, website added value, cover photos, model engineer exhibition, workshop specials, another complaint, Cutwell Ltd tool catalogue. the requirement, gauges, achieving precise diameters, the mounting, need for accuracy, the thread, why 1.054in diameter?, ready for the next stage. basic types of reamer, the reaming process, hand reaming, taper pin reaming, cutting compounds and coolants. using the lathe faceplate, mounting the faceplate, working to dimension, machining the face, the angle plate, Hemingway's method, the accessories, pillar support, tee nuts, setting hub/pin, alternative setting pin, a painting tip, references. the mirror tool, 2D into 3D: the lathe tool, v-belt pulley, v-belt, simple collet, helical components, leadscrew, 2D into 3D: macro/sweep, your own paths, spiral objects, macro sweep paths. lathe bed, headstock, mandrel, main drive, polyvee belts and pulleys, indexing and detent, chucks, saddle and slides, micrometer dials, swivelling topslide, quick-change toolpost, apron, screwcutting, screwcutting gears, leadscrew variable speed drive, tailstock, barrel, locating the pinion position, shaping up the tailstock, finishing the lathe, conclusion, backgear, taper turning attachment, steadies, saddle stop, filing rest, suppliers. grinding straight shank drills 2mm to 13mm, point thinning, grinding the end teeth of slot drills and end mills, grinding along the flutes, setup, cutters with chipped corners, grinding reamers, grinding single point square tools (lathe, shaper, etc).

155

41

Making a pinstriping tool

Dave Fenner thinks about lining and pinstriping

155

46

An introduction to superglues and engineering adhesives.

Mike Haughton takes a look at the basics of polymers used as adhesives in engineering

lining tools, wheel tools, assembly, materials, in use, areas for improvement. monomers, polymers and initiators, inhibitors, co-polymers, branched and cross-linked polymers, toughened adhesives, fillers, aliphatic adhesives, health and safety, heating adhesives, adhesives class 1: superglues (CA; cyano, krazy glue), several superglues, a few thoughts on degreasing before glueing, ca conclusions, adhesive class 2: anaerobic engineering adhesives, the bond gap, activators, temperature, heat ageing, solvents, surface preparation, a huge range of products, conclusions, adhesive class 3, epoxy, epoxy as a structural adhesive, temperature stability, epoxy putty, potting, mixing and cleanup, other adhesive classes, references.

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Trade counter

Dremel model 335 plunge router attachment, new Dremel stockist, Dremel model 231 shaper/router table. Dremel model 670 mini saw attachment. the professional approach to model railways by John Wylie, detailing and modifying ready-to-run locomotives in 00 gauge volume 1 by George Dent, narrow gauge by Sudanese Red sea coast by Hentry Gunston, steam power by Brian Solomon, professional airbrush techniques by Vince Goodeve, how to master airbrush painting techniques by Joann Bortles. evening classes, Harrison M300 and a dynamic converter, knurling - a reply, remagnetising, painting aluminium, lathe clutter, overalls, gear hobbing, bandsaw problem, Jowitt poppet valve engine, Readout spares, using the faceplate, some more tips, unknown surface grinder.

155

52

Fireside reading

155

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In the next issue

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Scribe a line

156

11

On the editor's bench

Dave Clark's commentary.

an apology, the world gone mad, rocking horse c**p, a sit down job, incompetence, a sweet problem, fire fighters outlawed, the men in white coats, not child's plat, dying banned, flight of fancy. background, manufacture, conclusion. sizes, dynamic applications, design considerations, grove features, ring in spindle/piston, ring in cylinder, ring in triangular groove, ring in flange, id dependent, assembly, standards, further reading.

156

12

Making a tangential tool holder for the lathe

Peter Boonham improves his turning equipment

156

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Using O rings in the home workshop

Harold Hall looks at this useful item

156

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Making replacement machine labels

Mick Whittingham adds the finishing touches to his rebuilt machines

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modifications to the super x1l base, modifications to the saddle, manifolds, check valves, oil pump, adjustments, conclusion. form and step drills, making a spinning Making and using D bits, form tools and fixture for use on a surface grinder, Mike Knight makes his own form tools spade drills grinding a step drill, spade drills, making a simple D bit. truespace draw modes, multiple object copies, grid arrays, radial arrays, fluted creating multiple object copies, and a look at the truespace fillet, First steps in 3D design column, graduated dial, division plate, chamfer and shell tools the fillet tool, the chamfer tool, the shell tool, precise mouse control, more tools. starting the process, overarm and cutter spindle, table, saddle, knee, power feed How to refurnish a Tom Senior M1 Mick Whittingham rebuilds his mill gearbox, belt covers, motor assembly, horizontal mill column, splitting the column from the base, coolant tray, base unit. spindle assembly body, shaft, pulley, Making a high speed engraving spindle Dave Fenner gets up to speed motor pulley, commissioning. Improving a cheap offhand tool grinder Dyson Watkins takes a rest making the rest. background, the anodising process, power supply, anodising using the supply, anodising larger pieces, a quick How to anodise titanium Tony Jeffree adds a decorative finish to some clock parts warning about machining titanium, related techniques, suppliers and other useful links. wheel balancing, plain grinding, counter Living with the Stent cutter grinder (3) Charles Woodward shows us how to use this versatile machine rotating drilling unit. Installing a central lubrication system on Dave White makes light work of a repetitive chore the Sieg Super X1L mini mill

156 156

56 59

Scribe a line In our next issue

Philip Bellamy, M300 inverter, website, website 2, domestic clutter, not up to the mark, authors wanted, centre point, engineering development. cover photo, articles wanted, practical engineer, the editor's current projects, MEW overseas supply, rogue traders, model engineer exhibition, win a Stirling engine, cutting edge competition. the body, machining Tee slots, marking out at 45 deg, positioning on the table, set up an index position, aligning the mill spindle, setting the slot position, setting the slot length, machining the long Tee slots, machining the short Tee slots, finalising the Tee slot, references.

157

11

On the editor's bench

Dave Clark's commentary.

157

12

How to make a four-jaw chuck alternative (1)

Harold Hall looks at a different type of work holder

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A useful addition to a Kennet tool grinder Roy Henshaw makes his Kennet toll and cutter grinder easier to and cutter grinder. use. Making a wobble broaching holder. Making a simple double ended tailstock die holder for the mini-lathe. Jock Miller throws a wobbly. what is wobble broaching, components of the tool, general, the spindle, broaches, setting up, operation, editors note. background, manufacture, operation. design constraints, how I made the device, the end cap, insulating washer, top unit, the internal bits and electronics, battery case, LED mounting unit, trouble shooting. Preparation, pipe runs, freehand pipe forming, scale as you go, reshaping a pipe, adding sharp bends, a pulley Vbelt, a flywheel, modelling ion inches, a locomotive wheel, and finally the spokes. stripping the sub-assemblies, coolant pump, power feed gearbox, saddle, knee, swarf tray, base, belt covers, column, the cutter arbor, conclusion. turning the tool holder, milling, the fly cutters, machining the radius. part 1 theory, quick and accurate, part 2 practical issues, the worm, redundant CDs.

157

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Dave Fenner makes another attachment for the mini-lathe.

157

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Making an edge finder.

Mel Martin makes a useful tool

157

32

First steps in 3D design (6)

Modelling pipe runs, belts and castings.

157

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How to refurnish a Tom Senior M1 horizontal mill (2) Fly cutting of radial forms (1) Dividing on the lathe.

Mick Whittingham rebuilds his mill

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Mick Knights looks at advanced flycutting Roy Smalley has a different approach.

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Workshop heating costs. Adapters for parallel shank milling cutters. Living with the Stent cutter grinder (4) Scribe a line In our next issue On the editor's bench

Harold Hall looks at workshop heating.

157 157 157 157 158

54 56 59 61 11

Harold Hall makes holders for commercial cutters. Charles Woodward shows us how to use this versatile machine

the workshop, the heating, the tests, the costs, the readings, blinds, day/night consumption, making economies. making the adapter, fitting the cutter, adhesive why?, the finished task, smaller adapters, references. editors comments Philip Bellamy an apology, screw threads, central lubricating system, superglues and engineering adhesives, engineers wanted.

158

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How to make a four-jaw chuck alternative (2)

158

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Workshop photography

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Basic spur gear milling (7)

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First steps id 3D design (7)

model engineer exhibition, unavailable, next issue, more competitions, Australia and the USA, articles still required, Allendale electronics ltd. other parts, the jaws (2), thin piece larger diameter clamp (6), small In the last issue the manufacture of a body was described diameter auxiliary jaw (5), some typical leaving a number of smaller and much simpler parts to be made. uses, comparisons with a four-jaw A few examples of the device being put to use are also included. chuck, minus points, plus points, worthwhile?, references. lighting, the setup, using a tripod, non SLR cameras, available flash guns, Harold Hall offers some tips. some lighting tips, presentation, the zoom facility, slides, references. common gear tooth forms, gear tooth pressure angles, spur gear tooth elements and definitions, gear tooth Don Brymer continues his series on milling calculations, backlash for fixed centre gearing, measurement of teeth, cutting a gear, cutting a short rack. adding detail by modelling, some modelling tips, object materials, reflectance settings, saving materials, Using modelling techniques and object materials to produce face painting and inspection, faceted or believable images. smooth, modelling surface finishes, a turned surface finish, milled cast and grinding finishes, texture maps, making a seamless texture, further possibilities.

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Win a 5 litre tin of Morris metal cutting lubricant. The twelve days of Christmas Model engineer exhibition show guide

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The practical engineer A centring microscope Using small CNC milling machines Coming to a dead stop Making space saving mobile work stations In our nest issue Trade counter Make a novel quick change toolpost

It has probably been twelve months since I last did a practical engineer article. Dave Fenner converts a commercial item. Mike Palmer looks at what they don't tell you in the manuals Mike Havard fits a quill stop to his new mill. Ian Strickland offers a useful storage solution. Warco DH-1 vice review, Warco magnetic bases. Mike Cox improves on Asian mini-lathe

machining cast parts dismantling, new arbor, reassembly, a short digression, back to reassembly. work holding, drawings, running a file, coolant, making multiple parts. the fixed ring, the adjustable ring, guide plates, the scale. the problem, the solution, construction, details, finally.

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Scribe a line

159

On the editor's bench

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How to make a fully adjustable grinding head

David Haythornthwaite builds a useful tool grinding head

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Harrisson M300 with DRO An electrically operated spindle drive clutch

Keith Wilson fits a digital readout

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Ken Wilson modifies the drive to his lathe

background, the pillar, expander cone, the step plate, the toolholder, final assembly, note on milling in the minilathe. Tom Senior paint, beat the rust fairy, not an error, newbie problems. overseas readers, model engineer's workshop online archive, US and Canadian subscriptions, 2009 - the year of the website, MEX 2010, articles for 2010, free adverts, the greatest model show of the north, competition page. carbide lapping machine, the design, moving head, grinding spindle, dimensions, making a start on construction, base plate and column, clamping cotter, central pivot block, constructing the pivoting casting, assembly of the picot casting, clamping the spindle, head raising screw and pillar top swivel, fine adjustment screws, motor drive pulleys and guards, mounting the grinding wheels. power circuit, cable chain. the Myford clutch, electrical clutch, foot brake modification, motor mounting, motor extension, the components, clutch guard, turning the pulley vees, power supply, setting the clutch up.

159

28

Making a high speed spindle

Dick Stephen describes his high speed milling spindle

the original spindle, the new spindle, materials required, constructing the spindle, the shaft extension, the spindle housing, spindle assembly, the spindle collar, the pulley.

159 159

33 34

Plan tailstock turret Plan the ME 1/2" universal swivelling vice

Edgar T Westbury Edgar T Westbury Christmas time, turning video, quality components, tool rest, methodology for turning the pens, the first cut, assembling the pen, freehand turning tips, general observations on the pens made so far. the tool holders, cross drilling the bit holder, the grinding jig, operation, design considerations, templates, the tool grinding holder, the guide base, the maths behind it, the tip angle, calculation of tip angle, calculation of side relief angle, effect of back rake.

159

39

Learning how to hand turn

Mike Freeman makes some Christmas presents

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44

Really simple threading tools

Gary Wooding looks at thread cutting tools

159 159 159 159 159 159 159 159 159

49 50 52 54 55 56 58 59 60

Articles wanted Fireside reading Caring for your CNC machine A surface table for free Tool tips, questions and ideas Trade counter A simple tool polishing fixture In our next issue Scribe a line Peter's railway and the forgotten engine, Thomas the tank engine Haynes manual, detailing and modifying ready to run OO gauge, the Hornby book of model railways, Messerschmitt BF109 manual. Dick Stephen looks at cleaning your ballscrews Mark Noel recycles some builders waste Tool tip for drilling large holes in thin material, question smelly metals, tip and question getting rid of burrs. Seismometer kit Ron Wright improves his surface finish the local dump, builders skip, construction.

a fine finish, using the fixture. anodising titanium 1, anodising titanium 2, keeping warm, milling articles, REMAP Scotland, saving back issues gremlins, overseas gremlin, office gremlin, hard drive gremlin, phone gremlin, a happier note, MEX DVD, filing machine, best of model engineer vol 2, beginners book librarian, back issues. overview, bracket, disc, pivot, arbor, return to the disc, assembly, conclusion.

160

11

On the editor's bench

160

12

Make a tailstock turret for the mini lathe

Dave Fenner makes another useful lathe accessory

160

16

Machining tool blocks and rear toolpost for the Myford series 7 lathe

Mick Knight adds a tool holding system to his new Myford lathe. overview, boring the tool blocks. Dave Fenner unearths a project that was set aside some years ago.

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overview, Kennet overview, adding the bench grinder, changing the wheel, A sort of Kennet guarding, mounting, safety note, conclusion. overview, design considerations, material preparation, soldering, drilling and reaming, separating and machining, Two axis clock depthing tool David Rogerson makes a simple clock making tool assembly, adjustment mechanism, knobs, pivot rods, final assembly, conclusion. overview, the sequence of operations A pair of vice jaw stops Peter King makes a simple workshop aid was. overview, a modified detent, a custom Adding a rotary table facility to the Emco made wrench, the rotary converter, Maurice Rhodes describes another useful Unimat modification Unimat 3 making the gear milling mandrel, the worm gear housing, chuck clearance. Installing a pre owned Myford super 7 in overview, choosing the lathe, riser Mick Knights installs a secondhand Myford lathe a confined space blocks and tray. overview, NC/CNC a brief history, commissioning the KX1, programming, Learning to love the Sieg KX1 Mick Knights looks at the smaller CNC mill from Arc Euro Trade editors note, a quick word about the manual, in conclusion. overview, how accurate?, marking out, Musing on drawings, dimensions, Cave Fenner looks at marking out for the beginner surface plate substitutes, home made tolerances and marking out. height gauges spur gear trains, gears with teeth, creating a 2D tooth shape, a 60 tooth spur gear, other DP gears, a metric spur First steps in 3D design (8) Linton Wedlock looks at modelling gears gear, helical gears, creating a rack, modelling bevel wheels, bevel gears with teeth, a 20 DP bevel gear. In our next issue making a division plate, a surface table for free, Sieg Super X1L milling Scribe a Line machine, Ken Wilson an apology, electric clutch, cross drilling. on the web, Myford open day, Gremlins, On the editor's bench in the workshop, more storage, workshop special, projects included.

161

12

How to make a filing machine (1)

Harold Hall makes a useful machine

161

18

How to machine castings (1)

Harold Hall makes a Keats Vee angle plate

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24 29

Fitting a one-shot lubrication system to a Tony Jeffree makes a lathe easy to lubricate Myford ML7 lathe CNC milling - engraving on the Sieg KX1 Mick Knight makes a Roll of Honour CNC mill

the basics, the drive, the basic design, materials, brief notes, the subassemblies, the main frame assembly, the posts, bottom plate and top plate, lathe mounting plate. the nature of a casting, the first task, machining cast iron, Keats angle plate the main casting, the clamp. system components, designing a system, assembling the circuit, testing and final comments.

161

34

First steps in 3D design (9)

Linton Wedlock models belt drives and chain drives

modelling a worm, a matching worm wheel, a flat belt pulley, hub and spokes, a poly-v belt and pulley, using guide grids, timing pulley, timing belt, modelling a sprocket, a sprocket chain. 3 Morse taper to 3C collet system design, CNC machine setup, G-code generation and CAD, MT2 test taper.

161 161 161 161 161 161 161

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In our next issue 3 Morse taper to 3C collet adapter (1) Workshop equipment at the 2009 ME exhibition ME and MEW deputy editor requited Competition Machining tool blocks and rear toolpost for the Myford series 7 lathe (2) Fly cutting of radial forms (2) Richard Gordon puts his Orac CNC lathe to work competition, judges work, club stands, magazine duties, website duties, events duties. parting off tool, tool block back support, Mick Knights adds a tool holding system to his new Myford lathe quick change mounting, left hand turning. Mick Knights looks at advanced flycutting milling the convex radius. mandrel nose gauge, painting aluminium, Victoria milling machine, fighting the rust fairy, quality service, electric clutches, bandsaws run-out, turners smock, boring opportunity, tailstock cross drilling, engineering courses, condensation, slideway oil, a letter from the editor. Dyson Watkins makes a useful modification to an angle grinder. David Clark in the workshop, Arrand engineering, Myford 2010 spring show, Chester sale, Armortek new product.

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Scribe a line

161 162

62 9

Convert your angle grinder into a compact drill for restricted access On the editor's bench

162

10

How to make a filing machine (2)

Harold Hall makes a useful machine

162 162

16 21

How to machine castings (2) Edge and centre finding (1)

Harold Hall makes a small vee angle plate Michael Christiaens looks at work setting

162

26

A beginners guide to workshop materials Dave Fenner looks at different materials

162

32

First steps in 3D design (10)

Linton Wedlock concludes his interesting series

input drive spindles assembly, spindle, outer clamp ring, drive spindle body, drive spindle carrier, drive spindle pulley, inner clamp ring, oscillating assembly, slider blocks, file carrier assembly. the vee block, accuracy, the base, the clamp assembly. the simple approach, the drill, the sticky pin, the ruler, using dedicated tools, the wiggler, the mechanical edge finder. tensile strength, shear strength, fatigue strength, hardness, creep strength, materials - ferrous, explanation of the system, metals - non-ferrous aluminium and it's alloys, magnesium, copper, brass, bronze, wood, plastics, others, suppliers. a simple cam, 2D shapes from coordinates, automated 2D drawing, TurboCAD, snap modes, importing and exporting, advanced trueSpace, using stereograms, camera objects, assigning camera views, free-viewing technique, an alternative method, stereogram use, series conclusion. writing the G-code, machine setup and cutting the taper.

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37 38 42

The story behind the models DVD 3 Morse taper to 3C collet adapter (2) Phoenix battery drills

This DVD was filmed at the 2009 Model Engineer Exhibition Richard Gordon puts his Orac CNC lathe to work Martin Gearing considers how to make use of all those low voltage drills with spent lost batteries rules and rulers, digital and vernier callipers, micrometer, clock gauge or dial test indicator, feeler gauges thread gauges and radius gauges, calipers spring and friction hinge, measurement of angles, reference equipment, conclusion. choosing the lathe, first steps, damaged track, drive considerations, the drive layout, the drive motor, the vee belt drive, the power supply, the switch box, the inverter, the suds pump motor, the tool post and others, gearbox operator, tooling, the paint job, finally.

162

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Engineering Measurement

Dave Fenner looks at accuracy in the home workshop

162

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Resurrecting a Colchester Chipmaster lathe

Jim Perry brings an aging Chipmaster back to life

162

60

In our next issue

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Scribe a line

163

On the editor's bench

David Clark

163 163 163 163 163

10 16 19 22 26

How to make a filing machine An improved mini lathe from Sieg High profile clamps How to machine castings (3) Edge and centre finding (2) Updating the Myford ML7 one-shot lubrication system Method and madness

Harold Hall Dave Fenner tries out this updated lathe Harold Hall describes another useful type of clamp Harold Hall compares the Keats and the Vee angle plate Michael Christiaens looks at work setting Tony Jeffree offers a lower component count making for a cheaper system Dave Fenner looks at batch production

Coventry die heads, electric clutches, dividing in the lathe, slideway oil 1, slideway oil 2, a letter from the editor. Myford open day, Transwave competition, Harrogate exhibition, we are expanding, new Super C3 minilathe, no truth in the rumour, CNC articles, 3D design, in the workshop, new camera, new web editor. variable stroke mechanism, bearing carrier, body, the turned parts, table assembly, lathe mounting, drive spindle, guard assembly, files, saws. general, headstock, summary. manufacture, a by product. the two compared, uses. electric and electronic edge finders, the laser edge and centre finder, a dial test indicator, more expensive measuring instruments.

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30 32

163

34

Lubricants for the home workshop

Mike Haughton looks at the basics of lubrication and lubricants

163 163 163 163 163 163 163

40 44 46 50 54 60 61

3 Morse taper to 3C collet adaptor (3) Myford S7 saddle clamp CNC milling using subroutines to aid machining of multiple parts A simple sub-table for the KX1 Establishing and using a tool library Scribe a line In our next issue

Richard Gordon puts his Orac CNC lathe to work Shelly Curtis overcomes a problem Mick Knight looks at this useful programming feature Mick Knight adds a work holding plate to his KX1 CNC mill Mick Knight organises his tool holders

method 1 and 2, conclusion. friction, the pin and disk tribometer, tribology, stick slip, jo blocks (slip gauges), oils fats waxes, petroleum based lubricants, viscosity index, viscosity grades, lube oil additives, synthetic and semi-synthetic, silicones and fluorocarbons, grease. the 3C collet design and G code, machine set-up and air-cut testing and g-code. assembly. basic programming rules, program construction, multiple part programming, retaining tabs, proving the program.

happy subscriber and electrical danger, unhappy subscriber, first steps in 3D design, truespace, magazine content.

164 164 164 164 164

9 10 18 24 30

On the editor's bench How to make a filing machine (4) Making and developing a parallel vice Make a five way tailstock turret for your lathe Edge and centre finding (3) Harold Hall adds a hold down facility Mick Knights makes a beginners project Dave Fenner makes a useful tool Michael Christiaens looks at work setting

164

32

Lubricants for the home workshop

Mike Haughton looks at the basics of lubrication and lubricants

subscriptions, magazine contents, backlog of articles, Imsi TurboCAD. manufacture, in use, files returned. machining. turret, pivot, the body, arbor, detent, assembly, drilling the tool locations, clamp screws, tool holders, operation. the 3D sensor, the centre cam, the centricator, the UMI. old machine tools and workshop machine lubrication, lubricants for imported machines tools, ATF fluids, metalworking cutting oils, which metal cutting lubricants do you use, homebrew solutions, conclusions. general arrangement, the stem, collet, external taper, external screwcutting. materials required, construction, head and tailstocks, the dividing plate, the spindle and locking screws, the tailstock centre, the detent arm, setting up the pinion mill. cutting the collet bodies, the MT3 to 3C adapter body design and G code, making the cutter, the 5mm HTD pulley.

164 164

34 36

Trade counter Making a marking gauge

Chester machine tools Bill Morris offers a machining exercise for advanced beginners

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42

Making a pinion milling attachment

Dick Stephen adds to his clock making toolkit

164 164 164 164 164 165

48 52 58 59 60 9

3 morse taper to 3C collet adapter (4)

Richard Gordon puts his Orac CNC lathe to work

Making toothed belt form relieved cutters John Pace has a eureka moment The editor visits the Myford open day In our next issue Scribe a line Dave Fenner replies, D design, the last word, deburring tube. On The Editor's Bench

165

10

Learn how to make a back stop Making and developing a parallel vice (2) The beginner's guide to lathe attributes

Harold Hall makes an essential piece of lathe equipment

new director at Myford, a letter from Myford, earn extra cash, the website, Thomas Barnes. the design changes, dimensions, manufacture, stop bar holder, body, securing nut, stop bar support, workpiece support, using the backstop. assembly and applications, finally. bed, headstock and spindle, motor and transmission, gears, gearbox and screwcutting, saddle, cross slide and top slide, tailstock, conclusion.

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Mick Knights makes a beginners project

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Dave Fenner looks at lathe features

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Making a marking gauge (2)

Bill Morris offers a machining exercise for advanced beginners

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3 Morse taper to 3C collet adapter (2) Making a simple internal threading tool Harrogate national model engineering and modelling exhibition 2010 Lathe work a beginners course Building a screwcutting gearbox for a Myford Super 7 lathe (1) Trade Counter In Our Next Issue Fireside Reading

Richard Gordon puts his Orac CNC lathe to work Dave Fenner renovates an engine Dave Fenner makes his annual pilgrimage to Yorkshire Don Brymar starts the series by showing you how to set up and look after your lathe Alec Payne describes how he built his gearbox using drawings and castings supplied by Hemingway kits Eccentric engineering, Myford collet adaptor, Myford extended Piddington type tool holder, Science Replicas Newton reflecting telescope. The Iron Sherpa, Machine shop know how

parting off, collet closing cap, knurling, internal screwcutting, internal taper, finishing the collet, body, point/blade collet, cutting wheel, wheel mounting screw, assembly. cutting the MT3 to 3C adapter body, the MT3 to 3C draw tube design and Gcode. repair method, toll making. competition, club stands. checking the machine alignment, lubrication and cleaning. general introduction, getting started, the milling machine and it's accessories, machining the gearbox.

165 165 165

56 57 58

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60

Scribe a Line

166

On the editor's bench

166 166 166 166 166

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Miniature depth gauge Marking out gauge Making and using soft jaws Making a mini pipe bender An improved headband magnifier for your workshop

specialised lubricants, reasons to subscribe 1, reasons to subscribe 2, reasons to subscribe 3, reasons to subscribe 4, reasons to subscribe 5, reasons to subscribe 6, reasons to subscribe 7, reasons to subscribe 8, reasons not to subscribe 1, a thank you from the editor. health and safety, MEW issue 166, online communications, workshop special, using soft jaws, new turning Dave Clark's commentary. series, index, model engineer exhibition, articles wanted, threaded stock off - the outcome. From Harold Hall a gauge to measure in those awkward corners manufacture, a set up note. Harold Hall describes an easily made accessory the body, the clamp. Mick Knights looks mainly at the milling machine Mick Knights gets into tighter corners Dick Stephen takes a closer look soft jaws on the lathe, producing soft milling jaws. manufacture. fitting the lenses, the construction.

166

28

Knurling - a follow up

Dave Fenner goes for cutting rather than crushing

166

31

Building a screwcutting gearbox for a Myford Super 7 lathe (2)

Alec Payne describes how he built his gearbox using drawings and c castings supplied by Hemingway kits

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Lathe work, a beginners course (2) A small welding turntable Interchangeable soft jaw pads soft jaws and slot drills Bandsaw blade welding

Don Brymer offers guidance on high speed steel tooling John Pace avoids getting in a spin Pete Worden offers a couple of useful wrinkles John Pace shows a simple method using a regular MIG welder

construction, knurl wheels, bearing, clamp straps, operation, caveat and possible improvements. the selector arms, the shafts, bearings, bearing housings, first assembly, gears, fitting out the gearbox, back to the cover, final assembly, fitting to the lathe, the leadscrew, a final word. the pros, the cons, angle gauge, side and front clearance angles, approach angle, trailing angle, rake angle, nose radius, setting spindle speeds. using the table. easy milling. cutting the draw tube and end thread piece, the MT3 to 3C thrust bearing holders - design and G-code, cutting the left and right thrust bearing holders, the MT3 to 3C handle lock nut - design.

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3 Morse taper to 3C collet adapter (6)

Richard Gordon puts his ORAC CNC lathe to work

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Fireside reading In our next issue Scribe a line

The Iron Sherpa (vol 2) lathe size, why do people rebel, magazine content, articles in MEW, CNC, USA subs update, a good balance, the Piddington tool holder. health and safety, future projects, back to the workshop, the internet, index, optical aids for the workshop, model engineer DVD, Bristol model engineering and hobbies exhibition, TurboCAD 17 deluxe. manufacture, round and hexagonal. the RCBO, dual purpose, protection against fatal electrical shocks, insulation leakage, prevention of electrical fires, legal requirements, split load consumer units, testing, test equipment, sockets with built in RCD protection, passive or active, sensitivities, RCD's types AC A and B, international regulations, discrimination, in closing, on another subject, and finally.

167

On the editor's bench

David Clark's commentary

167

10

Collet jaws for square material

Harold Hall makes a useful accessory

167

12

The use of residual current devices in the home workshop

Harold Hall looks at electrical safety in the home workshop

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The Taig lathe bets a makeover

Tony Jeffree tries out the new Taig lathe

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22

Tapping small threads

Chris Dunn makes a simple threading holder

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Making a bespoke power hacksaw stand Mick Knights moves around in his workshop Index for issues 153 to 164 of MEW Fitting and using a hydraulic copying attachment Andrew Johnston improves the versatility of his lathe

fitting the new lathe, upgrading an old lathe, the power feed, headstock improvements, saddle and cross-slide, improving the handles, the power feed in use, conclusion. pillar tool, the tapping tool, tapping in the lathe, tapping in a drill press, tap buttons, tap guide in use. materials, the frame, cutting sizes, the jacking pads, fabricating the frame, finishing off. the hydraulic copying attachment, mounting arrangement, using the hydraulic copying attachment, conclusion. emery cloth holder, I need a third hand, chuck removal/replacement, lathe tool storage, CNC remote adjustments, CNC cutting oil, drilling and tapping assistant, Morse tapers. draw tube the finishing touches, collets the finishing touches. metalworking fluid: a migraine precipitator, Coventry die heads, headband magnifiers, the cost of a project, slideway oil, scribe a line, lubricants for the home workshop, workshop tips, CNC machining services. Myford's autumn show, stop press finance for Myford lathes, pre-owned workshop equipment sale, Horley miniature locomotives LLP. why bore small holes?, the problems, the boring tool types, forming high speed steel boring tools, the grinding sequence, the alternative form, using the boring tool, other tools. the worm drive, mounting bracket, worm box, bushes, handwheel, setting collar, assembly. measurement, machining the new base parts, assembly, operation.

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A beginner's journey

David Reece embarks on his third apprenticeship

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46

3 Morse taper to 3C collet adapter (7)

Richard Gordon puts his ORAC CNC lathe to work

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Scribe a line

167 168

54 9

In our next issue On the editor's bench Dave Clark

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Small boring tools and others

Harold Hall describes his small hole boring system

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15 16 22

Trade counter

Chester tools

Micrometer down feed for the Hobbymat Jim Wheeler adds another improvement mill/drill quill Adding a capstan attachment to the Chipmaster Dave Fenner adds a multi-tool turret

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26 30 34

High speed screw cutting attachment Chemical blackening of metal A Boxford saddle stop with readout

Bill Leslie describes an essential add-on Terry Owens looks at component finishing Geoff Josey adds a digital indicator DRO

the stop brackets, using the attachment.

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Lathe work, a beginners guide (3)

168 168 168 168 168

42 48 52 56 57

Electrical discharge machining Screw threads of the world unite Improvements to a 12in Taiwanese cross slide Faced with a boring problem In our next issue

four-jaw independent chuck, three jaw chucks, holding work between centres, hints for between centre turning, use of Don Brymer looks at lathe holding methods lathe steadies, holding work on a faceplate, holding work using a standard mandrel. industry use, build and experiment, Chris Walter makes a small spark erosion machine background and history, the complicated bits, taking charge, separate units. Martin Gearing offers an explanation with suggested alternatives firstly what is a thread. making the felt cover, felt material, By Latherworks proper lubrication. Ted Barclay used his head flexible joint. simple square collets, electrical safety, more or less skilled, centre height or swing, backstop assembly, drunken rivets, flexible tube, somewhere safe, swarf fires, Toyo taper, cycle threads, speed control, speed control design, no electronics, know your mill, slideway lubricants, sub routines, centring round work. in the workshop, model engineer exhibition, Kelvin Barber, the website, Harold Hall, Peter's railway. workpiece support, manufacture. apologies and a warning, tools and materials, components, component list, nosepiece, chuck body, pusher control, pusher, assembly, testing and error correction, summary and conclusions.

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58

Scribe a line

169 169

9 10

On the editor's bench Drilling vice workpiece support Harold Hall looks at drilling in the drill vice

169

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A chuck for a tool and cutter grinder

John Shaw-Shang makes a 4-jaw chuck

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22

Lathe work a beginners course

169 169

28 29

The practical engineer Model Engineer exhibition

ISO metric screw threads, common methods of thread cutting, metric thread tracking calculations, preparation for external thread cutting, resharpening the threading tool, preparation for internal Don Brymer looks at screw cutting vee form threads in the lathe thread cutting, tracking an imperial thread, measuring the thread, finding the wire sizes, distance across the wires, limitations, of the three wire method, lefthand threads. Making a toolpost holder for a Dremel grinder

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170

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definitions, three essential ingredients, which metals do you want to join, a few experiments in soldering, filler alloys, Soldering and brazing in the home Mike Houghton looks at the basics in the home workshop for the nature of the bond, liquation, viscosity of workshop (1) beginner filler alloys, commercial alloys for brazing and soldering, cost of materials, fluxes, solder and silver solder paints. additional requirements for cutting helical gears, drawings, double bevel Using the Jacobs gear hobbing machine Chris Robinson modifies this versatile machine drive, corrective gear train, longitudinal to cut helical gears (1) slide for LH gears of 30 deg to 45 deg helix angle, other modifications. design and construction, electronics Electrical discharge machining (2) Chris Walter makes a small spark erosion machine (main unit), electronics, machine frame. Job vacancy Deputy editor/web editor design criteria, the main plate, the Simple headstock dividing Chris Walter offers an improvement for the small lathe (Myford) mandrel sleeve, the detent block and plunger. edge finding, impregnated MDF, Coventry dieheads, more light relief, light short circuit, metric system, Scribe a line Coventry dieheads 2, cordless resurrection, incorrect terminology, thread chasers, rust and warmth. In our next issue free adverts, the 1020 model engineer exhibition competition, coaches to model On the editor's bench engineer exhibition, exhibition show guide, Polly is moving, a non-mover. table, stop and feedscrew, body, dial, Sharpening end mills on an offhand Harold Hall makes a simple holding fixture support, cutter holder, using the rest, an grinder alternative mounting.

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16 18 20

Coventry die heads High profile end clamps postscript Lathe work a beginners course (5)

Harold Hall offers advice on using this useful tool Harold Hall updates us on one of his clamp designs (MEW 163)

Pros, cons, basic details, how is it used, use on a centre lathe, short threads, sharpening, obtaining.

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22

Soldering and brazing in the home workshop (2)

170 170

28 32

A Boxford/South Bend screw cutting indicator

measuring a taper, limitations of offsetting the tailstock. joint design, lead and cadmium, for the beginner, soldering, photo etched brass or nickel silver, leaded stained glass, variable temperature soldering irons, Mike Haughton looks at the basics in the home workshop for the lead free solders electronic, lead free beginner solders plumbing, brazing for the beginner, start practicing, what to braze on, hot rodding and scratchers, heat source, SIF brazing, alloys to braze with and not, in conclusion. making the wormwheel, making the Anthony Reid makes a useful lathe accessory mounting, the cylindrical components, assembly. Don Brymer looks at offset tailstock taper turning workpiece motion correction, gears. the drive-system, removing the guards, removing the motor drive belt, removing the countershaft, removing the chuck, the ML7 spindle bearings. Shavings dust and general safety, space considerations, mitre sawing work, router work, worktop jig, turning.

Using the Jacobs gear hobbing machine Chris Robinson modifies this versatile machine to cut helical gears (2) Changing Myford lathe belts (1) Mark Frampton takes a comprehensive look at the ML7 drive system

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44 50

The occasional woodcutter Thread comparison table No 2 - larger sizes

Dave Fenner puts his chippie hat on

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Electrical discharge machining (3)

170

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Scribe a line

171

On the editor's bench

Martin Gearing adds to his thread information published in MEW guide for using the comparison table. 168 main and drilling slides, tool arm and vibrator, tool clamp, stepper motor and Chris Walker makes a small spark erosion machine leadscrew assembly, dielectric tank, cross vice and tank mounting, dielectric pump and filter, dielectric pump. coolant on machines, boring problem, consumer unit 1, consumer unit 2, down feed, evening class misunderstanding, amongst my many vices, Toyo tailstock, Myford miracle. the same content, increased page count, 2010 model engineering exhibition, continuation of articles, articles required, digital subscriptions, the website, new David Clark's commentary deputy editor for ME and MEW.

171

10

Low profile clamps

Harold Hall adds to his specialised clamping set

171

12

Changing Myford lathe belts (2) Mark Frampton takes a comprehensive look at the ML7 drive system Ian Howitt makes Tornado components

single fixing clamps, improved clamps. removing the spindle, reinstating the spindle, the countershaft vee pulley, reinstating the countershaft assembly, aligning the cone pulley, checking and adjusting the headstock belt tension, the motor drive belt final assembly and testing, conclusion. the purchase decision, power and space considerations, R8 tooling, buying importing and delivery, extra importing costs, unpacking and moving, stand and coolant tray, strength calculations, installation and connections, coolant, software. the base unit, the circular guide, the pivoted slideway, brazing the pillars, the slide, the adjustable link, using the attachment. how it works, R8 arbor adapter, toolholders, future work.

171

18

Using a Bridgeport mill

171

20

Experiences with a Tormach CNC vertical mill Andrew Johnston upgrades his milling facilities

171

26

Making a taper turning attachment Antonis Askanis makes a useful lathe accessory

171 171

36 40

Easy change toolholders Refurbishing an Aceria 23 milling machine

Dave Fenner looks at a commercial toolholder Roger Trewinnard adds a quality mill to his workshop

171

48

Lathe work, a beginners course (6)

Don Brymer looks at square, Acme and multiple start threads

171

54

Scribe a line

172

On the editor's bench

small lead square thread forms grinding a square threading tool, angle calculations, cutting the thread, small lead Acme thread forms, cutting the thread, multiple start threads, effect of pitch and lead on the minor diameter, machining multiple start threads in a lathe, tool grinding calculations for small leads - front clearance, back rake, leading edge and trailing edge side clearance angles, indexing the thread starts, using a star wheel or chasing dial, indexing by moving the tool, indexing by moving the work. universal joints, metric model engineering threads, Myford Belts, Coventry dieheads 1, Coventry dieheads 2, simple dividing, slideway lubricant, beginners courses, oil staining issue. a milestone, Sandown Park exhibition, 2010,1011, scribe a line, free adverts.

172

10

Milling using a fly cutter

Harold Hall looks at this useful tool holder 172 172 172 172 172 172 172 172 172 14 20 22 24 28 30 34 38 40 Experiences with a Tormach CNC vertical mill (2) Making a Myford mandrel adaptor for a milling machine A new woodwork bench More home made tools The occasional woodcutter (2) A swarf stick Fiddling' in the workshop Abuse to innocent Bridgeports A simple suds system Using the Jacobs gear hobbing machine to cut helical gears (3) Chris Robinson modifies this versatile machine 172 50 Electrical discharge machining (4) Chris Walter makes a small spark erosion machine Realistic Railway modelling layout design by Iain Rice, 2011 shipwright, Workshop machinery 46 by Alec Weiss, Beginners guide to pocket watches, John Derry by Brian Revas and Annie Bullen, Railway modelling, Camden winter 2010 news, Videoscene winter 2010/2011 steam and diesel DVD catalogue, Hawker Hurricane The editor visits this well-established show near Leamington Spa Eccentric engineering, TurboCAD 17 deluxe, Dremel 8200 cordless drill, Dremel 290 engraver Andrew Johnston upgrades his milling facilities Dave Fenner asks is it a mill, lathe or machining centre Dave Fenner produces more sawdust and shavings Dave Fenner makes a set of hex key drivers Dave Fenner puts his chippie hat on David Haythornthwaite discovers there is a much better way of removing swarf than using your hands David Haythornthwaite discovers a quick and easy way to shorten small BA screws Ian Howitt use a Bridgeport mill on large components John Harris lubricates his turning tools

the theory, diameter, number of cutting edges, actual fly cutter diameter, feed rates, cutter shapes, the tests, the first test, speed feed and depth, the second test, back cutting explained, some conclusions, concave surface, a final comment, a final final comment. machining parts, hints, conclusions and further learning. manufacture. evaluation. keys, handles, a short digression on knurling, the female of the species. an easy tune up, appearance, sharpening. the general design, the magnet, using the swarf stick, storing the swarf stick, notes on using Neodymium magnets. the Christmas fairy. the system, suds tank, on/off tap, testing. hobs, cutting a pair of parallel shaft helical gears, cutting a pair of Mod 1 90 deg skew gears, limit switches, conclusions. filtering, practical usage, uses, work duration.

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Fireside reading

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The 2010 Midlands model engineering exhibition Trade counter

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training courses, unusual tool, MDF gears, content of model engineers' workshop, Myford belts, gear cutting shaft alignment.

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On The Editor's Bench

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Making fixed and travelling steadies Harold Hall makes two less common lathe accessories Mogen Kilde makes a useful tool

a look at the past, new year milestone, digital subscriptions, subscriptions, snow, pricing, subscription letters, Canada. manufacturing, up cut versus down cut milling, the fixed steady, base, clamp, lessons learnt, arms, the washers, the travelling steady, using the faceplate, which method. Mk 1 design, manufacture, assembly and use, possible improvements and mk 2 version, making the mk 2. mind the gap, scale formats, design considerations, beams, calliper dismantling, read head housing, read head, initial testing, mountings, drilling the cross slide, final testing and adjustment, swarf protection, summary.

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Making an airbrush Two wood strip cutters

Dave Fenner revives his interest in model aircraft

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Fitting Chinese scales Ben Clark recycles a Shumatech DRO Harry J Cosh offers a universal edge and centre finding method using a standard DTI

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A different method of edge finding

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A sensitive knurling tool Modelling in reverse Model engineer exhibition Scribe a Line In our next issue On the editor's bench Jim Whetren builds a Hemingway kit Alan Hopwood multiplies a retracting toolholder by 1.5 The deputy editor spends a happy four days at Sandown Park with camera and notebook

milling the curves, rounding the arm ends, side plates, guide plates, side plate bushes, upper pivot, lower pivot, nut, trunnion, knurl slots.

ME and MEW content, Harld Hall's flycutting article, getting started, Record plane quality. make do and mend, the Model Engineer website, article bank, in the workshop, practical CNC, the practical engineer, subscription problems, magazine rental. the fixed steady, the extremes, deflection measured, centring a bar, designed for production, other uses for the fixed steady, travelling steady, dual support, points to consider, teething problems.

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Using a lathe steady Harold Hall puts his home-made steadies to good use

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A hacker's guide to building the Worden grinder (1) Tony Jeffree builds the Hemingway kit

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Work lights in the home workshop (1) Martin Gearing improves his machine lighting Practical CNC creating G code part programs using wizards Fitting an indexing travel stop to a lathe A draw bar for a Myford ML7 A square collet block Trade counter Some more make do and and with Exemplar project Len Parker offers advice to beginners Scribe a line In our next issue On the editor's bench Mick Knight waves a wand over more CNC matters Mick Knights modifies an old Colchester lathe stop Richard Wightman describes an adaptable home-made drawbar Richard Wightman saves setting time Dremel Trio

the kit, deburring, doing the numbers, the base unit, painting the sheet steel bits, machining the sliding block, machining the locks screws handles and cams, machining the spacer bars and washers. building guide, sheet metalwork: marking out, clips, body, strap, riveting up, drill the mounting hole, grill, stalks. inputting data.

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the project - Wakefield lubricators on a rebuilt West Country, further modifications to the Unimat, lubricator construction. why do young people rebel, Warco vice, ER collets, magazine content. basic workshop practice, beginner's series wanted, Myford open day, the south west model engineering model making and hobbies exhibition. manufacture, revised hinge design, finishing the main faces, drilling the lugs, modified hinge assembly, assembly, belated task, tee slots, finishing. building the work-slide assembly, the tool holder and feed screw block, the feed screw and feed nut assemblies, the electrical bits. modifying coolant tubes, turned parts: adaptor, modified attachment bolt, lamp holder, assembly, fitting the lamp retaining clips, mounting. thoughts on taper roller bearings, experimental fitting, so what are the steps to be taken and how to go about it?, reassembly. advantages of a capstan, tooling, setting, other applications.

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An adjustable angle plate

Harold Hall makes and adjustable angle plate using commercially available castings

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A hacker's guide to building the Worden grinder (2) Tony Jeffree builds a Hemingway kit

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Work lights in the home workshop (2) Martin Gearing improves his machine lighting

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Improved bearings for the Myford Super 7 headstock Ken Wilson needed to change the bearings in his Myford Super Seven so he tried out an experiment Dave Fenner writes about repetitive production work in the Capstan lathe work home workshop

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An accurate CNC 4th axis (1) Converting a Myford Super Seven lathe to CNC (1)

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Using collets in my lathe (1)

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Coventry die heads Making new lathe chuck jaw screws Scribe a line Trade counter Fireside reading In our next issue On the editor's bench

Richard Gordon makes an affordable 4th axis for small CNC and the design, manufacture, spindle, front manual milling machines and back plates, base block. planning a CNC upgrade, research, the design concept, the cross slide Glen Blunt upgrades a Myford Super Seven whilst maintaining conversion, machining of the support it's original manual functions plates, machining the top plate. my Chester UK lathe, so called 'gear head lathes' why collets?, not using collets, split collet types, Morse taper collets for the lathe headstock, 5C Mike Haughton describes his use of collets both commercial and collets in a collet block, WW collets, a home made in the headstock of his Chester Craftsman 6in lathe 5C to 5MT headstock adaptor. Philip Bellamy shares some further information about Coventry sharpening the dies. die heads Norman Hurst takes inspiration from industrial sized chucks to repair his four jaw chuck do you really need a grinder and if so which one?, yet another index. Dremel power tools, the bender Fine tuning and maintaining OO gauge models by Nigel Burkin, Creating realistic landscapes for model railways by Tony Hill. Myford open day 14 15 and 16 April, Harrogate model engineering and modelling exhibition, R J (Bob) Loader. making the rests, in use, accessories, swivel base, square tool holder, round tool holder, other holders, slitting saw pivot, the end mill attachment, using the off-hand grinder, final comment, a final thought. the cup wheel mounting hub, final tweaks. advantages of a QCTP system, which QCTP system to go for?, machining the tool post mount, in use, modified parting off blades, screw cutting with parting off blades, a DTI holder, other tool holders, conclusions. the stepper motor and cross slide leadscrew pulleys, the assembly, leadscrew modifications, modifying the leadscrew bracket, first lesson on boring, additional support tooling,.

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Grinding rest update Harold Hall demonstrates grinding techniques on his improved rest

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A hacker's guide to building the Worden grinder (3) Tony Jeffree completes the Hemingway kit In our next issue

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Quick change tool post

Mike Haughton describes his installation and use of a commercial quick change tool post on his Chester UK Craftsman 6in (300mm or 12in swing) lathe

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Converting a Myford Super Seven lathe to CNC (2)

Glen Blunt upgrades a Myford Super Seven whilst maintaining it's original manual functions

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An accurate CNC 4th axis (2)

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Using collets in my lathe (2)

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Drill sharpening jig (1)

Richard Gordon makes an affordable 4th axis for small CNC and motor plate, sundry parts, progress, manual milling machines pulleys and problems,. making a 5C to 5MT adapter, machining the 5MT adapter, making a drawbar and handwheel, testing times, length stops for 5C collets, and ER32 to 5C adapter, Mike Haughton describes his use of collets both commercial and more testing times, a spindle nose home made in the headstock of his Chester Craftsman 6in lathe protector. John Shepherd describes his own design and puts it into initial design, building the jig. practice

Some more make do and with Exemplar project (2) Len Parker offers advice to beginners Making a box angle plate The model engineer exhibition December 2011 entry form Scribe a line On the editor's bench Side supported two wheel knurling tool Using collets in my lathe (3) dieheads, tool and cutter grinder, Tony Jeffree. Harrogate exhibition, Myford training courses, clocks for sale, the recent Myford spring open day. manufacture. Harold Hall offers an improved version a 5C collet chuck, testing the 5C collet chuck, an ER32 collet chuck, threading Mike Haughton describes his use of collets both commercial and notes, an R8 to 5MT adaptor, in home made in the headstock of his Chester Craftsman 6in lathe conclusion. end stop, bearing, pivot, base, John Shepherd describes his own design and puts it into assembly, use, results and observations, practice health and safety. missed drawing from issue 169. by John Low-Shang machining the support plates, assembly, Glen Blunt upgrades a Myford Super Seven whilst maintaining spindle sensor, the controls, controller it's original manual functions board. Richard Gordon makes an affordable 4th axis for small CNC and re-cutting the 36T pulley. manual milling machines preliminary work, dismantle remake assemble, making new panels, welding together, conclusion. the project. screwcutting operations, settings for metric pitches, making the parts, metric banjo, tumbler cluster and dog clutch, the gear case cover, installation and operation. Shelley Curtis cuts a box angle plate from the solid material, side slots tee slots access pockets, access pocket.

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Drill sharpening jig (2) A chuck for a tool and cutter grinder Converting a Myford Super Seven lathe to CNC (3) An accurate CNC 4th axis (3) Readers survey 2011 Automotive rebuild An introduction to CNC milling Metric screwcutting without tears on the Myford

Dave Fenner looks at the tools and the methods Mick Knights starts some basic program building blocks

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D A G Brown updates his screwcutting modification

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Aciera milling machine refurbishment, incorrect thread, grinding attachment improvement, fixed steadies. articles in this issue, MEW content, the survey, Harrogate exhibition, future exhibitions, authors wanted, passing off action, Maplin launches iPhone app, new Proxxon catalogue available in June. hobbies, earning my keep, my 20 years in the workshop. the image, adhering the resist to the stock metal, masking and preparing for etching, the etching cell, electrolytes, power supply, notes regarding safety, in conclusion. mounting the flexible drive, boring and sleeving the chuck and die casting, the new chuck and shaft, mounting the flexible shaft, in use. construction main body of the banjo, the clamp nut and washer, the sliding stub axel, the retaining ring, assembly. design criteria, the design, construction, the worm gear, the base plate, the spacer, the clamp bars, the pivot pin, the clamp nuts, the follower.

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On the editor's bench

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Twenty years writing for model engineers workshop Acid-free electrolytic milling of steel aluminium and brass

Harold Hall looks back on the past two decades

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Chris Gabel creates incised scales, labels, motifs and nameplates in a variety of materials

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A tool post drill Michael Cox improves and sets up a flexible attachment

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A change gear banjo for the Asian minilathe A taper turning attachment with micrometer adjustment (1) Unimat 3 sensitive tailstock capstan An accurate CNC 4th axis (4) In our next issue A low cost rev counter for the Asian minilathe An oiler for the Myford lathe

Michael Cox speeds up gear changing

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Michael Cox makes a useful taper turning attachment Maurice Rhodes makes another improvement to his Unimat Richard Gordon makes an affordable 4th axis for small CNC and spindle dust cover, covers, setting up manual milling machines and testing. fitting the cycle computer,.

Michael Cox fits an inexpensive rev counter Barry Forrest simplifies oiling the lathe

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A tailstock turret for small lathes Michael Cox improves his mini-lathe

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The swing-up tool holder Scribe a line

Michael Cox describes a method of single point screwcutting

the basic design, Myford oiler nozzle, conclusion. the Morse taper, the turret block and base plate, the detent mechanism, assembly, tooling, centre drill, drill chuck, 60 degree running centre, die holder. a better way?, version 2, construction, assembly, testing, conclusion. machine paint, a useful project.

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On the editor's bench A new topslide with high-resolution readout (1) A three speed gearbox for a Dore Westbury mill Another centring tool Setting up a dividing head or spin indexer Setting work true Editors workshop The Colyer/Caseley cutter grinder Sawing short pieces with a mechanical hacksaw or bandsaw Index for issues 165 to 176 of MEW Fitting a feed motor to a vertical mill A quick and easy tangential tool holder A digital readout for under 20 Turning with tapered mandrels A taper turning attachment with micrometer adjustment (2) In our next issue Armig, Armig the other way round, three phase conversion workshop practice series no 47, Made simple -made easy a selection of gadgets to assist the model engineer, W MacMillan and Co illustrated catalogue of models, I worked with traction engines by Jack Hampshire, Antique tractors and gas engines a DVD about vintage machinery. John Reed improves his milling machine Michael Cox describes an easily made tool holder Mick Knights produces an inexpensive but effective accessory Mick Knights describes a classic use of tapered mandrels David Graves improves accuracy on his Chinese lathe

John Pace describes a three speed head assembly David Piddinigton finds a centre Ron Wright show us an easy method to align a spin indexer Ron Wright looks at setting work in a four jaw chuck A centre finder for the lathe Alan Hooper of the Bristol Society of model and experimental engineers

extended warranties on speed controllers CL750 CL1500 introducing the project, machining the pieces. the Dire Westbury milling machine, the head assembly, thoughts on CNC conversion.

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reasons for the fixture, the Rapidor 'Manchester' hacksaw, my hacksaw Mike Haughton collaborated with Alan Maclean to produce these fixture (jig), length stop, sequential taps, jigs to allow the cutting of short pieces conclusion. controller box, now for the final assembly of the box and components, motor bracket, limit switch bracket. construction, tool grinding jig, use.

Michael Cox makes a useful taper turning attachment

the follower arm, the pillars, the guide bar, the worm, the bearing blocks, the adjuster knob, setting up and use.

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Fireside reading

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On The Editor's Bench

saddle stop for lathe, Super 7 bearings, kitchen knives, acid free etching, technicolour machinery, articles of interest. John Moore, Myford has gone!, buying a small lathe, articles wanted, Crowood books, social networking.

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Balancing grinding wheels Keith Johnson eliminates vibration on his home-made cutter grinder

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Improvements to the mini-lathe top slide Tool grinding on a wetstone grinder

Michael Cox now makes good consistent tapers on the minilathe Ron Wright adapts a wet stone for grinding lathe tools

cradle, parallel bars, corner posts, levelling studs, assemble cradle, wheel spindle, wheel spindle weight, wheel spindle headed bush, wheel spindle drawbar, balancing weights, wheel and weight mounts, balancing weight position, wheel balancing sequence, adjusting weights, finally, storage. construction:the bearing block, the extension plate, the feed screw assembly, modification of the top slide nut, final assembly, in use. safety, design parameters, inverter operating manual, a dual voltage three phase motor, installing an inverter in an electrical box and connecting it to a motor, fixing the inverter in the box, the inverter, programming the inverter, keying in codes and data, remote control beyond the keypad, keying in codes and data, wiring the inverter.

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Variable speed drive using a digital inverter

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Measuring and improving bandsaw blade life A lathe centre height gauge for the beginner Facing discs by means of a wax plate

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Shaping with a lathe

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A pair of manual Pratt Tudor industrial scroll chucks

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Construction of a top slide In our next issue Magnetic strip digital read-outs

Alan Hearsum explains the wiring of a digital inverter Richard Clark makes several improvements to achieve longevity Clarke 4 1/2" bandsaw of blades John Hinkley uses a number of skills to make a simple but general layout, materials and useful device construction. Peter Shaw overcomes the problem of holding a thin disc for machining an idea, designing the device, the saddle attachment, the push-bars, the pivot support, the operating lever, the Linton Wedlock describes an accessory to enhance the bearing block, the bearing cavity, versatility of small lathes conclusion. Pratt Tudor, clean up, making a new backplate, testing times, handling soft jaws, using the Pratt Tudor chucks on Mike Houghton describes his refurbishment and use of two well the mill table, a PT chuck mount for 6in used Pratt Tudor 6 1/4" 'concentric' replaceable jaw chucks HVRT table, conclusions. Roger Trewinnard overcomes several difficulties machining ductile cast iron

Dick Stephen fits an accurate digital read-out to a Nova mill

fitting the strip in the cover, installing the read head, .

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On the editor's bench Adapting a vernier caliper

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Basic measurement for beginners

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Coolant systems for hobby lathes Fireside reading Easily made micrometer holder Revolving centres for the lathe In our next issue A tangential tool flycutter Using a USB microscope for remote viewing and tool inspection Making a wheeling machine or 'English wheel' Aluminium casting in the home workshop

CAD software, knife sharpening, minilathe special, making a cutter grinder, quick change tool post, Quorn. Myford Ltd - new spares, Myford second-hand spares - lathe parts in Lincolnshire. Stephen Bondfield creates two useful tools from one vernier cutter and mandrel, the digital depth caliper gauge. fractions and decimals, measuring tools, the Vernier calliper, dividers, odd leg Ted Holloway describes the workshop's essential tools for the callipers, internal and external callipers, absolute beginner squares. the coolant system, electrical Michael Cox makes a neat cooling system with controllable flow components, installation. The Milling Machine by Harold Hall, Workshop Electrics by Alex Weiss and Jon Barden Santiago R Santafe makes a simple but useful workshop tool Michael Cox makes his own compact running centres to an construction, use. Edgar Westbury design Michael Cox increases the depth of cut by lateral thinking Chris Gabel can see clearly with the aid of an easily fitted USB microscope Dave Fenner makes a useful addition for his car body repair shop construction, testing.

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Digital readouts on the smaller lathe

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Improving a low-cost rotary table A new topslide with high-resolution angular readout (2)

manufacturing the wheels, making the frame, operation. the furnace, the burner, initial firing of the furnace, other equipment, scrap aluminium, melting and refining scrap Michael Cox gives a through description of the setting up of a aluminium, preparing a lost foam home foundry pattern, making a casting, conclusion. early consideration of different types of DRO, my requirements for a DRO on my lathe, the BW Electronics DROI system, fitting the DRO to my lathe, first method of fixing the X direction sensor, the Z direction sensor, second method of X David Haythornthwaite looks at the problems encountered when direction sensor attachment, the final fitting a digital readout on the smaller sizes of workshop lathe solution for the X sensor, adapting the and describes his particular solution to these difficulties sensor. solving the first problem, the locking mechanism, improving the locking mechanism, avoiding the backlash, two Richard Allendale makes his new 6in rotary table fit for purpose final problems, conclusion. David Graves improves accuracy on his Chinese lathe machining the pieces.

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A boy's toy?

Linton Wedlock makes an automatic electrical coil winding machine with Lego

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Heart-shaped cams Linton Wedlock describes how to draw and make these useful components Ian Greaves writes about horological cutter making in the UK

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Micron accuracy and garden rakes Some workshop storage ideas

Mike Haughton looks at tool storage A new topslide with high-resolution angular readout (2) David Graves improves accuracy on his Chinese lathe

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Converting a Myford Super Seven lathe to CNC (4) Glen Blunt upgrades a Myford Super Seven whilst maintaining it's original manual functions

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Aligning a machine vice

David Haythornthwaite looks at ways of ensuring your milling machine vice aligned to the machine table

simple CAD 1, simple CAD 2, simple CAD 3, simple CAD 4, simple CAD 5, simple CAD 6, simple CAD 7, simple CAD 8. Upgrade your workshop and turn trash into cash, home and workshop machinery. functional description, the bobbin support, the gearing, the heart-shaped cam, the lever, other components, using the winder, observations, conclusion. heart-shaped cam types, constant velocity motion, drawing cams, making edge cams, drawing a translating follower cam with no offset, cams with roller followers, an offset translating follower cam, a pivoted follower cam, drawing other cams, dividing a line, dividing arcs and circles. tooth profiles. workshop drawer storage, recent storage additions, heavy stuff, conclusion. making a tap and the threaded block to match the drive screw, comments on the mechanical portions of the project, the electronics and software, the proof of the pudding. power supply, emergency stop, breakout board, printer card and cable, monitor arm, Mach 3, controller housing, sockets for connections, the assembly, stepper motor wiring, connecting it all together, emergency stop functions, cooling fan. how to align your vice, making a device to suit your vice and mill, design concept, construction, using the alignment tool. machining the billets, final machining. a look at metals, mild steel, silver steel, gauge plate, stainless steel, brass, copper, bronze and gun-metal, gun metal, aluminium, cast iron.

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Squaring up and machining larger billets (1) Mick Knights prepares the billets for two crankcase halves Engineering for beginners Mick Knights looks at basic workshop practice

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An accurate CNC 4th axis (5) In our next issue On the editor's bench Engineering for beginners (2) Lathe tools and carousels for quick change tool holders A small quick change tool post for the Unimat BD200 and SL1000 In our next issue A simple pillar tool (1) A simple rivet shear Anti-fatigue workshop flooring Squaring up and machining larger billets (2) Making a Keats type angle plate Making a 30 tonne hydraulic press

Richard Gordon makes an affordable 4th axis for small CNC and final points. manual milling machines 2011 model engineer exhibition, boiler test review, tour to Karlsruhe model exhibition, free ticket. engineering drawing, units of measurement, the bench and vice.

Mick Knights looks at basic workshop practice Murray Lane improves the accessibility of a selection of tools

Dick Van Beusekom improves efficiency at the lathe

construction, components, the tool post block, the tool holders, assembly, operation. the Lidl drill stand, conversion of clamp castings, the tapping spindle, the slotted table. blades, shear plates, assembly. using the dividing head to machine larger workpieces.

Michael Cox turns a cheap drill stand into a pillar tool Brain Moseley offers a better way to cut rivets to length Mike Haughton looks at flooring Mick Knights prepares the billets for two crankcase halves Michael Cox makes a work-holding accessory

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Converting a Tom Senior light vertical milling machine to CNC (1) On the editor's bench

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Engineering for beginners (3)

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Care and lubrication of Myford Series 7 lathes

to buy or make?, construction of a hydraulic press, design and manufacture, operation of the press, Alan Hearsum can now bend 3mm steel plate in the workshop welding, conclusion. planning the CNC upgrade, assessment of the machine, removing the knee Glenn Bunt converts a mill and saves space assembly. on the move, deputy editor, articles, beginner's series, video at the exhibition. drill press and drills, marking out and measuring devices, files, hacksawing, time to make something, threading, Mick Knights looks at basic workshop practice knurling, drilling and tapping. general care, lubrication of the lathe, countershaft and headstock lubrication, headstock lubrication, gear train and gearbox lubrication, leradscrew lubrication, saddle and apron lubrication, saddle apron lubrication, tailstock David Hythormthwaite gets to the bottom of a question bothering lubrication, cross slide and top slide many Myford owners lubrication.

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Simple centre finders for lathes A versatile rear tool post for the Myford lathe (1) A hot wire cutter for expanded polystyrene (1) A simple pillar tool (2) An adjustable broach fore cutting internal keyways in small holes A micro-adjustable surface gauge A tailstock offset for the mini-lathe In our next issue A sheet metal hole punch

Murray Lane creates a very simple and quick to use centre finder Murray Lane develops two ideas and offers a design for a versatile tool post Michael Cox makes more complex patterns for one-off lost foam the hot wire cutter. castings the number stamp holder, conclusion. Michael Cox turns a cheap drill stand into a pillar tool the broach, using the tool, Michael Cox cuts internal keyways improvements. Neil Wyatt makes an accurate marking out tool Michael Cox describes a means to obtain an offset without then construction, assembly and finishing, having to reset the tailstock use. Neil Wyatt punches neat holes in a straight line an appreciative beginner, beware of magnesium, simple CAD 9, simple CAD 10, simple CAD many thanks, potentiometer and inverter alternatives, Flexispeed lathe?. welcome to 2012, get model engineers workshop for 16 pence per issue, Myford lubrication error, articles wanted, beginners series, the association of 16mm narrow gauge modellers handbook, tools at exhibitions, junior engineers. hardening, tempering, sharpening, wheel dressing, grinding wheel selection, time to make some more tooling, accurate marking out, a cheap height gauge, squaring a hole, producing the toolmakers clamp, marking out, drilling in pairs, tapping squarely, ball nose cutter. q-cut. adjustable mounts, the studs, levelling the level, levelling the lathe, testing, final test. the trimmer and wheels, fabrication, in use, grinding dust, carbide cutters, so now. quick change tool post, raising blocks, power cross feed interlock, lubrication.

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Engineering for beginners (4)

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Using tipped lathe tools Levelling a lathe

Mick Knights looks at basic workshop practice Marcus Bowman looks inside his tool drawer

John Harris looks at setting up a lathe 185 185 24 28 A poor mans tool post grinder John Viggers adds a useful accessory My first experiences with a Myford Super Seven 7 Ian Strickland prevents a potential disaster

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A tool tip measuring aid Converting a Tom Senior light vertical milling machine to CNC (3)

Terry Owens looks at making form tools

Glenn Bunt converts a mill and saves space

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Rotary broaching the easy way A versatile rear tool post for the Myford lathe (2) A hot wire cutter for expanded polystyrene (2)

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Headstock belt clutch and brake for Drummond lathe

Michael Cox makes shaped holes Murray Lane develops two ideas and offers a design for a a cantilevered rear tool post. versatile tool post Michael Cox makes more complex patterns for one-off lost foam electrical circuit, assembly and setting castings up, accessories, a typical job. background, making and fitting a headstock belt clutch and brake, the control box, balancing the flywheels, the initial design, the casing forming the control box, assembly, fitting the capstan Alan Hearsum gives new life to an old lathe brake belt, the finished project. free adverts, the 2011 model engineer exhibition, the 2012 model engineer exhibition, model engineers workshop 2012. filing to shape, the retaining clip, finished clamp. evening classes, lathe levelling, inverter drives, coolant system, Flexispeed lathes. Trident C mill, Lucas 12v dynamo, construction. AL960B lathe counterbalancing the machine moving parts, installing the gas struts, drilling the knee casting holes, fitting the Z axis ballscrew, the Y axis design. assembly of the carcase, manufacture of the drawers. keeping costs down, the steel structure, steel fabrication to hold the drive shaft and motor etc, power drive shaft, driving plate and main drive gear, driving pins, swinging link, sliding die block.

the measuring tool (that eureka moment), how to use the device. new bearing and washer, Nema 34 knee inner mounting plate, Nema 34 knee plate. the rotary broaching holder, construction, making the cutters. Testing the broaching tool, adapting the rotary broaching tool holder for other lathes.

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In our next issue On the editor's bench

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Engineering for beginners (5) Scribe a line A tool post adaptor for a horizontal mill A quick speed change for a Hafco lathe Converting a Tom Senior light vertical milling machine to CNC (4) Surface table trolley and storage unit combined

Mick Knights looks at basic workshop practice

Ian Strickland raises his sights Chris Dunn uses over centre levers to change between two speed pulleys

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Glenn Bunt converts a mill and saves space Martin Gearing gives a description of his solution to 'getting two for one.'

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Motorising a perfecto hand shaper (1) Alun Hearson adds motor to an old machine

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Electronic lathe control

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Cracking tee nuts and tee slots

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Notable things

introduction, building the ELS kit, building a case for the ELS, manual pulse generator, setting up the ELS, single axis ELS, setting up the auto turn, Tony Jeffree describes two lathe control devices that provide an spindle sensor, feature comparison, alternative to running a full CNC system E-Leadscrew threading, more machining examples, Automation Artisans AutoTurn Puttnam Engineering final words. Mike Haughton collaborated with Donald Jones in West Wales cast iron machine tables, why cast iron to report on more problems of tee nuts fracturing and damage to tee nuts. cast iron tee slots on machines early days, later books, manufacturing methods, photographs, different books for different things, project folders, drawings in the workshop, storing Marcus Bowman introduces sanity to the workshop notebooks. Alan Hearsum explains the wiring of a digital inverter control wiring, conclusion. initial considerations, laser housing, module mounting collar, power supply, setting up, in use, safety. what do beginners to home workshops know?, letters to scribe a line, the website, subscription problems, articles wanted, digital subscriptions, CAD CAM, readers workshops. establishing centre height, tool shapes and applications, grinding HSS tool bits, basic tool bits, back to the grind, the boring tool. ball screw modifications, changes to the travers slide flanged coupling, Y ball nut bush assembly, Nemo34 angle plate,. design and construction, milling mandrel, planting pin, depth gauge, M8 allen grub screw, marking out for milling, milling the pockets, planting the insert into position, drilling and tapping, assemble and test, speeds and feeds.

186 186 186

60 61 62

Variable speed drive using a digital inverter (2) In our next issue A simple laser alignment aid for the mill

John Shepherd sees the light

187

On The Editor's Bench

187

10

Engineering for beginners (6) Mick Knight looks at basic workshop practice

187

18

Converting a Tom Senior light vertical milling machine to CNC

Glenn Bunt converts a mill and saves space

187

24

A flycutter with a tungsten carbide insert Keith Johnson makes a metal removal tool

187 187 187

30 33 36

Simple modifications to the small Asian universal bandsaw Mechanical hacksaw and band saw fixtures A Norfolk tale

Murray Lane modifies his bandsaw Mike Haughton offers an update A Flexispeed 2.5 x 12in screwcutting back geared centre lathe by '42' an improvement to the fixture design, conclusion. the lathe in my workshop, future plans, finally.

187 187 187 187 187 187

39 44 50 54 58 60

Tailstock parking and lathe bed extension Alternative batteries for electronic micrometers Motorising a perfecto hand shaper (2) Improving the Colchester Bantam fine feed facility Tailstock dial readout Fretting about a fretsaw

Stephen J Roberts adapts his woodworking lathe John Pace improves his test equipment Alan Hearsum adds a motor to an old machine a replacement battery supply. final assembly, conclusion. removal and dismantling of the apron and worm box, how it all works, the knock off pin mechanism, lubrication. the dial calliper, the lathe, construction, assembly and use. ideal requirements, commercial machines, machine description, extending the versatility, fretsaw blades. adapting a vernier calliper, tee nuts, balancing grinding wheels article, no more Myford articles. digital editions, spammers on the website, workshop hints articles, reply to MEW 187 editorial. turning processes, inserted tip tools, choosing the lathe, small lathes, change gears, basic gearboxes, small capacity, large billets, basic equipment, the machine's construction, compromises, bed condition, the slides, dial calibrations, spindle speeds, bolting down, levelling the machine, testing for parallelism, spindle bore diameter, holding the work, chuck accuracy, checks on backplates, out of truth. assembly of the Y axis components, flanged coupling, motor tooling, the X axis, the X ball screw, ball screw bush, X axis end plates, aluminium spacer blocks, new longitudinal DRO position, the DRO mounting plate, the X axis assembly. making it, assembly, further work, postscript. manoeuvring, swarf collector.

John Connaghan improves the knock off effect Fred Maddalena makes a simple accessory

Dave Fenner extends the versatility of a fretsaw 187 187 188 62 63 9 Scribe a Line In our next issue On the editor's bench

188

10

Engineering for beginners (7)

Mick Knights looks at basic workshop practice

188

18

Converting a Tom Senior light vertical milling machine to CNC (6) Glenn Bunt converts a mill and saves space Shelley Curtis says "Don't hit it with a hammer" Dave Fenner makes a useful workshop tool Murray Lane modifies his bandsaw

188 188 188

24 26 30

Morse taper ejector Making a bead roller Simple modifications to the small Asian universal bandsaw (2)

188

34

A home made milling machine (1)

Rob Stephens raids the scrap box 188 38 Warco WM240B lathe Dave Fenner reviews Warco's new lathe

188

42

Rebuilding a Raglan 5 inch lathe Rob Stephens restores an old lathe

188 188 188

48 50 54

X, Y and Z edge finder Precision milling on the cheap Soft grip adjustable pipe wrench

Paul Boscott gets the edge Rick Sparber goes off on a tangent Laurie Leonard rolls his own

188

56

Bridging the CAD CAM divide Martin Widdowson brings CAD and CAM together Alan Jackson describes the construction of his award winning Stepperhead lathe

188 188

60 62

Stepper head lathe construction (1) Scribe a line

189

On the editor's bench

189

10

Engineering for beginners (8) Mick Knight looks at basic workshop practice

requirements of a vertical head miller, building a solid foundation, keep plate and pillars, slide locking mechanism, leadscrew and bearings, changes to the cut-off slide, the milling table, handwheel and graduations, modifications to the pillar drill. initial impression, what's in the box, headstock, spindle and drive, saddle and cross slide, tailstock, operation, overall perspective. moving the lathe, strip down, paint stripping, cleaning the parts, painting and brushes, reviewing the switchgear, adjusting the variable speed pulleys, breakdown of costs. manufacturing instructions, to use, discussions. precisely move your Z axis. design considerations, construction, conclusion. first steps, computer aided design, computer aided manufacture, the computer, the software, ViaCAD, Cambam, starting with ViaCAD, how to draw a connecting rod. disclaimer, production set-ups, bed bock overview. tailstock tapers, flycutter article, back issues. gas fittings for Michael Cox's furnace, model making articles in model engineers workshop, workshop hints and tips, digital shadowgraph, articles, the model engineer website spammers, compatibility of browsers, subscriptions and cover price increase, digital magazines, accessing digital magazines. four jaw independent chuck, self centring four jaw chuck, faceplate work, turning between centres, basic turning techniques, popular turning processes, basic facing and turning of diameters, internal boring, combating vibration.

189 189

18 20

Backstop for a Myford Super 7B Converting a Ton Senior Light Vertical milling machine to CNC

Shelly Curtis does a production job

Glenn Bunt converts a mill and saves space

189

24

A lathe mounted travelling dial test indicator holder (1) Keith Johnson adapts a charity shop find John Pace uses electronics in the workshop Steve Roberts adapts an attachment to a different machine

189 189

30 32

A poor man's shadowgraph (1) Right-angled head modification

189

36

Bridging the CAD CAM divide (2) Martin Widowson brings CAD and CAM together

operation, safety note. stepper motors, timing pulleys - initial problems, timing pulleys - the final configuration, modifying the timing pulleys. adapting it to my Simonet DZ 450 lathe, using the DTI holder, swivel clamp items, clamp washer, sliding collar, clock mounting arm (end piece), clock mounting arm (shaft), the column, clamping block. making a start, the base of the unit. modification to bevel gear head. making a start with CamBam, what are polylines and why are they important, so why all the talk about polylines, outline tool path, time to advance, it's in the post. bed block, machining the block. how to use saws, tubular frames for rigidity, under no tension, choosing blades, how to make a cut, scrapers and how to use them, precision tools, contact angles, use of scrapers. making a back plate for the ER40 chuck, adjusting the ER40 chuck, other large collet systems, conclusions. assessing the condition, sizing the replacement slab, tapping the table bed, final result. motive power and speed control, on the cheap, wiring up, drive belts and motors, back to handwheels and graduations, an ER32 collet holder for JT2. making the setting gauge parts, setting the gauge to size, using the gauge, proving the gauge settings rear tool holder, boring head, tool and cutter grinder. Rikky Milnes' letter in MEW 172, mini depth gauge, making the Worden.

189 189

40 42

In our next issue Stepperhead lathe construction (2) Alan Jackson describes the construction of his award winning Stepperhead lathe

189

46

Workshop hints and tips a model engineers handbook Geometer offers help and advice

189

48

Supersize ER40 collets Mike Haughton thinks even bigger Refurbishing a broken milling machine table

189

51

Steve Fisher renovates a Bridgeport mill

189

55

A home made milling machine (2) Rob Stephens raids the scrap box

189

58

Return to centre dimensions unknown Keith Johnson makes tool setting easy

189

61

Scribe a line

190

On the editor's bench

190

10

Engineering for beginners (9)

Mick Knights looks at basic workshop practice

190

18

Converting a Tom Senior light vertical milling machine to CNC (8)

Glenn Bunt converts a mill and saves space 190 24 A lifetime of engineering Roger Boyes show us around his workshop

190

26

Refurbishing a 2 Morse taper drill shank John Slater salvages scrap industrial tooling John Pace uses electronics in the workshop

190

31

A poor man's shadowgraph (2)

190

36

A home made milling machine Rob Stephens raids the scrap box

what do beginners to home workshops know?, workshop hints and tips, the model engineer exhibition, digital editions, Stepperhead lathe, major international model air show comes to the Fleet Air Arm museum, inserted tooling, parting off, tailstock support, different steps, screwcutting on the lathe, tooling, setting the tool square, thread systems, setting up for screwcutting, fast traverse, screwcutting thread dial indicator, opposite leadscrews. assembling the outer motor plates and Z limit switch, th4e electrical build, Mach3, controller cabinet, stepper motor drivers, power supply, breakout boards, printer card, emergency stop, sockets for connections, the electrical assembly, mains voltage, stepper motor wiring connections, connecting it all together, emergency stop connections, limit switch circuit, pulse and direction connections, cooling fan, configuring Mach3, the software settings, motor outputs input signals. a basic workshop, my own first workshop, the garage workshop, the garage rust prevention, better machinery, more workshop space. what do I mean by large holes, here enters a stroke of luck, the resurrection process, turning the taper, taper turning attachment, a drawbar no tang, a simple exercise. fine positioning, the Y axis slide. over to the experts, a disaster waiting to happen, disaster recovery, finish machining, final assembly, the first cut (was definitely not the deepest), addendum.

190

38

Restori8ng an eBay purchase Tony Jeffree renovates a Cowels 90E lathe

and eBay opportunity, the lathe, three different models, the fabricated base, assessing the damage, removing the tailstock, removing the mandrel, the initial work, cleaning and derusting. headstock overview, headstock block, boring the headstock, vertical column overview. the tube concept, clear plastic. hardening and tempering, setting the duck on centre, drilling a size hole, the second method, the second use of this gauge. initial setting up, the dummy spindle, the adaptor, angleplate support, read to machine. the selection and use of files, file sections, for use on flat surfaces, the right length, avoiding scratches, nuts and spanners, pin and 'C' spanners, causes of distortion, square socket spanners, marking off procedure, marking centre lines, straightness check, dividing a line, obtaining angles, dividing into 12 parts. searching the internet, mimic a Clarkson, making a start, an afternoons work, machining the taper, the Piddington toolholder, removing a Clarkson holder, a drill chuck adaptor, a minor problem. cutter sharpening, correct balance, Harold on the web, gas fittings, beginners to the hobby, beginners to the hobby 2, beginners to the hobby 3, model making projects in MEW, Morrison's ring-light, surface table trolley.

190 190 190 190

41 41 46 48

In our next issue Stepperhead lathe construction (3) Storing goggles safely A tool height setting gauge with a twist Alan Jackson describes the construction of his award winning Stepperhead lathe Phillip Brien protects his goggles

Henry Hicks describes his design of tool setting gauge "The Duck"

190

50

Locating work accurately on the faceplate

John Slater simplifies faceplate work

190

54

Workshop hints and tips a model engineers handbook (2)

Geometer offers help and advice

190

57

Clarkson Autolock FC3 adaptor and mill accessories David Piddington makes a copy of a commercial adaptor

190

60

Scribe a line