MultiMachine, an open-source machine tool

The MultiMachine -- a complete machine shop in one tool. Entirely built from scrap material.
Pat Delany MultiMachine Box 1629, Palestine, Texas 758 1 !"# 9 $ 72$ 98 "upport at% http%&&'roups(yahoo(com&'roup&multimachine&

)ntro*uction
The MultiMachine is a multi purpose machine tool* that a semi-skilled mechanic with just regular hand tools can build using scrap car and truck parts. Electric power is not needed. In Developing ountries! the MultiMachine has the potential "or saving or improving the lives o" man# thousands o" people. These machines can be used in man# wa#s$ In the health sector b# its use in building water pumps! "ilters! water well drilling rigs and hospital "urnishings. In a'riculture b# its use in building "arm machiner# and irrigation pumps. In transportation b# its use in building and repairing parts "or vehicles. In communications b# its use as as a cell phone charging station. In +illa'e li,e b# being a source o" batter# power "or home lighting. In e*ucation b# providing vocational education students with machine tools that the# build themselves and then are able to take back to their villages when the# graduate. It could provide a local sel" supporting in"rastructure that would be available to keep water and irrigation pumps in repair. Man# %&'s go to great e""ort and e(pense to drill water wells and provide pumps in rural areas o" underdeveloped countries. These pumps o"ten "ail because there is no person able to repair them. ) small MultiMachine based business could provide a pump repairman with the means to earn a living in an area where these pumps and wells are used. The pump repairman could support himsel" b# doing machine shop t#pe jobs like making and sharpening agricultural tools and e*uipment and resur"acing vehicle "l#wheels! brake drums and disks. Machine tools o"ten draw power intermittentl# "rom gas or diesel engines or electric motors. )n# surplus power could run a welding machine built "rom a vehicle alternator and also recharge batteries that in turn could be used "or home lighting or recharging cell phone batteries. The combination o" a MultiMachine and a welder can be used to build di""erent t#pes o" metal bending and rolling machines that can be used to manu"acture "uel e""icient cook stoves! pots! pans and similar products. The MultiMachine also provides a wa# to machine simple +inc and aluminum castings made "rom the metal "ound in old car parts. ,ithout this machining! the castings are o" limited use but simple machining can turn them into hundreds o" di""erent kinds o" products. -ocational education takes .hands on. learning. /ew vocational schools in developing countries have su""icient numbers o" the machine tools that are necessar# "or training students. This is no problem with student built MultiMachines.

* # machine tool is a po-ere* mechanical *e+ice, typically use* to ,a.ricate metal components 0

/oo0 aroun* you( #lmost e+ery manu,acture* pro*uct that is ma*e o, metal is a com.ination o, parts that ha+e .een machine* 1castin's, scre-s an* .olts2 an* sheet, .ar an* tu.ular metal that has .een -el*e*, .ent, rolle* or spun into a nee*e* shape( The essentialy ,ree MultiMachine an* the tools it can pro*uce can *o all this( # 'roup o, speciali3e* MultiMachines can *o much more( The MultiMachine can .e easily .uilt in *o3ens o, special +ersions that are specially .uilt to *o 4ust a sin'le type o, metal -or0in' 4o.( ), these special machines -ere 'roupe* to'ether an* *ri+en ,rom a common po-er source, they coul* .e use* in a ,orm o, De+elopin' 5orl* mass pro*uction( Most o, these machine +ersions coul* .e .uilt -ith 4ust one or t-o .ro0en +ehicle en'ines, a piece o, pipe, a ,e- ,eet o, steel .ar, a sac0 o, cement an* a ,e- easily ma*e 3inc&aluminum castin's(

) am certain that MultiMachine ne-s'roup mem.ers -ill help a*apt our *esi'ns to the types an* si3es o, material a+aila.le in any community(

"pecial than0s to 6eor'e 7-en o, 87n'ine Mill9 ,ame, :e,, ;ansen, <e+in =lson an* to my cra,tsman ,rien*, >ran0 Patterson( #n* a +ery special than0s to my -i,e, ?larissa, -ho put up -ith me *urin' the ,our years this pro4ect too0(

Ta.le o, contents
pa'e 1 ?o+er 2 )ntro*uction @ Ta.le o, ?ontents 6 5hat the MultiMachine can *o 1 5 construction techniAues 1 secrets2 1 !sin' en'ine .loc0s as .uil*in' .loc0s 2 Borin' the .loc0 to ,it the .earin' outsi*e *iameter $ The spin*le can .e a piece o, pipe the *iameter o, the .earin' insi*e *iameter @ The use o, a three .earin' spin*le 5 The en'ine .loc0s are clampe* to'ether -ith plate an* 0eystoc0 rather than *o+etails 12 The machine is ma*e o, 5 mo*ules that attach to a +ehicle en'ine .loc0 1 The +ertical sli*e 2 The *ri+e unit $ Mountin' the machine @ The o+erarm 5 The spin*le #.out money, accuracy an* s0ills Tools ?onstruction starts The spin*le in *etail "tep 1, 5hat *o you -ant your machine to *oB "tep 2, Ceally learn the instructionsD "tep $, 6ettin' the stu,, to'ether( "tep @, The machine an* en'ine shops "tep 5, 5hen you 'et the .loc0s to your shop "tep 6, The MultiMachine nee*s somethin' to sit on "tep 7, Mo*i,yin' the .loc0 "tep 8, Mountin' the .loc0 "tep 9, Po-erin' the machine "tep 1 , The .i' plate that replaces +ery har* to ma0e *o+etails "tep 11, Mountin' the .i' plate "tep 12, The +ertical sli*e "tep 1$, The cross sli*e "tep 1@, The o+erarm "tep 15, Buil*in' your o-n 8Bro0en .it9 1tan'ential2 cuttin' tools "tep 16, Buil*in' your o-n lathe chuc0

1$ 15 17 22 2@ 25 26 29 $@ $8 $9 @$ @8 5 52 2

5$ 5@ 5@ 55 57 6 6$ 6@ 66

"tep 17, ;o- to cut threa*s 1the -ay it -as *one 9 years a'o, it still -or0s to*ay2 ;o- to .uil* a really .i' MultiMachine The ratchet *rill T-o easy to .uil* EtemporaryE lathes The E'iantE MultiMachine( Pipe si3e chart Morse taper chart Metric .earin' chart 6lossary

The MultiMachine is a metal lathe that can .e .uilt to machine somethin' as .i' as a manhole co+erD )t can ,ace an* cut tapers .y simply rotatin' the cross ,ee* on the 8turnta.le(9 )t can *rill an* .ore in many *i,,erent -ays

)tFs an en* mill

)tFs a hori3ontal mill that can -or0 -ell -ith really cheap eBay cuttersD This resharpene* cutter cost 75 centsD My MultiMachine ma*e a @ rpm sin'le pass-cut o, (8229 x 1&29 in this piece o, 6 61 aluminum(

=ther ar.ors can .e easily ma*e ,or ,ly cutters, -oo* an* metal sa.la*es, sur,ace 'rin*in' -heels an* san*in' *rums an* *iscs(

;o- can the MultiMachine *o all these thin'sB

In almost ever# kind o" machining operation! either the work piece or the cutting tool turns. I" enough "le(ibilit# is built into the parts o" a machine tool involved in these "unctions! the resulting machine can do almost ever# kind o" machining operation that will ph#sicall# "it on it. 5ou ma# have heard o" 1-in-1 machine tools -- basicall# a combination o" lathe! mill and drill press. The MultiMachine starts there but adds man# other "unctions. It can be a 16- in-1 7or even more89 machine tool that is built b# using vehicle engine blocks in a :E&'-like "ashion.

It can be built as a one-engine block machine with a plate and angle iron vertical slide.

'r as a two-block version with an engineblock-based vertical slide. 'r as a two-block-lathe-onl# version. 7;ee the "i(ed lathe bed version below.9

This is a three-block version with a "i(ed! long lathe bed and a rear-mounted vertical slide. &reat i" #ou have limited space8 This version is similar to a <itchen and ,ade multipurpose machine 7below9 that was used aboard ships "or man# #ears -- a "ar more use"ul design "or a machine tool than the common 1-in-1 machine. =

>

=Double-sided? MultiMachines 7lathe on one side! all-"unction machine on the other9 are per"ect candidates "or -ariable /re*uenc# Drives that make the machine spindles both variable speed and bi-directional. @ictured below is a "our-block version with doubled vertical blocks mounted back to back so it can support a 2A-long spindle B use"ul with a heav# chuck. The machine can also have a rear vertical slide! and a 2- or 3-block version with a Cridgeport-like head could have an added hori+ontal block with powered spindle added on top.

The most common si+e "or a MultiMachine has 10-to-13. o" table vertical travel and a 10. lathe =swing.? The horsepower re*uired "or regular lathe-t#pe cutting tools makes them hard to use large work pieces. CDT...I" #ou replace the cutting tool with a simple E16 bench grinder or even a homemade toolpost grinder! #ou can machine reall# big jobs. 5ou can even resur"ace large clutch and brake parts "or a truck.

C# using the simplest metal casting techni*ue! a skill that has been around thousands o" #ears! #ou can turn out products using machined aluminum allo#. It then becomes possible to build things like pump parts and to cast allo# bushings that could replace e(pensive ball bearings. 'ne common allo#! F)-10! contains about 10G aluminum! with +inc as most o" the remainder. Coth H

aluminum and +inc are materials commonl# used in vehicles! making them easil# available. F)10 has a tensile strength approaching that o" cast iron and is such a good bearing material that it is used "or bushing-t#pe bearings in steel-rolling mills. ;ee the possibilitiesI

The MultiMachine is extremely simple - .asically 6 unusual construction techniAues that -e call 8secrets9 an* 5 +ery simple 8mo*ules9 that .olt to an en'ine .loc0( Using engine blocks as building blocks is the first MultiMachine secret. ;ince c#linder bores are bored parallel to each other and at exact right angles to the c#linder head sur"ace! MultiMachine accurac# begins at the "actor# where the engine block was built. The second MultiMachine secret! In the most common version o" the MultiMachine! one that has a roller bearing spindle 7the kind I built9! this precision is maintained during construction with simple c#linder re-boring o" the K1 c#linder to the si+e o" the roller bearing outside diameter 7'D9 and re-boring the K1 c#linder to "it the overarm 'D. The best part is that the c#linder-boring operations will probabl# cost less than E36. )n engine machine shop provides the most ine(pensive and accurate 7.6663. on a 2. c#linder89 machine work commonl# done an#where and guarantees #ou that the spindle and overarm will be both aligned and at an e(act right angle to the "ace 7head sur"ace9 o" the main engine block that serves as the base o" the machine. The third MultiMachine secret! The spindle can be as simple as a piece o" pipe machined to "it the inner diameter o" the bearings. The fourth secret is the addition of a third bearing to the spindle. The three-bearing spindle is necessar# because the =main? spindle bearings just ="loat? in the c#linder bore so that the third bearing is needed to =locate? the spindle! act as a thrust bearing! and support the heav# pulle#. The fifth MultiMachine secret! The main engine block and the vertical-slide engine block "it together with the help o" two 1L0. ( 10. steel plates! along with m# uni*ue wa# o" clamping the plates together. ItAs easil# built! easil# adjusted! and easil# clamped into position without the workpiece moving. /ar superior 7I think89 to a homemade attempt at a "our-"oot-long dovetail. :ong! angled cuts similar to this commercial dovetail assembl# on the cross slide shown below would be "ar more di""icult to build than the MultiMachineAs simple! s*uare sections that are bolted together. 5hile the MultiMachine +ertical sli*e reAuires only a *rill to .uil*, a lon' *o+etail reAuires a +ery lar'e millin' machine( # hu'ely important *i,,erenceD

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The use o, smaller steel .ar stoc0 or an'le iron may .e necessary in some areas -here the G9 x 129 steel plate may .e har* to ,in*( Pieces o, truc0 ,rame rail coul* .e use*( #li'nment o, these 8,oun*ation9 parts is critical, an* su.stitutes ,or the pre,erre* steel plate may .e har*er to a*4ust( DonFt let the *i,,iculty o, ma0in' a sli*in' ,it *eter you ,rom 'ettin' starte*( Buil* a ,ixe*-.e* lathe +ersion ,irst an* later a** a MultiMachine-type +ertical sli*e to the rear o, the .loc0( Mere is one kind o" substitute that could work well$ =doubled? "rame walls that are common in big trucks. The rivets can be ground o"" and the two pieces made into a good sliding "it.

The sixth MultiMachine secret is a *e+ice similar to this that can .e clampe* to a sha,t( )t can ha+e capscre-s that pass si*e-ays in or*er to push or pull another *e+ice or can .e ma*e lar'e enou'h to *o *o3ens o, 4o.s .y itsel,( More a.out this laterD

11

The 5 simple mo*ules that attach to the en'ine .loc0%

112 The +ertical sli*e mo*ule is basicall# a short engine block with a steel plate bolted to the head sur"ace and a cross slide attached to to the end bell 7upper9 end. There are man# kinds o" cross slides that can be bought or built. I" #ou have a little mone# to spend! think about bu#ing a E4J E% ' one to use at "irst 7in developing countries! however! a similar one ma# be the e*uivalent o" a thousand dollars9. :ater! #ou can build something like a massive concrete and steel =Nomig? single or twin lathe bed and cross slide. 7;ee the =Nomig? turret lathe design in the MultiMachine newsgroup ="iles? section.9 O.-. Nomig designed machine tools that were "eatured in @opular Mechanics maga+ine "or almost thirt# #ears. The designs still work well. This small cross slide also can be used "or man# other projects. E(ample$ #ou can "it it on top o" a turntable and use it "or cutting tapers. 7) turntable could also be "itted to the top o" a big =Nomig? bed to cut tapers.9 122 The *ri+e unit mo*ule( There are literall# do+ens o" wa#s to drive the machine. ) combination o" small and large pulle#s makes a good medium-speed drive. 'ther setups might include multiple-groove pulle#s or even the transmission "rom a lawn mower! garden cultivator! or pickup truck. @ower can be provided b# an#thing "rom an electrical appliance motor to a car or truck engine.

1$2 The machine mount mo*ule The *ualit# o" the "inish #our machine can make will be greatl# a""ected b# the rigidit# and weight o" the base. ;ince I lack work space! I had to have a machine that I could move around. Mine is built with an engine stand and mobile base. 7) permanent base made "rom concrete or a heav# steel "rame would be much more rigid.9 An overhead hoist is a necessity since #ouAll be using a machine that ma# weigh well over a ton. I" #ou decide to use an engine-stand-t#pe machine mount! tr# to make it a one-ton model. In the D;)! Marbor /reight has these "or about a hundred dollars.

10

1@2 The o+erarm mo*ule ma# not even be needed b# some people but others ma# see it as the heart o" an entire tooling s#stem. Cecause it is important that the overarm alwa#s sta# in alignment! the #1 cylinder is rebored to fit your overarm pipe at the same time the #3 cylinder is re-bored for the spindle.

152 The spin*le mo*ule is the heart of the machine. %o machine tool can do a proper job with an inaccurate spindle. Because the .earin's actually run in the pro,essionally .ore* cylin*er .ore o, the en'ine .loc0 an* the spin*le is ,inish-machine* on the MultiMachine itsel,, accuracy is achie+a.le e+en .y a no+ice machinist( 7To be treated in much more detail later9

#ccuracy, money, tools an* s0ills

Your machine's accuracy is determined by the care you put into building it. ThereAs no one checking #our mistakes but #ou. ompounding a "ew barel#-good-enough "its could make #ou end up with a machine that chatters too much to use. The chattering ma# be so severe that #ou canAt even discover what causes it. "a,ety also *epen*s on you. #/5#H" use protective guards on #our machine. I canAt stress it enough. )lso...the MultiMachine is taller than it is wide! is ver# heav#! and is prone to "all over8 Mine "ell on me once and now I have a new! titanium knee8 I liked the old one better.

11

# little extra -or0 lets you sa+e a lot o, moneyD IAm assuming that #ou would like to spend as little mone# as possible on this project. I" #ou can a""ord to spend a lot! just search eCa# and raigAs :ist "or some o" those wonder"ul machines le"t behind when D; jobs went to hina. ,hen I built m# MultiMachine! I tried to "ind wa#s to build it that could take almost no mone# and little or no electrical power either "or building or operating it. I wanted a machine that could be built and run an#where in the world B outdoors! in a shed without power! or in the "inest workshop. The result is a machine that could be grouped with others like it to make a small "actor#. The machines could be powered b# a single gas or diesel engine running an overhead sha"t that is connected to them b# simple pulle#s and belts. Hou may ha+e to learn a ,e- ne- s0ills to .uil* the machine, .ut these s0ills are also nee*e* to ma0e .est use o, the MultiMachine( Two important skills covered in man# old machining books are grinding cutting tools to the correct shape and clamping work on a lathe "aceplate. These kinds o" subjects are also usuall# covered in just 06 or 16 pages in almost an# o" the older machining books that can be "ound in #our local librar#! In our MultiMachine newsgroup or elsewhere on the web. The shape o, the cuttin' tool is important in ever# lathe! milling and shapingLslotting machine operation. The tool has the same basic shape "or man# o" these di""erent operations. :earning the basics o" grinding metal-cutting tools to the proper shape will save #ou lots o" mone#. ;o- to clamp -or0 to a lathe ,aceplate is the other basic machining skill needed. There are man# wa#s to do this that are described in older books. 7;ee samples below.9 ;ince three- and "our-jaw chucks were not common "or the "irst H6 or J6 #ears o" wide metal-lathe usage! metal workers did without them. ;o can #ou i" #ou have to.

12

)nci*entally--- The enlarged picture taken "rom the "aceplate 7shown on the right above9 shows a wonder"ull# use"ul clamping device. To make it! just weld a short piece o" threaded rod to the side o" one o" the long! coupling nuts commonl# used to connect two pieces o" threaded rod. Then add a bolt and a nut. It ma# help to grind a slight angle on the coupling nut so that the screw "orces the work- piece into the "ace plate. ThatAs all it takes8

<no-in' ho- to cast aluminum alloy is vital to building a reall# cheap 7or almost "ree9 MultiMachine. ast aluminum allo# parts can replace e(pensive bearings! spacers! adjusters and pulle#s in #our machine. ;ince #ou donAt need "anc# pattern-making "or the MultiMachine! casting "or it is simple. 5ou can just cast round sections and turn them into the parts #ou need b# using one o" the =temporar#? lathe designs "ound at the end o" this booklet. These cast parts let #ou adapt junk-priced pipes and sha"ts to the si+es #ou need so #ou can avoid bu#ing new stu"" at retail prices.

Tools you -ill nee*

/or those who donAt have a power drill 7or power9! see the end o" this booklet "or a wa# to build a ratchet *rill( I" #ou have onl# a pistol-type electrical *rill, #ou should bu# or make some kind o" stand "or it. I" #ou have a small, .ench *rill press that can be made to run at slow speed 7b# changing pulle#sI9! turn the head around and clamp the stand to the work. I" #ou have a .i' *rill press, lower the head almost to the ground and make a ground-level 0(2 and pl#wood table to put #our work on. This provides a sa"e wa# to drill holes in 106-pound pieces o" steel. /or large holes! just .step. drill 7start with a small drill bit and work up an eighth o" an inch at a time.9 ) hac0sa- 7and a bunch o" high-*ualit# blades such as the 21-cent ;tarrett ones "rom E% '9 will work "or sawing. I" #ou donAt have a electric 'rin*er, #ou can use a hammer! chisel! "ile! and a hand cranked grinder 7"or grinding cutting tools9 as mechanics did "or hundreds o" #ears. I was serious when I said onl# basic tools were needed but I need to add three kinds o" more unusual tools that some mechanics wonAt have. 'ne o" these is a set o" trans"er punches. ) set o" these will usuall# cost under ten dollars. Trans"er screws 7one hal" inch long pieces o" threaded rod with a point ground on one end9 are e(tremel# use"ul in machine building. ) mechanic should be able to make both these tools The third tool is a dial indicator that also is usuall# under ten dollars. The dial indicator is needed "or checking spindle and elevating table adjustments. 13

Trans,er scre-s

Trans,er punches

Dial in*icator

5ou can weld some o" the machine parts that donAt have to be in per"ect alignment. 5our -el*in' setup can be as simple as connecting 0 or 1 car batteries in series 7positive on one to negative on the ne(t9 b# using long jumper cables and keeping the welding job a sa"e wa# "rom the batteries. are"ull# protect the batteries "rom an# welding spark8 DonFt -el* anythin' that can ha+e the sli'htest e,,ect on machine ali'nmentD The ,astest -ay to ruin any machine tool is to -el* it T-o thin's to 0eep in min* -hen rea*in' this .oo0let% ) am an in+entor an* not a precision machinist 1or precision anythin' elseD2 or an en'ineer( Ta0e e+erythin' ) say as my personal experience an* nothin' more( 14

"a,ety a'ain((( Ever# machiner# book or video stresses sa"et#! and well the# should. :i"ting and drilling accurate holes in the MultiMachineAs big! heav# parts re*uires a lot o" thought. T;)I<D Measure e+erythin' se+eral times an* -or0 on hea+y stu,, as close to the 'roun* as possi.le( # slippery, hun*re*-poun* piece o, oily steel on top o, a steel ta.le can .e +ery *an'erous(

?onstruction startsD
onstruction should be almost "oolproo". In the "inal chapter IAll tell how to build an even bigger 7ma# weigh "ive or more tons9 MultiMachine that can be built with no store bought stu"" at all8 It also can be built b# using onl# hand tools and no electric power.

;o- to .uil* a 8mi**le9 si3e roller .earin' +ersion that is .ase* on easily a+aila.le car an* li'ht truc0 en'ine .loc0s( Middle si+ed or not! this is no to# since
just the spindle assembl#! bearings! chuck and pulle# ma# easil# weigh well over 116 pounds and the whole machine ma# weigh over hal" a ton.

The "pin*le in *etail

/etFs start -ith the spin*le since it is the heart o, the machine and there are man# wa#s it can be built. Each o" these di""erent wa#s a""ects the wa# the rest o" the machine is built. :ook care"ull# at the roller bearing spindle picture and #ou will reali+e that the spindle works just like a bic#cle "ront a(le with just three small di""erences. The big spacer that separates the bearings! the wa# the bearings are adjusted and the third spindle bearing that "unctions both as a thrust bearing and to support "or the weight o" a heav# pulle#. Cut "irst lets talk about spindle and bearing si+e so that #ou can keep these things in mind when we stud# the individual parts. The maximum spin*le si3e is closely relate* to the .ore si3e o, your en'ine .loc0 an* also to -hat is the machine 'oin' to .e use* ,or( I" the MultiMachine is going to be used in a model makers shop! a small 4 c#linder block with a bore o" 1.3? to 1.4. would be "ine. huck thread si+e would probabl# be the ver# common 1 1L0. H and the spindle would have a bore o" about 1.. 'ne similar to the one I ended up with would probabl# have c#linder bore o" 1 >LH or 2. 7 This 1LH. di""erence can be ver# important because the smaller bore can just be re-bored without needing to be sleeved. It can easil# have the ver# use"ul spindle chuck thread si+e o" 0 1L2. H 7like the ;outh Cend heav# 16 lathe9 and would also have 1 1L2. spindle bore. This is a much more use"ul machine than one just that is just slightl# smaller because having the largest possible 1>

spindle bore si+e is ver# important. Modern lathes do not usuall# have long beds and a long bed is especiall# di""icult to have on a conventional MultiMachine since the vertical slide would have to be deep 7long9 enough to support the bed. ) long bed like this could be di""icult to raise evenl#. Modern lathes "eed the work through large 7or giant9 spindle bores like one on our largest MultiMachine designs. ;trangel# enough the 166 #ear old :indsa# book .@ractical Metal Turning. talks about just this as the .modern. wa#8 I would choose one o" the common hevrolet! Oeep or similar straight 4 c#linder engines with a 1 >LH. bore. I would use 166 mm 'D bearings and bore the block to that si+e. 71.J1>.9. /or a spindle I would use a 06. piece o" 0 1L0. ((h# pipe 7a pipe si+e chart is at the end o" the book9 that has an 'D o" 0.H>3? and an ID o" 1.>>1. This would allow plent# o" room "or a 0 1L2. H thread and the shoulder and register that the chuck =centers? on when it is mounted. ;imple so "ar. The reason "or the metric bearing si+e is because the# seem to cost a lot less. I used 2 1LH. 'D Timken bearings in m# 4 c#linder /ord 166 cubic inch pickup block and the cheapest roller bearings I could "ind were E>3 ea! I later "ound metric 166mm 10611( and 10611 bearings "or E00 to E10 7probabl# di""erent *ualit#9. These bearings have an ID o" 43mm and 33mm respectivel# which is per"ect "or this si+e pipe. It also means that the spindle can be threaded 7use a dial indicator to center the spindle thread on the bore9 and room le"t "or the .register.! shoulder and bearings. The K1 c#linder can be bored to the si+e o" a .cleaned up. piece o" 2. 'D pipe or tubing that is used "or the overarm. :ike ever#where! there are trade o""s here! and in this case it is that .(. at the end o" the 10611( bearing number. This is not a heav# dut# bearing even though it is supposedl# rated "or automotive use. I" we would go to a heavier dut# bearing 7106119 with a 33mm or 0.143? ID then the spindle wall is just .0. thick which seems thin but will probabl# work "ine. %othing is written in stone in this project! a clean 166mm c#linder bore gives #ou man# choices in spindles that use single or double ball bearings! tapered roller bearings 7like mine9 or cast aluminum allo# bushings. I" #ou spend a nice a"ternoon at #our %)@) dealer! #ou will probabl# be able to "ind ine(pensive bearings to "it almost an# block within a 1.>3? to 2.03? range o" bore si+es. ;o what to use i" #ou are totall# broke or stuck a hundred miles "rom nowhere in <en#aI %o problem8 Oust build our ratchet drill and one o" the =temporar#? lathes described at the end o" this booklet! cast bushings or take apart ever# "ront and back a(le that #ou can "ind to harvest the bearings! pile these and whatever pipe pieces that #ou can "ind under a good shade tree and sit down and think8 MultiMachines are thinking peoples tools. I guarantee #ou will "ind a wa# since there are do+ens o" wa#s to build the spindle 7and almost ever#thing else here98

/ets start ,rom the ,ront en* o, the spin*le to 0eep thin's in some 0in* o, or*er( I am going to assume that #ou have a wa# to thread the spindle but i" #ou donAt! no
problem again8 5ou will soon learn about our =miracle? device that can cure almost ever# problem8 )t can mount a .i' chuc0 on one en* o, an un-threa*e* spin*le, .e a roller .earin' a*4uster, a thrust .earin', a pulley mount or a mounte* pulley an* also clamp all 0in*s o, attachments to the .ac0 en* o, the spin*le( Cut "irst! what si+e pipe to use "or the spindleI It could be almost an# si+e8 Cut since we have to 1H

start somewhere I am going to assume #ou chose to use the si+e o" pipe I recommended above 7and "ound! which ma# be hard in some places 9. 7pipe chart at end o" this booklet9 This picture 7below9 shows the critical spindle =nose? that #ou would thread 0 1L2? H threads per inch to match a chuck backplate. I7JT comes the important part8 :ook care"ull# at the little section between the thread and the spindle shoulder. It is called the =register?. The register area centers the backplate on the spindle when the backplate is screwed on "ar enough to hit the spindle shoulder. This is e(tremel# important since it means that the spindle can be threaded on another lathe and still be accurate on #our MultiMachine. )"ter #ou get #our machine powered up and the bearings adjusted! take light cuts on the register and shoulder sur"aces until the chuck backplate is a =wringing? 7gentl# screwing the backplate "orwards and backwards until it works itAs wa# over the register9 "it. The chuck backplate will then be a custom "it on the MultiMachine itsel". The spin*le threa*s *onFt center the chuc0, the re'ister an* shoul*er *oD )"ter this care"ul "itting is done! take a cut 7machine the sur"ace9 on the chuck backplate to make sure it is running true be"ore #ou bolt on the chuck. The MultiMachine newsgroup ="iles? section has an e(cellent article about mounting chucks. Mow long should this shoulder beI In this case! at least an inch and a *uarter. I" #ou eventuall# want to be able to cut threads! add another inch to this "or a timing gear pulle# that will drive a thread "ollower device that is currentl# being developed. Nemember that a 1L0? plate bolts to the "ront o" the block and that #ou will need additional shoulder space "or set screws etc. )"ter the shoulder comes the space "or the "ront roller bearing. The big spacer between the bearings takes the place o" the bic#cle hub and must be care"ull# made and and "itted so that the roller bearings are absolutel# parallel. The spindle can be slightl# undercut the same length o" the spacer to make it easier to press the "ront bearing on. The inner roller bearing should be a slightl# 7polish with emer# cloth9 looser "it on the spindle to make it easier to to adjust. I" #ou over-tighten this bearing then slightl# back o"" the adjustment screws! run the machine and let it =shake? lose a little. The a*4uster is the really B)6 MultiMachine secretD It is not the usual nut on a threaded spindle. It is a combination o" two common industrial devices. Dave &inger# used the idea on his hori+ontal milling machine arbor and I added the clamp bolts to avoid having to pock mark the spindle with set screw marks. This design is a wonder"ul idea that can be used man# times in 1J

machine construction and also in building necessar# tooling. This is an earl# adjuster design! a better one would also have clamp bolts like the designs on the right and below. ) hub with twin clamp bolts would be even better.

06

The 6in'ery hori3ontal mill ar.or( I would replace the three setscrews that position the "i(ed collars with just one setscrew and a clamp bolt 7or bolts9 like the hori+ontal mill cutter. I" #ou donAt alread# own the &inger# casting and cast machine tool books! bu# them8 ombining the power o" the MultiMachine with skills that #ou learn "rom building the &inger# tools will let #ou build almost an#thing8

I mentioned the third bearing earlier. It locates the whole spindle assembl#. It serves as a thrust bearing which is necessar# with the roller bearing spindle because these bearings just ."loat. in the c#linder bore and it also supports the drive pulle#. This pulley may -ei'h 2 to $ poun*s an* .e 1 E out ,rom the inner roller .earin' so a**itional support is +ital. Three bearing spindles are unusual because o" possible alignment problems! we will cover our eas# solution to this a little "arther along. The thrust bearingLbushing can be as simple as a cast sleeve with a shoulder that would bolt to the main bearing pads and two thin versions o" our =adjusters? clamped to the spindle. Io-((( somethin' ) consi*er +ery important( 7+ery.o*y -ill -ant to put his o-n EstampE on his machine( Thin0 care,ully .e,ore you *o it here( The spin*le M!"T .e centere* on the cylin*er .ore .ecause this lets you ali'n the lathe .e* or cross sli*e -ith the .loc0 cylin*er hea* sur,ace( Tryin' to ali'n machine parts .y usin' the short piece o, spin*le that stic0s out ,rom the main .loc0 is almost impossi.le( Thin0 care,ully .e,ore you chan'e somethin' here( Thin0 ease o, re-ali'nment >)C"TD The ta.le can 'o up an* *o-n 16E or more an* the cross ,ee* may .e a.le to rotate $6 *e'rees .ut all this -ill .e -aste* i, the ta.le an* cross sli*e has to stay loc0e* in place .ecause they are simply too har* to re-ali'nD #nother extraneous .ut +ery important thou'htD The si+e and weight o" the MultiMachine reall# do matter8 In the late 1H66As the vertical slide alone on a similar capacit# hori+ontal milling machine commonl# weighed 1666 lbs. In the earl# 1J66As incinnati! the great )merican milling machine compan# increased the weight o" their machine bases b# over 466G when the# "ound that under heav# cuts the cast iron bases were "le(ing like drum heads. Toda# 0 or 1hp Cridgeport milling machines weigh over 0266 pounds "or a good reason. 5our MultiMachine ma# weigh onl# a third o" this so alwa#s keep in mind the importance o" using sheer mass to suppress vibration.. oncrete is #our "riend! when #ou get #our machine to work like it should then "ill the base o" the main block and also the vertical slide with pol#mer concrete mi(.

01

The most important rule ,or .uil*in' anythin'D 1) thin098 .@a# in"inite attention to detail. This is an old Mercedes Cen+ racing team slogan. ,ork as care"ull# as #ou can. ) careless "it will cause .chattering. 7cutter vibration9 that ma# take months to diagnose8 ;everal careless "its will compound the errors. Cecause o" the "le(ibilit# o" the MultiMachine #ou will eventuall# tr# things that are almost impossible8 &ive the machine a chance8

"o((( to -or0D
"tep 1, 5hat *o you -ant your machine to *oB ,hat kinds o" machining jobs are likel# to come up in the "utureI ;hould it be able to make models or oil "ield tools. ;hould it weigh 166 lbs or 136 times that much. The smallest and largest machines can be built in almost the same wa# and in each case there are interrelated choices between things like c#linder si+e! spindle si+e! spindle bore si+e and bearing and chuck t#pe and si+e. Nemember that a vertical slide that is meant to be raised and lowered is not going to be long enough or wide enough "or some kinds o" jobs 7o" course no lathe is long enough "or some jobs89. The MultiMachine can make up "or this b# having a huge bore in the spindle "or the workpiece to pass through. Most modern lathes work this wa# but "ew have a 2.H. or larger bore si+e that is eas# to get on a MultiMachine that is based on a DodgeL ummins pickup engine block. Ever# design decision involves trade o""s. ) reall# big spindle and chuck in a relativel# light MultiMachine will onl# work at low spindle speeds. Migh speed sawing and grinding will be almost impossible without care"ul and e(pensive balancing.

"tep 2, Ceally learn the instructionsD !nless you ha+e a lot o, money to -aste, *onFt .e'in construction until you ha+e thou'ht out e+ery tiny *etail o, ho- the parts -ill ,it to'ether( ;a+in' to .uil* a machine t-ice ma0es it cost t-ice as much an* -orse than that, may rele'ate it to your un,inishe* pro4ect pileD #s ,ar as ) 0no- no machine tool is .uilt usin' en'ine .loc0s li0e /76= an* no machine tool uses a $ .earin' spin*le in this -ay( "it .ac0, thin0 e+erythin' throu'h( <no-here e+ery sin'le part is 'oin' to come ,rom an* that inclu*es e+ery .olt an* nutD The extra extra hea+y -alle* pipe that is use* ,or the spin*le may .e common in one area .ut har* to ,in* in another( Hou may ha+e to re*esi'n your -hole machine i, one component canFt .e ,oun*( Be sure to 0no- the exact si3e an* con*ition o, your chosen en'ine .loc0 .ore an* to -hat si3e it can .e re-.ore* to ,or our purposes 1not to hol* -ater2( "tep $, 6ettin' the stu,, to'ether( 5ou obviousl# have to have planned ever# detail "irst. This is what would be needed "or a conventional two engine block version. 719 The .big. 4 c#linder engine block! this can be an#thing "rom a Mercur# 4 c#linder outboard block "or an apartment si+ed MultiMachine to a 16Q "oot long industrial engine block. /or these instructions IAm going to assume a si+e common in the D;)! a 1 >LH. bore 4 c#linder engine block. ;imilar si+es have been used "or trucks in man# other places. The "irst place to look "or 00

engine blocks is in the junk pile behind engine shops. These usuall# have the big advantage o" being de-greased8 5ou will need a smaller cast iron block "or the vertical slide. ,ell! not e(actl# at this stage but #ou will need it when assembl# "irst begins and it is easier to search "or it while #ou are searching "or the =big? block. ,hat ever #ou choose! it needs to be as short and heav# as possible. )n iron -4 will probabl# work "ine or look "or a ver# common small Dodge D36 truck "our c#linder block. IAve used ever#thing "rom a Model ) /ord to a -olvo turbo block. 709 2A o" 2. 'D .round. 7i" possible! most is not trul# round9 pipe "or the over arm. Nemember that the overarm ma# not be needed "or some machines but is critical "or others. )t the ver# least! make the K1 c#linder bore able to be retro-"itted to an available si+e o" pipe without having to take the entire machine apart to have it re-bored later. 719 ) 06I. long piece o" e(tra-e(tra heav# wall 0 1L0. ((hw pipe or a similar si+ed hollow bar to use "or the spindle. The length o" course depends on the si+e o" the engine block that #ou use. Tr# to leave at least three e(tra inches o" spindle outboard o" the pulle#. Di""erent kinds o" tooling like a traveling head boring bar ma# need this space. Tr# not to settle "or less than a 1 1L2. spindle bore on a short bed lathe that is to be used "or a wide range o" projects. 729 0 roller bearings and a "lange or home cast thrust bearing The roller bearings could be an#where "rom about 0 1LH. to 0 R. ID 7assuming 0 1L0. ((hw pipe9 and between 1 >LH. and 2 1LH. 'D. The "lange bearing 7third spindle bearing9 bore could be a little smaller than the roller bearing IDs and the pulle# bored slightl# smaller still. Think seriousl# about using those Metric 166 mm spindle bearings. 739 ) threaded chuck or back plate to test the spindle thread i" #ou are going to use a threaded spindle. 749 ) 1 1L0?. slice o" 1-1L0. steel sha"t or a similar si+ed F)-10 casting that can be bored to "it the spindle. It will be needed "or the bearing adjuster. &et at least 4 e(tra two inch .slices. "or hori+ontal mill arbors! boring heads! "l# cutters! thrust bearings etc. 7>9 ) 0. washer "or the "loating part o" the adjuster. 7H9 ) 1 or 0 groove 10. 'D pulle# that can be adapted to "it the end o" the spindle. 7J9 )n appro(. 4. long piece o" 1 1L0. pipe to make into a separator "or the roller bearings. )mportant! length is bore length less the width o" the bearings. This spacer ."loats in the c#linder so it should be just a "ew thousandth o" an inch smaller than the bore! use shim stock and :ocktite to make a snug "it because a loose "it can be the source o" strange noises. Ends must be accuratel# machined or the bearings will slightl# .cock. and cause great trouble8 The spindle can be slightl# undercut in the area underneath this spacer to make it easier to press on the "ront bearing. . 7169 Dsed head gaskets "or both blocks. 7an eas# wa# to mark holes but not absolutel# necessar#9 01

Ever# one o" those parts should be on hand when #ou start the "itting process.

"tep @, The machine an* en'ine shops

The en'ine shop .ores an*&or slee+es the .loc0 to ,it the .earin' an* o+erarm outsi*e *imensions( ;imple enough! but i" "or some reason this boring is not possible and the c#linder bores are not badl# worn then simple sleeve t#pe bearing adapters could be made. Nemember there is the potential o" a loss in accurac# with each bearing adapter #ou use so be ver# care"ul here. The spindle is the heart o" the machine and is not a good place to make shortcuts. I" #ou do have to use bearing adapters! all #ou ma# reall# need is the ver# top and bottom end o" the o" the c#linder to be true and unworn.

"tep 5, 5hen you 'et the .loc0s to your shop

It is important to "ind out how the# "it together. M+n# combinations o" blocks will work but now is the time to "ind out e(actl# how. The blocks should be care"ull# tested to see how the# "it together. :a# the big block on itAs back. :a# on a piece o" the steel bar than #ou plan to use or an identicall# si+ed piece o" pl#wood and then la# the small block "ace down on top o" the main block. heck "or clearance "or the clamps that hold the blocks together. Tr# to get at the ver# least 0. clearance on each side. To help get this clearance! protrusions ma# have to be ground o"" and either the plate or the small block that is used "or the vertical slide ma# have to be o""set to one side.

"tep 6, The MultiMachine nee*s somethin' to sit on

oncrete is alwa#s best! two steel tables or "rames that would isolate the power unit "rom the MultiMachine would be almost as good but mine had to roll around so I chose to modi"# a store bought engine stand. It has worked ver# well even though it tends to rock back and "orth under a heav# cut. 'ne inch jack screws on each corner would be a good idea. Oust burn holes in each corner o" the stand! weld on nuts and use bolts or allthread to slightl# raise and level each corner. 02

The complete* en'ine stan* It bolts to the engine main bearing pads instead o" the end bell. The vertical post should be cut at the point where it connects to the hori+ontal "rame and re-welded so that it will be in a trul# vertical position. The post has had 1 diagonal braces added. 1? pipe would be best here. the "ront brace must stick out no more than the normal height o" the block or it will inter"ere with the big plate that bolts to the "ront o" the block. ItAs had a .crane. added.

DonFt mount your 8crane9 li0e thisD The 1 1L2 pipe base o" the 1. crane pipe should reall# be mounted as low as possible on the s*uare tube that the wheels are attached to. The bottom crane support should allo- the .ase o, the crane to rest on he ,loor. The mount should also stick out at least 1 1L0 . more than is shown in this picture..

03

Drill at the circle* position, -el* on a $&89 nut ,or a clamp .olt so that the crane -onFt s-in' un*er loa*( I" #ou have to work in a spot with a low ceiling! the top support should be removable. I "ound out this when the crane was in the wa# o" something I was tr#ing to do. I tried to use the crane to hold up the block! power unit and vertical slide plate. Cig mistake8 the crane tried to swing the load behind the engine stand! knocked me through a big window.

)dd 1? jack screws at each corner or take the wheels o"" and back it up against a wall i" #ou are going to tr# something with the slightest risk8 The original mounting plate was notched with a grinder and lined up per"ectl# with the main bearing bolt holes.

"tep 7, Mo*i,yin' the .loc0

Coring the block to "it the overarm and the spindle was the "irst step in block modi"ications. &rinding e(traneous bits o"" is ne(t. /irst! one important point! grinding cast iron is not a clean process! tr# to do it outside i" possible. )lso! be ver# care"ul with sa"et# here! I had iron particles bounce o"" m# "ace and get under both a "ace shield and sa"et# glasses and then ended up in m# e#es. Mave lots o" "iltered water or e#ewash easil# available. I have used *uarts o" =e#e wash? that was just "iltered water "rom m# re"rigerator on this project

04

&rind awa# an#thing that is going to get in the wa# o" the overarm and the spindle since the# need to pass all the wa# through the block. %o grinderI Dse a smaller chisel to to make small notches along a line that marks what #ou want to remove and then use a bigger chisel to chip awa# the e(cess up to that line. I have alread# mentioned the di""erent kinds o" bearings that can be used in the c#linder bore! There are lots o" choices "or thrust bearing also. The block modi"ications are about the same "or whatever bearing #ou choose. Ce certain to check "or clearance so that the spin*le assem.ly can .e inserte* ,rom the rear. )lso check "or clearance around the main bearing bolt holes so that the thrust bearing can be bolted to the main bearing pads. ) round "lange t#pe bearing that can "it into the main bearing pads works with spindles up to about 1 13L14? in diameter. In the D;)! ;urplus enter o"ten has these "or about E06. "pecial note(((()mport ,lan'e .earin's seem to .e o, +ery une+en Auality( ) ori'inally use* a /in0Belt ,lan'e .earin' on the ,ront en* o, the spin*le 1as sho-n in some o, the pictures2 .ut Auit -hen the next one ) .ou'ht -as too loose to use( ), you .uy one ,or the pulley en* o, the spin*le, .e sure to chec0 it out .e,ore you install it( Premium !"# ma*e ,lan'e .earin's may .e ,ar too expensi+e to use(

This was what was cut awa# "or the round :inkbelt bearing.

0>

5ou can easil# see that a reall# large pipe spindle thrust bearing is just not going to "it on the main bearing pads even with some kind o" adapter. Incidentall# the one shown here should have the ends marked with tape cut o"". 'ne alternative would be to not mount the bearing on the main bearing pad at all but instead use a large adapter plate that would mount on the "lange that the oil pan normall# attaches to. Cigger bolts would probabl# be needed and there ma# not be room "or them however. The best 7and b# "ar cheapest89 wa# would be to cast a simple bearingLbushing out o" F)-10. The cast bushing could be a simple bushing with a "lange that would bolt to the main bearing pads. 5ou could use two o" our clamp t#pe collars 7adjusters9 on the spindle. Cron+e rings should be used between the F)-10 parts but there is probabl# no rush "or this i" #ou are care"ul to keep ever# thing well oiled. T-o important points a.out this thrust .ushin'. Ce"ore the thrust bearing is installed! install the pulle# and run the spindle with ver# little belt tension "or a "ew hours as #ou adjust the bearing adjuster. :et ever#thing wear in until the spindle turns "reel# and #et has no measurable pla# shown on a dial indicator. /it the bushing then and mark the "lange bolt holes with trans"er screws. Drill the "lange bolt holes with no clearance "or the mounting bolts and bolt the "lange up evenl#. This will insure that all three bearings are in alignment.

0H

)s the support plate that ) put .et-een the .loc0 an* the en'ine stan* mount really necessaryB @robabl# not i" the big "ront plate goes to the top o" the block.

These were the onl# block modi"ications I needed "or the support plate. I onl# had to grind o"" about one si(teenth inch o"" the edge o" the main bearing pads. :ook care"ull# at the main bearing bolt holes and #ou will see the trans"er screws I used here. 'ne more thing! the engine stand motor mount adapter wasnAt meant to bolt to main bearing pads so grind o"" an#thing that gets in the wa#8

Iecessary chan'es to the ,ront o, the .loc0B 5ou "ound out what was needed when #ou "irst "itted the blocks together. %ow is the time to get an# grinding done. In m# case it actuall# took ver# little.

0J

"tep 8, Mountin' the .loc0

The crane is great "or li"ting heav# tools and workpieces! picking up the block like this was simple.

"tep 9, Po-erin' the machine

I" a steel or concrete table is to be used "or MultiMachine! make certain that it is wide enough to have a two "oot space o"" to one side to use "or the drive unit. I" possible give the drive itAs own table since that is a good wa# to suppress vibration. I" the drive is to be attached to the side o" the block then it is easier to build it while the engine block is turned on its side. Ce care"ul here because the heav# swinging electric motor is ver# hard to handle. The motor and its mount can be dangerous.

I" #ou plan to use the machine onl# as a hori+ontal mill used "or milling iron or steel then a single 36 to 166 rpm speed range is needed but ma# take si( 0 grove pulle#s. I" #ou want a ver# use"ul! simple general purpose lathe! end mill and drill then a single 236 rpm speed is a good choice. I have "ound that this speed also works well on aluminum with a three or "our inch hori+ontal milling cutter. Dse three inch and twelve inch two grove pulle#s to get this speed. &ri++l# tools has some ver# nice cast iron pulle#s that will work here. ,h# two grooveI Three groove pulle#s with matched belts would be even better but are much more e(pensive and also are also hard to "ind. &etting a 166Q lb. spindle up to speed with a 0Q hp motor causes a lot o" nois# belt slipping with just a single belt. I" #ou tr# to use cheap +inc hardware store pulle#s #ou ma# "ind that the# soon "l# apart8 /or more reduction! "it in a small truck transmission that has an e(tra low "irst gear. The best but E166 answer is a -/D 7variable "re*uenc# drive9 1hp motor and a 0 speed 72 pulle#9 belt arrangement. This could give #ou a high range o" 166 to 1666 rpm and a low range o" 36 to 366 rpm. The MultiMachine idea is to do ever#thing as cheapl# as possible so this goes against the grain a little but i" #ou have mone# to spend! this is a good place "or it to go. )"ter thinking about all this! the single 236rpm speed ma# sound better and better8 # -arnin' a.out .elt *ri+es an* aluminum pulleys( /or man# #ears I worked on large industrial belt drives that used iron pulle#s and never noticed a "riction problem. Mowever! just slightl# increasing belt tension with the multiple aluminum pulle#s will make m# machine bog completel# down to a stop. This is another reason to start with a single 236rpm speed.

16

)gain... onl# mount the power unit on the MultiMachine i" the machine needs to be movable. -ibration makes machining a smooth sur"ace di""icult. ) mechanicall# isolated motor and speed reducer is the best wa# to reduce vibration. There are almost unlimited wa#s to power the machine but no matter how #ou plan to power #our machine! #ou will probabl# need a mounting plate like this one that I made "rom scrap. It is securel# bolted to the side o" the block. Make it as long and wide as possible and use 1L2. plate i" possible. I used 1L14. and it tended to "le( under load. 'n the plate I used! the bottom holes were marked with trans"er screws and the top holes were =guestimated? because I did not have the right si+e trans"er screws. Cig mistake8 Do it right the "irst time8 I" the tapped hole is not level with the others then use a short piece o" allthread! a nut hal" screwed on and then the trans"er screw screwed into the rest o" the nut. Dnless #ou are ver# e(perienced at such things donAt tr# to estimate the hole location. I welded on 0 pieces o" bed rail to use to mount the motor and pulle#s. Mis was a bad choice. There is too much "le(ibilit# in the kind o" steel used "or bed rails. I should have used heavier angle iron rails mounted "arther apart. are"ull# la# ever#thing out "irst. DonAt "orget that belts can be changed b# unbolting rails and pillow blocks so mount the angle iron rails close to the plate edges. )n# .twisting. o" the mounts will cause belt slippage when the motor brings the heav# chuck up to speed. ) 0! 1 or 3 hp motor accelerating a 26 lb chuck "rom a dead stop is going to put serious "orce on the pulle#s and mounts. The notch on the bottom right o" the plate is there "or clearance "or the clamp bolts on the vertical slide.

Mere the plate is shown bolted to the side o" the block.

11

)n earlier picture showed the whole "inished motor mount made with slotted bed rails. ;lotted bed rail pieces can work well work well onl# i" the# are welded to heav# angle iron. This pipe handle was added "or more than ease o" speed changing! it reall# cut down on twisting o" the assembl# under load. #ll the pulley .rac0ets shoul* ha+e these pipe han*les ,or this reasonD DonAt "orget that the motor electrical connection bo( can get in the wa# i" plent# o" room is not le"t "or it.

)gain! it would be best i" the pulle#s were mounted inboard the mounting rails i" possible. Ce sure to la# ever#thing out "irst so #ou can be sure the motor and pulle# assemblies all "it properl#. ,ork care"ull# here and #ou will get a *uiet! power"ul machine that is less likel# to .chatter..

The intermediate pulle# bracket.

This is what I call the "inal drive bracket. It should be made out o" one "oot long heav# angle iron and as wide as possible. )dd a pipe handle at the top to make it more rigid and easier to adjust. I rein"orced this one several times and it still twisted.

Mere is the "inal drive adjuster. @rett# crude but like I said be"ore! I am an inventor not a 10

cra"tsman. Cest use two o" these! one on each side rail. I" #ou separate the power unit "rom the block #ou will probabl# mount the assembl# on itAs back and #ou wonAt have gravit# to keep the belts tight and #ou will de"initel# need 0 adjusters on the motor and two each on the pulle# brackets also.

More top pulle# pictures

11

The back o" the machine. Incidentall# the second motor is used to drive the spindle at a single 1666 rpm speed. It is cheaper and more e""icient to do it this wa# than tr#ing to use multiple pulle#s get a 166 to 1666 rpm speed range. ,hen this speed is needed "or a grinder or chop saw! the spindle pulle# is replaced with a smaller one that is slightl# larger than the motor pulle#.

12

"tep 1 , The .i' plate

I" #ou have alread# bored the block and "inished the spindle there is reall# just one big job le"t 7assuming that #ou bu# a cross slide9! measuring! cutting and drilling the plates that bolt to the engine block head sur"aces. ) 1L0? ( 10? plate is obviousl# is what I used but it is not "or ever#bod#. It was the easiest wa# "or me but such a steel si+e ma# not even be available or a""ordable in man# parts o" the world ,hat else could #ou useI Mow about two parallel pieces o" bar stock. Two nominall# si( inch wide pieces should be about twelve inches wide. The e(act width is not as important as having the outside edges absolutel# parallel. Dse a metal scraper or "ile to adjust i" necessar# )ngle iron could also be made to work. Two pieces o" large angle iron would be needed "or each engine block. ;ince we use both the inner and outer sides o" the angle iron! the iron ma# have to be the lighter grade that has parallel instead o" tapered sides. /our pieces o" vehicle "rame rail will o"ten be the =Developing ,orld? solution. 'ne o" the best wa#s came "rom Oe"" Mansen o" the 5ahoo MultiMachine newsgroup. The .doubled. "rame pieces 7shown earlier9 "rom a big truck. ut them apart and lap them together 7with sandI9 "or a good sliding "it C# now #ou have probabl# reali+ed that I canAt tell #ou how long this plate should be because I donAt know how long #our block will be since #ou can use an engine block "rom a Mercur# outboard! a big industrial engine or an#thing in between. The "irst thing to do is to li"t the block into place and to measure how high #ou want the plate to go up on the block. Mine onl# went hal" wa# up because I was a"raid o" warping the plate b# burning a hole in it "or the spindle. M# "ears were groundless because later burning e(periments did not warp the plate at all. I" I did it again I would e(tend the plate to the ver# top o" the block and burn holes "or the the spindle and the overarm. ,h# so longI The more mounting bolts the better. 5our MultiMachine ma# be used "or man# di""erent kinds o" work in the "uture. 5ou ma# install a slotterLshaper in the K0 c#linder. 5ou ma# even add an additional hori+ontal block to the top o" #our machine "or a vertical =Cridgeport? like spindle. 13

5ou ma# also use the K1 c#linder "or the spindle i" #ou donAt need #our machine to be a hori+ontal mill that would normall# use this c#linder "or the overarm. eCa# makes hori+ontal mills e(tremel# use"ul because o" the cutters o"ten being available at J3G discount. Even i" #ou donAt have access to cheap cutters! a homemade "l# cutter is much easier to make than a homemade end mill. I" the block is mounted on a concrete pedestal! the plate could even go down into a pit and then the top o" the vertical slide could be as low as "loor level. This photograph shows how I did it on m# engine stand version. I used a piece o" 1L0. ( 10? "or the baseplate and "ound that it was use"ul "or suppressing vibration. ) close "it here will also suppress vibration. 5ou also should use a heavier thickness o" angle iron than I did. ,hen in doubt about which metal thickness to use! alwa#s select the heaviest plate or angle that is practical. ountersink the holes and use "lat head cap screws in the angle iron. Negular he( head bolts alwa#s seem to get in the wa# here.

14

The base plate was attached to the engine stand using a simple clamp like this.

)mportant points to remem.er a.out the .i' plate /lat head >L14. screws and "lat head metric screws are o"ten hard to "ind. In the D;)! McMaster- arr has them in small lots. /or a totall# poor bo# wa# to attach the plate! mark the holes ver# care"ull# and drill to the e(act si+e o" cheap bolts! counter sink the holes #ou drilled in the plate! saw the studs o"" a little long and peen 7hammer9 the e(cess into the counter sinks. ) heating torch would help here but it is not vital i" #ou work care"ull# and use lo- Auality 1so,ter2 .olts instea* o, hi'h stren'th hea* .olts( DonFt use the en* o, a plate that has .een sheare* 1choppe* o,, at the steel mill2( "hearin' is 'oin' to *istort the en* so that it -ill .e *i,,icult to use ,or our purposes( Mot rolled plate is o"ten not trul# "lat. This causes no problem with the MultiMachine. The important thing to remember is that the outer edges and not the center o" the two plates make contact. I" there is just center contact the table will be able to rock sidewa#s when making a heav# cut. This will cause the machine to chatter. /ace the plates so that the edges touch and make these contact areas as smooth as possible. ) good wa# to do this is to care"ull# degrease the plate and then use a "lap t#pe sanding disc on it. This will probabl# work well enough so that lapping the plates together wonAt be necessar#. To mark the holes in the plate! put a trans"er screw in the top head bolt stud hole #ouAre going to use and also in the bottom one. Measure e(actl# the distance between the top o" the trans"er screw point and the bottom trans"er screw point. ,hat I actuall# did was to la# a thin )luminum bar across the top and bottom trans"er screws and lightl# tapped to mark the positions. I drilled through these marks with a ver# small bit to mark the top and bottom hole positions. I located the top hole position on the big plate and center punched it then dragged 7picture below9 that measurement down to about where the bottom hole would be.. I scribed a line and then used the aluminum bar with the tin# holes in it to mark the position o" the second hole. heck ever#thing again and center punch and drill a shallow 1LH. hole. The eas# wa# to mark the remaining holes is to use a head gasket and a trans"er punch. I" #ou donAt have a head gasket 1>

or want a more accurate method! then with the block on its back turn the plate over so that the punched and drilled holes "ace the block and slide the center punched and drilled holes over "irst two trans"er screw points. 'ne reason "or drilling the center punch marks is that #ou have to "eel the =clicks? when the trans"er screws ="all? into the marked and drilled holes. <eep inserting one trans"er screw at a time to mark the rest o" the the holes. ,hen marking these holes be sure to keep #our brain in gear so that #ou punch the right side o" the plate. The vertical slide plate is done in the same wa#. DonFt ,or'et that many other holes ha+e to .e *rille* an* tappe* in the plates ,or the clamp mechanism( DonAt use heav# grease between the plates when #ou assemble the machine. ool weather will make the grease too stick# and this makes it di""icult to raise the vertical slide in small increments. I" all o" this seems a little =jackleg?! it probabl# is but it works e(tremel# well8 -er# important8 5here shoul* you mount the 4ac0 on your machineB I reall# donAt know8 M# outboard jack works beauti"ull# e(cept when I tr# lower the vertical slide a small amount. I o"ten have to lower it a bit too "ar and then raise it again to the e(act height. The dial indicator is vital here. ,hat should #ou doI Most =knee? t#pe milling machines have a large acme threaded screw about two thirds o" the wa# out "rom the inner edge o" the vertical slide. It is more complicated on a MultiMachine because the ver# heav# bed and carriage will probabl# be o""set to the le"t 7"acing the machine9 side. I suggest #ou tr# a small jack such as a scissors jack! weld some kind o" a plate on top so that the top o" the jack will not "all in a =hole? in the end o" the short engine block and tr# di""erent jack positions until #ou "ind the best one.

1H

"tep 11, Mountin' the .i' plate

Mounting the plate to the "ace o" the big block is simple but re*uires great care. Turn the block so that it is in its normal vertical position and line up the holes care"ull#! donAt cross thread8 DonFt *rop on ,ootD 5our plate could weigh over 106 lbs. I" #ou use a short plate or need additional rein"orcement then put a long coupling nut on the center screws! attach pieces o" all thread and add the rein"orcing plate on the main bearing pads at the rear o" the block.

"tep 12, The +ertical sli*e

Dse almost an# short and heav# engine block as the core o" the vertical slide. Mark and drill the 1L0? ( 10? plate the same wa# as the plate "or the large block. I used an old head gasket to mark the holes. #'ain(((remem.er that many tappe* holes ,or the clamp mechanism nee*e* to .e a**e* to .oth plates( Thin0 ahea*D The 8,irst9 +ertical sli*e clamp This clamp actuall# worked well when I used a worn hacksaw blade as a =gib?.

1J

/ater ) replace* that clamp -ith this one so that the contact sur,aces -ere only ma*e -ith smoother an* more accurate pieces o, three Auarter an* one inch col* rolle* 0ey stoc0(

The *ra-in's on the next t-o pa'es sho- the current clamp mechanism( By properly a*4ustin' the top an* .ottom $&@9 clamp .olts 1puttin' a little more pressure on the .ottom clamp .olt than on the top2 an* a**in' a little pressure -ith the 4ac0, the +ertical sli*e can .e raise* in increments o, ( 19 1.y li'ht tapsD2 an* the ta.le *oes not mo+e -hen the clamp .olts are ti'htene*D

26

21

20

"tep 1$, The +ertical sli*e turnta.le an* cross sli*e

Bi''er is .etter so try ,or a t-o ,oot sAuare ta.le. The removable machine table top can be a wonder"ul tool itsel". Dnlike a store bought tool! #ou can 7with good conscience89 drill and mount holding "i(tures and adapters "or the cross "eed table. ,hen it looks like a swiss cheese! just call it .versatile.. ,hen #ou mount the top plate to the vertical slide block #ou probabl# need to use both trans"er punches and trans"er screws to properl# mark all o" the holes. Be sure that there is a $&@E hole in the center o, the plate that -ill let you turn a commercial cross sli*e $6 *e'rees( ) =Nomig? bed and cross slide will probabl# be too long to turn. Drill at least two more holes "or alternate slide positions. I chose one that was even with the "irst hole and 4. toward the le"t as #ou "ace the machine and also one closer to the chuck so that the tool post would be close to the center o" the cross slide "or heav# cuts. DonAt "orget clearance room "or the nuts. Ce certain that a cutting tool can cut "rom the center o" the spindle to the edge o" the largest "aceplate that #ou are going to use.

This is the smallest o" the common commerciall# available cross slide tables. E>6 in the D; but might be man# times that much in other countries

I" #ou use a =store bought? cross slide then mount it on a turntable. The turntable can serve as a lathe compound. I" #ou make the turntable 11.24 inches in diameter then a 14. length o" 1L2. tape measure will give #ou 146 degree graduations at one and a *uarter degrees each8 Be sure to chec0 ,or clearance ,or .ottom cross ,ee* 0no.( Hou may ha+e to a** a spacer ,or clearance(

21

Buil*in' your o-n cross sli*e

The ori'inal 8Comi'9 turret lathe cross sli*e 1a.o+e2( =ur +ersion 1.elo-2 clamps the carria'e *o-n -ith a -ei'ht alon' -ith scre-e* to'ether pieces o, 0ey stoc0 -hile this much earlier *esi'n use* pieces o, an'le iron( 5hat you shoul* *o *epen*s on the tools an* material that you ha+e a+aila.le( There is nothin' -ron' -ith mixin' an* matchin' i*easD

22

# MultiMachine exclusi+eD # t-in .e* +ersion o, the 195 Fs 8Comi'9 8Popular Mechanics9 turret lathe .e*( =ur *esi'n spans 12 years, startin' -ith a 8-ei'hte* carria'e9 *esi'n ,rom 1825 ( )t can .e .uilt any-here cement an* steel .ar stoc0 is a+aila.le( The components coul* e+en .e cut ,rom +ehicle ,rames( )t can .e .uilt as a sin'le .e* +ersion -ei'hin' 25 l.s or a *ual .e* +ersion -ei'hin' @ times that muchD

23

This -as ta0en ,rom the Popular Mechanics ma'a3ine article% =The construction o" the bed is somewhat o" a novelt#! although it has been thoroughl# tried out b# the writer in this and other machines! and "ound to be ver# satis"actor#. This method o" making the bed eliminates the hardest work o" making a small lathe! as it does awa# with the bed casting and the necessar# machining. ) piece o" S b# 2-in. cold-rolled steel! 16 in. long! is used "or the shears. This is "irst drilled and tapped "or a number o" 1L14-in. stove bolts! o" var#ing lengths! which are used to anchor the shears to the cement! also drilled and countersunk "or the leg screws and "or the S-in. headstock bolts. It is ne(t care"ull# straightened and scraped to a true sur"ace on top and sides! testing the width throughout with a micrometer! and using a kni"eedge straightedge on the sur"acesT these must be as true and straight as it is possible to make them! as upon their truth depends the accurac# o" the lathe. ,hen trued! all sur"aces should either be "rosted or polished. The shear anchor bolts should now be screwed home! the pipes! leg and rear leadscrew-bearing bolts placed in position! and a wooden "orm made to "it closel# around shears and legs! in which to pour the cement. The cement used is a mi(ture o" one part @ortland cement to three parts clean! sharp sand! mi(ed with just enough water to enable a hand"ul o" the mi(ture to be picked up and s*uee+ed and to leave the impression o" the "ingers in it. This cement is tamped down "irml# in the "orm! poking it around the screws and into the corners with an ice pick! or some similar tool. ,hen the concrete has set thoroughl#! the boards are removed and the cement thoroughl# wetted twice a da# "or about a weekT this will temper the cement! and is a ver# important part o" the work. The resulting bed is as strong as an#one could wish. Nein"orcing rods ma# be laid down in the cement! as it is being placed! or wires twisted throughout the bolts! adding "urther to the strength o" the bed. The main member o" the carriage is made o" cold-rolled steel! S b# 3 b# 3 U in. in si+e! machined as shown in the carriage-detail drawing. ) piece o" U b# 0-in. cold-rolled steel! > in. long! is "astened to the top o" the main member b# 1L14-in. screwsT on this piece the cross slide runs. The cross slide is also made o" steel! machined as shown! and is "itted with a turret tool post. The cross slide is held to its wa#s b# means o" angle pieces! as shown in the "ront view o" the carriage.? Hour machine -ill use *i,,erent *imensions .ut this is a 'oo* explanation o, cement an* steel construction(

24

2>

2H

"tep 1@, The o+erarm

These 1LH? clamp bolts are ridiculous! I kept "orgetting to order nice ones "rom E% '.

Top view o" a set o" clamps made "rom an old piece o" one inch ke# stock.

This "irst =tailstock? was made "rom an old piece o" service station jack that had a >LH? "lange bearing added. /or alignment purposes! it was step drilled with bits held in the lathe chuck. It has worked ver# well "or the last three #ears.

2J

This photo is o" an old Drummond round bed lathe tail stock. I" it were turned up side down! it would be a great design "or a MultiMachine. It was kept in alignment with a =-? shaped ke# on the bottom o" the round bed. ?astin' one li0e this out o, K#-12 -oul* .e 'reat( ), you .uil* a 8Comi'9 type .e* then a** a con+entional lathe type tailstoc0 to it( )t coul* .e similar to this .ut -oul* nee* a ,lat .ottom that -oul* match the 8Comi'9 .e*(

# 'reat le+er tailstoc0 that -as *esi'ne* to spee* up pro*uction in 55 2(

The next ,e- pa'es co+er three tools&techniAues that -ill complete your MultiMachine(
112 # 8.ro0en .it9 cuttin' tool system that can sa+e hun*re*s o, *ollars in tool expense( 7+en thou'h the inclu*e* pictures sho- only roun* .its, the .its can .e 'roun* into con+entional cuttin' tool shapes( 122 #n accurate homema*e lathe chuc0( 1$2 # +ery ol* .ut accurate -ay o, cuttin' threa*s( The MultiMachine Hahoo ne-s'roup -ill ha+e plans ,or a ?I? lea* scre- -hen one .ecomes a+aila.le( 36

"tep 15, Buil*in' your o-n 8Bro0en .it9 1tan'ential2 cuttin' tools
) lathe is not ver# use"ul without cutting tools. This ver# old idea is great because most toolbo(es contain the essential ingredient! broken or worn out drill bits8 This t#pe o" tool works especiall# well with a MultiMachine since the vertical slide can be raised and lowered to adjust tool height. This makes the adjusters and o""set ends that are shown in the ne(t pictures unnecessar#.

This is "rom a 1J03 =@opular MechanicsA book.

31

# mo*erni3e* *esi'n .y :e,, ;ansen

# partially complete* chuc0 ma*e ,rom an ol* en'ine ,ly-heel

30

"tep 16, Buil*in' your o-n lathe chuc0

31

"tep 17, ;o- to cut threa*s 19 years a'o2

32

;o- ho- to .uil* a really .i' MultiMachine 1or e+en a 8,ree9 metal -or0in' ,actory2 .y usin' 4ust common han* tools an* +ehicle partsD
/irst though we to have some kind o" a metal lathe to build a reall# cheap MultiMachine. )nd be"ore that! we need some kind o" a drill so lets start "rom the ver# beginning! assuming the builder has no mone#! no electricit# and no power drill. =ur 8re-*isco+ery9 o, the 8ratchet9 *rill may .e the the most important part o, the MultiMachine pro4ect( It began with the re*uest "rom an engineering pro"essor in <en#a "or a drill that would drill large holes in steel and aluminum plates that were being used to build and repair agricultural implements. ,e "ound a techni*ue that is now almost "orgotten but in the period between the middle 1H66As and the earl# 1J66As was how most holes were drilled8 5ou did not drill a hole! #ou ratcheted one8 This kind o" drill simpl# breaks down the drilling process into 0 separate parts and changes the usual moderate pressure and high drilling speed to putting great pressure on the drill bit and then turning the bit ver# slowl# b# =armstrong? 7#our strong arm89 power. More workI ;ure but can the normal power drill make a 1. hole in a "ileI This particular drill was a ratchet drill made b# the ole Tool ompan#. The power o" this t#pe o" tool lies in the "eed screw that can be tightened down b# hand! e(erting e(treme pressure on the drill point. Materials such as spring! stainless and tool steel can be drilled with b# using ordinar# high speed steel or masonr# carbide t#pe drill bits. The ole Drill is still use"ul "or drilling large holes in hardened steel or workpieces that are too large "or the drill press. ) ratchet drill can be built in man# di""erent wa#s b# using the throwout bearing and lever "rom a manual shi"t car or truck instead o" a harder to build "eed screw. The drill bit can be turned with some kind o" a handle or a socket wrench ratchet. 'ne hal" inch capacit# drill chucks are o"ten available "or under ten dollars. These are commonl# threaded 1L0. ( 06tpi so a threading die this si+e should be part o" #our tool kit along with good *ualit# taps and drills "or 1L2?! 1LH? and 1L0?. In Metric areas use their metric e*uivalents. In the D;)! E% ' .D;). made =screw machine? bits are low cost and ver# good *ualit#.

33

. ole. t#pe drills ma# re*uire a ver# small amount o" welding 7total bead length is less than 2?9 but this can be done using a simple temporar# welder that can be made b# connecting two or three vehicle batteries in series 7negative on one batter# to positive on the ne(t9. The drill spindle assembl# can also be made well in advance and the chuck just screwed on to complete construction. C# mi(ing and matching the ideas above #ou have man# wa#s to drill the holes needed "or a =temporar#? lathe and as I said earlier such a lathe will allow #ou to build almost an#thing. ,h# the =temporar#? name "or a machine that would be use"ul "or #earsI I had to call it something at "irst and this name just =stuck? 'nce #ou have the drill the ne(t step is to build the .temporar#. lathe. The reason we need the temporar# lathe is "or the machining o" bushings! spacers! adapters! pulle#s. These machined parts that can easil# be made "rom +inc and aluminum allo# lets the builder save most o" the mone# that would be needed to build a regular MultiMachine. These easil# cast and machined parts make a much larger machine *uite eas# and ine(pensive 7almost "ree89 to build. ) roller bearing with a 3.3.ID could cost thousands o" dollars while one made "rom homemade allo#s could cost almost nothing.

) reall# simple =temporar#? lathe! use a hub "rom a "ront wheel drive car. The cutting tool can be as simple as a large allen wrench 7good steel9 ground to the proper shape and attached to a long handle. Clacksmiths used this techni*ue on iron and steel "or man# #ears and using it on +incLaluminum allo# will be much easier. This is another ver# good reason to learn the basics o" tool grinding. 34

) conventional cross slide will be even easier to work with. I" #ou need too! build a .Nomig. t#pe bed and cross slide! or "or a "aster and easier job! bu# a cross slide table "rom E% ' "or E4J to E116. I" #ou alread# have a drill press cross "eed vise! perhaps #ou could lap 7use an abrasive paste to gentl# grind together9 the parts together to get a smoother and tighter "it. It ma# not be rigid enough "or machining steel but it ma# work well on aluminum allo#. I" things go wrong! just remelt the aluminum and do it again8 ;o- to .uil* a hea+ier *uty 8temporary9 lathe 719 Disassemble a junked engine that came "rom a manual shi"t car or truck! remove pistons and rods but leave the crank and "l#wheel in place. heck the main bearing clearances and add shims to "i( an# e(cess pla#. Nemember not to block the oil holes that #ou need to drill in the main bearing caps. :ubricate with oil through these holes or drill or tap "or grease "ittings. Drill and tap holes in "l#wheel "or .old time. "aceplate clamps 7page 119. I" #ou later get a 1 or 2 jaw chuck! then machine the mating grooves in the "l#wheelL"aceplate and just bolt it on. I" the onl# engines blocks #ou can "ind have thin automatic transmission t#pe "l#wheels! #ou ma# still be able to machine aluminum or drill holes in steel. Oust work gentl# on the aluminum and make an adapter "or a drill chuck that will bolt to the end o" the cranksha"t. Ce on the lookout "or a regular "l#wheel and replace the automatic transmission "l#wheel i" #ou want to use the machine "or heavier work . 709 ut one or two 7depending on "rame width9 2A to >A long straight pieces o" truck "rame 7or a piece o" eight inch wide channel iron9 and use the head gasket as a hole guide so that the rail piecesLchannel iron can be bolted to the head sur"ace. 719 Turn block with the bolted on "rame pieces upside down so that at least two "eet o" protruding "rame section can be used as a lathe bed. 729 Colt on the Nomig steel and cement bed or what ever #ou use "or a cross slide! so that top is about 0 or 1 inches below the center o" the "l#wheel. The bed should be o""set and located as close to the le"t edge o" the "l#wheel as possible. Ce"ore #ou permanentl# attach the cross slide! mount a lathe tool holder and be sure the cutting tool can cut "rom the center o" the "l#wheel to the outer edge. 739 Nunning the lathe with a simple motor and cranksha"t mounted pulle# arrangement ma# result in too high a spindle 7cranksha"t9 speed. 'ne wa# to slow the spindle down is b# using the built in reduction o" the ring and pinion gears. &ut and cut the starter motor "rame 7shown below9 to convert to "lat belt drive and use a timing belt pulle# on the motor end. Make a set o" aluminum allo# pulle#s to get other speeds once the lathe is running. 749 Dse "rame parts or angle iron and threaded rod to build an electric motor! bic#cle drive or small gasoline engine motor mount. DonAt "orget that the drive pulle#s have to line up so that the bolts that hold the starter together donAt inter"ere with the "lat belt. The belt could be a cut to si+e and glued together serpentine or timing belt. 3>

7>9 The tool holder can be a simple steel or aluminum cube with a boring bar hole in one side and a s*uare notch cut in the other. I" #ou have studied cutting tool shapes! #ou probabl# think o" plent# o" cutting tool holders that #ou can build with just a hacksaw and "ile.

The .i' 8,ree9 MultiMachine

The non-roller bearing ."ree. machine ma# be much larger than the MultiMachine that has just been described. It will probabl# use removable c#linders 7picture on right9 that will eliminate the need "or machining in the engine and regular machine shops. These c#linders 7wet sleeves9 are usuall# "ound in large truck! industrial and militar# engines. These c#linders can have aluminum allo# liners cast into them and then machined to the right si+e with the temporar# lathe. ;ounds like a big jobI ;ure! but #ou can make a machine can have the capacit# o" a machine tool that would cost over a hundred thousand dollars in the D;) and several times that elsewhere.

3H

719 Dse a +incLaluminum allo# as close to F)-10 as possible or as a second choice! aluminum "rom an overhead cam c#linder head that does not use separate cam bushings. The assumption here is that the engine manu"acturer has chosen a good aluminum bearing material "or the head. Meat the c#linder head in a charcoal "ire until it is near the melting point and use a big hammer to break it into small pieces. ast the metal into round sections that can be used "or spindle bushings! a thrust bushing and whatever pulle#s are necessar# "or a big MultiMachine.

7xcept ,or the steel spin*le, simple castin's replace each o, these partsD

)mportantD Try to ,in* a lar'e piece o, scrap iron or steel to use ,or the chuc0 .ac0plate( Many in*ustrial machines use iron castin's that loo0 somethin' li0e this( )t -oul* not .e *i,,icult to -el* up somethin' li0e this .ut it may .e *i,,icult to machine to si3e i, machina.le -el*in' ro*s are not use*(

>in* one that can .e .ore* to ,it the spin*le an* still ha+e room to *rill t-o cross .olt holes in the hu. to use ,or clamp .olts( Cemem.er the ,lycutter pictureB1a.o+e2 !se clamp .olts li0e these in a lon' hu.( The spin*le .ushin's shoul* .e as lon' as possi.le( They may ha+e to .e cast an* machine* in t-o separate sections( This -ill ma0e the machinin' 4o. much easier .ut coul* ma0e spin*le lu.rication more *i,,icult i, oil has to pass throu'h one spin*le .ushin' to 'et to the next one( # solution to this pro.lem -oul* .e to ha+e separate oil lines ,or each .ushin' section(

3J

Most oil lea0a'e coul* .e stoppe* .y a steel an* leather seal ,itte* to the outer en*s o, the .ushin's( # hole coul* .e *rille* in the metal part o, the homema*e seal an* a piece o, copper tu.in' oil line sol*ere* in so that it coul* pass throu'h the seal an* line up -ith the .ushin' oil 'roo+e(

709 &et the pieces o" pipe "or the overarm and spindle. /or a low cost spindle! tr# a piece o" heav# drive sha"t tubing. ;ince this and most other pipe is not trul# round! tr# to get a light cut taken o"" 7machined on a lathe9 whatever pieces o" pipe that #ou are going to use. I" #ou donAt have an# wa# to smooth the pipes! remember that the word =lathe? came "rom =lath?! a thin spring# piece o" wood used long ago as a wa# to make a workpiece turn. Oust mount the pipe between two wooden supports 7treesI9! attach a rope to a spring or spring# overhead limb! wrap the rope around the pipe a "ew times and tie the end to some kind o" a "oot petal and =pump? awa#. @olish the pipe with emer# cloth as it spins back and "orth8 @rimitiveI ;ure! but some o" the "inest woodwork was once done this wa#. The rest o" the machine could be a much scaled up up version o" a regular MultiMachine. # ,inal -or*( !sin' accurately ma*e en'ine .loc0s as .uil*in' .loc0s an* also .orin' the cylin*ers to ,it the spin*le .earin's an* the o+erarm means that the core o, the machine is accurate( The .usiness en* o, the spin*le is machine* in place so that it is also accurate( The cross sli*e can .e *one -ron' .ut since it is a 8.olt on9 mo*ule, it can .e a*4uste* or e+en replace*

Pipe si3e, metric .earin' an* Morse Taper speci,ications 7In the D;! tr# the bearing books at %)@)9
46

3/4"
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1"
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IP" $&@ $&@ $&@ $&@ $&@ $&@

=(D( 1( 5 1( 5 1( 5 1( 5 1( 5 1( 5

"ch L 5 1 @ 8 16 JJ;H

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"ch L 5

5all 5t&>t ( 65 ( 72 ( 8$ ( 95 (87 (96 1( 9 1(2@ 1(@1 1(59 1(68 2(17 2(85 $(66

)(D( 1(185 1(171 1(1@9 1(125 1( 97 1( 65 1( @9 (957 (815 (599

1 @ 8 16 JJ;H

(1 9 (125 (1$$ (179 (25 ($58

1-1/4"
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1-1/2"
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IP" 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@ 1 1&@

=(D( 1(66 1(66 1(66 1(66 1(66 1(66 1(66 1(66 1(66 1(66

"ch L 5

5all 5t&>t ( 65 ( 72 ( 8$ ( 95 1(11 1(22 1(@ 1(59 1(81 2( 5 2(27 $( $(77 5(22

)(D( 1(5$ 1(516 1(@9@ 1(@7 1(@@2 1(@1 1($8 1(278 1(16 (896

IP" 1 1&2 1 1&2 1 1&2 1 1&2 1 1&2 1 1&2 1 1&2 1 1&2 1 1&2

=(D( 1(9 1(9 1(9 1(9 1(9 1(9 1(9 1(9 1(9

"ch L 5

5all 5t&>t ( 65 ( 8$ ( 95 1(28 1(61 1(8$ 2( 9 2($7 2(72 $(6$ @(86 6(@1

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(1 9 (125 (1@5 (2 (281 (@

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(1 9 (125 (1@ (191 (25 ($82

2"
41

2-1/2"

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IP" 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

=(D( 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75 2($75

"ch L 5

5all 5t&>t ( 65 ( 78 ( 8$ ( 95 1(61 1(91 2( $ 2($1 2(6@ $( $(21 $($6 $(66 @( 5 @($9 5( $ 6(28 7(@5 9( @

)(D( 2(2@5 2(219 2(2 9 2(185 2(157 2(125 2(1 7 2( 9$ 2( 67 2( $1 1(999 1(9$9 1(81$ 1(687 1(5

IP" 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2 2 1&2

=(D( 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875 2(875

"ch L 5

5all 5t&>t ( 78 ( 8$ ( 9@ (1 9 2($$ 2(@8 2(79 $(22 $(5$ $(67 @(12 @(@8 @(5$ @(97 5(@ 5(8 6(1$ 7( 1 7(67 1 ( 2 1$(71

)(D( 2(719 2(7 9 2(687 2(657 2(6$5 2(625 2(59$ 2(567 2(56$ 2(5$1 2(@99 2(@69 2(@@$ 2($75 2($2$ 2(125 1(771

(1 9 (125 (1$@ (1@1

(12 (125 (1@1 (15@ (156 (172 (188

(15@ (172 (188

8 16 JJ;H

(218 (281 ($@$ (@$6

(2 $ (216 (25

8 16 JJ;H

(276 ($75 (552

3"
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3-1/2"
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40

IP" $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

=(D( $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5 $(5

"ch L 5

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IP" $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2 $-1&2

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"ch L 5

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)(D( $(8$@ $(812 $(782 $(76 $(75 $(718 $(688 $(656 $(62@ $(5@8 $(5 $(@$8 $($6@ 2(728

(12 (125 (1@1 (156 (172 (188

(12 (125 (1@1 (156 (172 (188

(226 (25 (281

(216 (25 (281

8 JJ;H

($18 (6$6

8 16 JJ;H

($ (@$7 (6

4"
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5"
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41

IP" @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @

=(D( @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5 @(5

"ch L 5

5all 5t&>t ( 8$ ( 9@ (1 9 $(92 @(@2 5(11 5(62 5(8@ 6(56 7(2@ 7(95 8(66 9($2 1 ( 1 1 (8 11($5 12(67 1$(96 15( 19( 2 22(5$ 27(57

)(D( @($$@ @($12 @(282 @(26 @(25 @(218 @(188 @(156 @(12@ @( 9@ @( 62 @( 26 @( $(9$8 $(876 $(826 $(62@ $(@$8 $(152

IP" 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

=(D( 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$ 5(56$

"ch L

5all 5t&>t ( 8$ ( 9@ @(86 5(@9 6($6 7(26 7(78 8(16 9( 1 1 (8 12(5 1@(6$ 15(85 17(5 19(17 2 (8 27( 6 $2(99 $8(59

)(D( 5($97 5($75 5($@5 5($1$ 5(295 5(281 5(251 5(187 5(125 5( @7 5( 1 @(9$9 @(875 @(81$ @(56$ @($1$ @( 6$

5 1

(1 9 (125 (1$@ (1@1 (156 (188 (219

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@ 6 8 106 146 JJ;H

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8 106 146 JJ;H

($75 (5 (625 (75

Morse taper speci,ications

Morse Taper 0 1 2 3 # 5 ' Taper 19.212:1 20.0#':1 20.020:1 19.922:1 19.25#:1 19.002:1 19.1(0:1 19.231:1 Gauge Line Diameter 0.35 1! "9.0#5mm$ 0.#'50! "12.0 5mm$ 0.'00! "1'.'(0mm$ 0.93(! "23.(25mm$ 1.231! "31.2 'mm$ 1.'#(! "##.399mm$ 2.#9#! " 3.3#(mm$ 3.2'0! "(3.05(mm$ Minor Diameter 0.252! 0.3 9! 0.5'2! 0.''(! 1.020! 1.#'5! 2.11 ! 2.'50! Taper Length 2.00! 2.12 ! 2.5 2! 3.1((! #.0 #! 5.1((! '.252! 10.00! Angle 1%29&2'! 1%25&#3! 1%25&50! 1%2 &1 ! 1%29&15! 1%20&2 ! 1%29&3 ! 1%29&25!

42

Metric .earin' speci,ications

M7TC)? "7C)7"
)earing *o. + D ) C T rmin r1min

16061 16062 16063 16064 1606> 1606H 1606J 16016 16011 16010 16160

1> 06 03 16 13 26 23 36 33 46 13

26 2> 30 40 >0 H6 H3 J6 166 116 20

10 12 13 14 1> 1H 1J 06 01 00 11

11 10 11 12 13 14 14 1> 1H 1J 11

11.03 13.03 14.03 1>.03 1H.03 1J.03 06.>3 01.>3 00.>3 01.>3 12.03

1.6 1.6 1.6 1.6 1.3 1.3 1.3 1.3 1.3 1.3 1.6

6.1 6.1 6.1 6.1 6.4 6.4 6.4 6.4 6.4 6.4 6.1

43

16161 16162 16163 16164 1616> 1616H 1616J 16116 10062 10063 10064 1006> 1006H 1006J 10161 10162 10163 10164 1016> 1016H 1016J 10116 10662V 10663V 10664V 1066>V 1066HV 1066JV

1> 06 03 16 13 26 23 36 06 03 16 13 26 23 1> 06 03 16 13 26 23 36 06 03 16 13 26 23

2> 30 40 >0 H6 J6 166 116 2> 30 40 >0 H6 H3 2> 30 40 >0 H6 J6 166 116 20 2> 33 40 4H >3

12 13 1> 1J 01 01 03 0>

10 11 13 14 1H 06 00 01

13.03 14.03 1H.03 06.>3 00.>3 03.03 0>.03 0J.03 1J.03

1.6 1.3 1.3 1.3 1.3 1.3 1.3 0.6 1.6 1.6 1.6 1.3 1.3 1.3 1.6 1.3 1.3 1.3 1.3 1.3 1.3 0.6 1.6 1.6 1.6 1.6 1.6 1.6

6.1 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.1 6.1 6.1 6.4 6.4 6.4 6.1 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.1 6.1 6.1 6.1 6.1 6.1

1H 06 01 01 01 1J 01 02 0> 11 11 14 26 13 13 14 1> 1H 1J

13 1> 1J 1J 1J 14 1H 06 01 03 0> 16 11 10 11.3 12 13 14 14

1J.03 01.03 02.03 02.>3 02.>3 06.03 00.03 03.03 0H.>3 10.>3 13.03 1H.03 20.03 13 13 1> 1H 1J 06

44

10616V 10611V 10610V 10611V

36 33 46 43

H6 J6 J4 166

1J 00 00 00

14 1J 1J 1J

06 01 01 01

1.6 1.3 1.3 1.3

6.1 6.4 6.4 6.4

6lossary
abrasive wheels ,heels o" a hard abrasive! such as arborundum used "or grinding. adapter ) tool holding device "or "itting together various t#pes or si+es o" cutting tools or other parts to make them interchangeable on di""erent machines. allo# ) metal "ormed b# a mi(ture o" two or more di""erent metals. angle iron )n iron or steel structural member that has been cast! rolled! or bent 7"olded9 so that its cross section is :-shaped. angle plate ) precision holding "i(ture made o" cast iron. steel! or granite. The two principal "aces are at right angles and ma# be slotted "or holding the work or clamping to a table. annealing The controlled heating and cooling o" a metal to remove stresses and to make it so"ter and easier to work with. arbor ) sha"t or spindle "or holding cutting toolsT most usuall# on a milling machine. assembl# ) unit o" "itted parts that make up a mechanism or machine! such as the headstock assemble o" a lathe. backlash The lost motion or looseness 7pla#9 between the "aces o" meshing gears or threads. bar stock Metal bars o" various lengths! made in "lat! he(agon! octagon! round! and s*uare shapes "rom which parts are machined. bearing -

4>

Nollers! and balls placed between moving parts to reduce "riction and wear. bed 'ne o" the principal parts o" a machine tool! having accuratel# machined wa#s or bearing sur"aces "or supporting and aligning other parts o" the machine. bevel )n# sur"ace that is not at right angles to another sur"ace. )lso! the name given a tool used "or measuring! la#ing out! or checking the accurac# o" work machined at an angle or bevel. bit! tool 7cutter9 ) hardened steel bar or plate that is shaped according to the operation to be per"ormed and the material to be machined. bore To enlarge and "inish the sur"ace o" a c#lindrical hole b# the action o" a rotating boring bar 7cutting tool9 or b# the action o" a stationar# tool pressed 7"ed9 against the sur"ace as the part is rotated. boring bar 7cu""er bar9 ) combination tool holder and shank. boring tool ) cutting tool in which the tool bitA. the boring bar and! in some cases! the tool holder are incorporated in one solid piece. broach ) long! tapered cutting tool with serrationAs which! when "orced through a hole or across a sur"ace! cuts a desired shape or si+e. bron+e ) non"errous allo# consisting essentiall# o" copper and tin. carbide tool bits :athe cutting tools to which carbide tip inserts have been bra+ed! to provide cutting action on harder materials than the high speed cutters are capable o". carriage ) principal part o" a lathe that carries the cutting tool and consists o" the saddle! compound rest. and apron. case hardening ) heat treating process! basicall# carboni+ing. that makes the sur"ace la#er or case o" steel substantiall# harder than the interior or core. castigated nut 7castle nut9 ) nut with grooves cut entirel# across the top "ace. casting -

4H

) part made b# pouring molten metal into a mold. center! dead ) center that does not rotateT commonl# "ound on the tailstock o" a lathe. )lso! an We(pression "or the e(act center o" an object. center drill ) combined countersink and drill used to prepare work "or mounting centers. center! live ) center that revolves with the work. &enerall#. this is the headstock centerT however! the ball bearing t#pe tailstock center is also called a live center. center punch ) pointed hand tool made o" hardened steel and shaped somewhat like a pencil. cham"er The bevel or angular sur"ace cut on the edge or a corner o" a machined part. chasing threads utting threads in a lathe or screw machine. chatter The vibrations caused between the work and the cutting tool which leave distinctive tool marks on the "inished sur"ace that are objectionable. chip breaker ) small groove ground back o" the cutting edge on the top o" a cutting tool to keep the chips short. chipping The process o" cutting metal with a cold chisel and hammer. chisel )n# one o" a variet# o" small hand cutting tools! generall# wedge-shaped. chuck ) device on a machine tool to hold the workpiece or a cutting tool. chuck! independent jaw ) chuck! each o" whose jaws 7usuall# "our9 is adjusted with a screw action independentl# o" the other jaws. chuck! universal 7sel"-centering chuck! concentric chuck9 ) chuck whose jaws are so arranged that the# are all moved together at the same rate b# a special wrench.

4J

clearance The distance or angle b# which one objector sur"ace clears another. climb milling ) method o" milling in which the work table moves in the same direction as the direction o" rotation o" the milling center. ;ometimes called down cutting or down milling. cold-rolled steel ;teel that has been rolled to accurate si+e and smooth "inish when made. In contrast! hot-rolled steel ma# have a rough! pitted sur"ace and slag inclusion. collet ) precision work holding chuck which centers "inished round stock automaticall# when tightened. ;peciali+ed collets are also a-! available in shapes "or other than round stock. compound 7rest9 The part o" a lathe set on the carriage that carries the tool post and holder. It is designed to swing in an# direction and to provide "eed "or turning short angles or tapers. coolant ) common term given to the numerous cutting "luids or compounds used with cutting tools to increase the tool li"e and to improve sur"ace "inish on the material. counterbore To enlarge the top part o" a hole to a speci"ic si+e! as "or the head o" a socket-head or cap screw. )lso! the tool that is used. countersink To enlarge the top part o" a hole at an angle "or a "lat-head screw. )lso! the tool that is used. cross "eed The "eed that operates across the a(is o" the workpiece or at right angles to the main or principal "eed on a machine. cutting "luid ) li*uid used to cool and lubricate the cutting to improve the work sur"ace "inish. cutting speed The sur"ace speed o" the workpiece in a lathe or a rotating cutter! commonl# e(pressed in "eet per minute 7/@M9 and converted to revolutions per minute 7N@M9 "or proper setting on the machine. cutting tool ) hardened piece o" metal 7tool steel9 that is machined and ground so that it has the shape and cutting edges appropriate "or the operation "or which it is to be used. dead center ;ee center! dead.

>6

die ) tool used to "orm or stamp out metal partsA! also! a tool used to cut e(ternal threads. die stock The "rame and two handles 7bars9 which hold the dies 7chasers9 used "or cutting 7chasing9 e(ternal screw threads. ) clamping device 7lathe dog9 used to drive work being machined between centers. )lso! a part projecting on the side o" a machine worktable to trip the automatic "eed mechanism o"" or to reverse the travel. dovetail ) two-part slide bearing assembl# used in machine tool construction "or the precise alignment and smooth operation o" the movable components o" the machine. dowel ) pin "itted or ke#ed in two adjacent parts to accuratel# align the parts when assembling them. down "eed 7climb cutting! climb milling9 ) seldom used method o" "eeding work into milling cutters. The work is "ed in the same direction as the portion o" the cutter which comes in contact with it. drill ) pointed tool that is rotated to cut holes in material. drill! center ) combination drill and countersinkdrill chuck ) device used to grip drills and attach them to a rotating spindle. drill! twist ) commonl# used metal-cutting drill! usuall# made with two "lutes running around the bod#. drill jig ) jig which holds parts or units o" a structure and. b# means o" bushings! guides the drill so that the holes are properl# located. drill press )n upright power-driven machine "or drilling holes in metal! wood! or other material. drill rod ) high-carbon steel rod accuratel# ground to si+e with a smooth "inish. It is available in man# si+es and is used e(tensivel# in tool making. drill sleeve )n adapter with an internal and e(ternal taper which "its tapered shank tools such as drills or reamers to adapt them to a

>1

larger si+e machine spindle. drill socket )n adapter similar to a sleeve e(cept that it is made to adapt a larger tapered-shank tool to a smaller si+e spindle. drill! twist ) commonl# used metal-cutting drill! usuall# made with two "lutes running around the bod#. drive "it 'ne o" several classes o" "its in which parts are assembled b# pressing or "orcing one part into another. ductilit# The propert# o" a metal that permits it to be drawn. rolled! or hammered without "racturing or breaking. "ace To machine a "lat sur"ace! as in the end o" a sha"t in the lathe. The operation is known as "acing. "ace milling Milling a large "lat sur"ace with a milling cutter that operates in a plane that is at right angles to its a(is. "aceplate ) large circular plate with slots and holes "or mounting the workpiece to be machined. It is attached to the headstock o" a lathe. "acing The process o" making a "lat or smooth sur"ace 7usuall# the end9 on a piece o" stock or material. "eed The rate o" travel o" a cutting tool across or into the work-! e(pressed in inches per minute or in inches per revolution. "eed mechanism The mechanism! o"ten automatic. which controls the advancing movement 7"eed9 o" the cutting tools used in machines. "it The relation between mating or matching parts! that is! the amount o"! or lack o". pla# between them. "i(ture ) production work-holding device used "or machining duplicate workpieces. )lthough the term is used interchangeabl# with a jig! a "i(ture is not designed to guide the cutting tools as the jig does. "lange ) relativel# thin rim around a part. "lute -

>0

The groove in a cutting tool which provides a cutting edge and a space "or the chips to escape and permits the cutting "luids to reach the cutting edges. "l# cutter ) single-point cutter mounted on a bar in a "l# cutter holder or a "l# cutter arbor- used "or special applications "or which a milling cutter is not available. "ollower rest ) support "or long! slender work turned in the lathe. It is mounted on the carriage! travels close to and with the cutting tool! and keeps the work "rom springing awa#. "ootstock @art o" an inde(ing! attachment which has a center and serves the same purpose as the tail stock o" a lathe. "orce "it ) "itting which one part is "orced o" pressed into another to "orm a single unit. There are di""erent classes o" "orce "its depending on standard limits between mating parts. gage! "eeler 7thickness gage9 ) gage consisting o" a group o" ver# thin blades! each o" which is accuratel# ground to a speci"ic thickness. gage! indicating 7dial indicator9 ) gage consisting o" a dial! commonl# graduated 7marked9 in thousandths o" an inch! to which is "astened an adjustable arm. gage! screw pitch ) gage consisting o" a group o" thin blades. used "or checking the number o" screw threads per unit o" distance! usuall# per inch! on a screw! bolt! nut! pipe! or "itting. gib ) tapered strip o" metal placed between the bearing sur"ace o" two machine parts to ensure a precision "it and provide an adjustment "or wear. hacksaw ) metal blade o" hardened steel having small! close teeth on one edge. It is held under tension in a D-shaped "rame. hal" nut ) lever-operated mechanism that resembles a split nut that can be closed on the lead screw o" a lathe when threads are being cut. handwheel )n# adjusting or "eeding mechanism shaped like a wheel and operated b# hand. hardening ) heat-treating process "or steel which increases its hardness and tensile strength and reduces its ductilit#.

>1

headstock The "i(ed or stationar# end o" a lathe or similar machine tool. heat treatment The process o" heating and cooling a solid metal or allo# to obtain certain desired properties or characteristics. he( ) term used "or an#thing shaped like a he(agon. high-speed steel )n allo# steel commonl# used "or cutting tools because o" its abilit# to remove metal at a much "aster rate than carbon steel tools. hole saw ) cutting tool used to cut a circular groove into solid material. honing The process o" "inishing ground sur"aces to a high degree o" accurac# and smoothness with abrasive blocks applied to the sur"ace under a light controlled pressure. and with a combination o" rotar# and reciprocating motions. hot-rolled steel ;teel which is rolled to "inished si+e. while hot. Identi"ied b# a dark o(ide scale le"t on the sur"ace. idler ) gear or gears placed between two other gears to trans"er motion "rom one gear to the other gear without changing their speed or ratio. independent chuck ) chuck in which each jaw ma# be moved independentl# o" the others. inde(ing The process o" positioning a workpiece "or machining it into e*ual spaces. dimensions. or angles using an. inde( or dividing head. indicator ) precision instrument which shows variations o" thousandths o" an inch or less when testing the trueness or alignment o" a workpiece! "i(ture! or machine. jack! leveling ;mall jacks 7usuall# screw jacks9 "or leveling and holding work on planner beds and similar places. Oacobs chuck ommon term "or the drill chuck used in either the headstock spindle or in the tailstock "or holding straight-shank drills! taps! reamers! or small diameter workpieces.

>2

jig ) production work holding device that locates the workpiece and guides the cutting tool 7see "i(ture9. ke# 'ne o" the several t#pes o" small metal objects designed to "it mating slots in a sha"t and the hub o" a gear or pulle# to provide a positive drive between them$ also. the name o" the T-handle wrench used on chucks. ke# seat ) recessed groove 7slot9 machined into a sha"t or a part going on the sha"t 7usuall# a wheel or gear9. knee That part o" a column o" a knee-t#pe milling machine which carries the saddle and the table and provides the machine with vertical "eed adjustments. knurl ) decorative gripping sur"ace o" straight-line or diagonal design made b# uni"orml# serrated rolls called knurls. knurling The process o" "inishing a part b# scoring 7pressing9 patterns on the sur"ace o" the work. lap ) tool made o" so"t metal and charged ,ith "ine abrasives "or precision "inishing o" metal sur"aces. )lso! to per"orm the operation using a lap lard oil ) cutting oil made "rom animal "ats usuall# mi(ed with mineral oils to reduce its cost and improve its *ualities. la#out To locate and scribe on blank stock the shape and si+e dimensions re*uired to machine or "orm the part. lead screw The long! precision screw located in "ront o" the lathe bed geared to the spindle! and used "or cutting threads. )lso! the table screw on the universal milling machine when geared to the inde(ing head "or helical milling. lip o" a drill The sharp cutting edge on the end o" a twist drill. live center ;ee center! live. machine tool ) power-driven machine designed to bore! cut! drill! or grind metal or other materials. machining! /inish -

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Machining a sur"ace to give it the desired "inish. machinist ) person who is skilled in the operation o" machine tools. Me must be able to plan his own procedures and have a knowledge o" heat-treating principles. mild steel ) term used "or low-carbon machine steel. mill ) milling machineT also! the act o" per"orming an operation on the milling machine. milling! climb ;ee climb milling. milling! "ace-;ee "ace milling. Morse taper ) sel"-holding standard taper largel# used on small cutting tools such as drills! end mills! and reamers! and! on some machines! spindles in which these tools are used. normali+ing @rocess o" heating a "errous metal or allo# to above its critical temperature and cooling in still air to room temperature to relieve Internal stresses. o"" center %ot centeredT o""set! eccentric! or inaccurate. oil hardening The process o" *uenching in oil when heat treating allo# steel to bring out certain *ualities. overarm The support "or the end o" a milling cutter which is on the opposite side o" the cutter "rom the spindle and column. parting The operation o" cutting o"" a piece "rom a part held in the chuck o" a lathe. peen To draw! bend. or "latten! also! the "ormed side o" a hammer opposite the "ace. pilot hole ) starting hole "or large drills to serve as a guide! reduce the resistance! and aid in maintaining the accurac# o" the larger hole. )lso called a lead hole.

pla# -

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The looseness o" "it 7slack9 between two pieces press "it-;ee "orce "it. punch! prick ) solid punch with a sharp point! used to mark centers or other locations on metal. *uench To rapidl# cool heated metal in water! oil brine! or air in the process o" heat treating. radial In a direction directl# outward "rom the center o" a circle or sphere or "rom the a(is o" a c#linder. The spokes o" a wheel! "or e(ample! are radial. ram That part o" a shaper which moves back and "orth and carries the tool head assembl#. running "it ) class o" "it intended "or use on machiner# with moderate speeds! where accurate location and minimum pla# are desired. scraper ) hardened steel hand tool used to scrape sur"aces ver# smooth b# removing minute amounts o" metal. scribe 7scribeT scratch awl9 ) steel rod H to 10 inches long and about 1L14 inches in diameter. It has a long! slender! hardened steel point on one or both ends. set screw ) plain screw used principall# "or locking adjustable parts in position. setup The preparation o" a machine tool to complete a speci"ic operation. It includes mounting the workpiece and necessar# tools and "i(tures! and selecting the proper speeds. "eeds! depth o" cut and coolants. shims -er# thin sheets o" metal made in precise thickness and used between parts to obtain desired "its. ;ometimes the# are laminated! to be pulled o"" to the desired depth. shoulder ) term "or the step made between two machined sur"aces.

slitting saw ) narrow milling cutter designed "or cuto"" operations or "or cutting narrow slots. slotter -

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)n attachment which operates with a reciprocating motion. Dsed "or machining internal slots and sur"aces. so"t hammer ) hammer made o" brass! copper! leadA. or plastic to a! non-marring "inished sur"aces on machines or workpieces. spindle ) rotating device widel# used in machine tools. such as lathes.! milling machines! drill presses! and so "orth! to hold the cutting tools or the work! and to give them their rotation. spindle speed The N@M at which a machine is set. ;ee cutting speed. s*uare! solid 7toolmakerAs tri s*uare9 ) ver# accurate tr# s*uare in which a . steel blade is set "irml# into a solid! rectangular-shaped handle so that each edge o" the blade makes an angle o" e(actl# J6. with the inner "ace 7side9 o" the handle. stead# rest ) support that is clamped to the bed o" a lathe used when machining a long workpiece. ;ometimes called a center rest. step block ) "i(ture designed like a series step to provide support at various heights re*uired "or setups. stock ) term "or the materials used to make parts in a machine tool. )lso! the die stock used "or threading dies. sur"ace grinding The process o" grinding "lat sur"aces on a sur"ace grinding machine. ,ith special setups! angular and "orm sur"aces ma# also be ground.

swing The dimension o" a lathe determined b# the ma(imum diameter o" the work that can be rotated over the wa#s o" the bed. tailstock That part o" a machine tool. such as a lathe or c#lindrical grinder which supports the end o" a workpiece with a center. It ma# be positioned at an# point along the wa# o" the bed! and ma# be o""set "rom center to machine tapers. tang The "lat on the shank o" a cutting tool! such as a drill! reamer or end mill! that "its a slot in -the spindle o" a machine to keep the tool "rom slipping. )lso! the part o" a "ile that "its into a handle. tap ) tool used to cut threads on the inside o" a round hole. taper -

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) uni"orm increase or decrease in the si+e or diameter o" a workpiece. tapping The process o" cutting screw threads in a round hole with a tap 7an internal thread cutting tool9. T-bolt Term "or the bolts inserted in the T-slots o" a worktable to "asten the workpiece or work-holding device to the table. tempering ) heat-treating process to relieve the stresses produced when hardening and to impart certain *ualitiesA! such as toughness-! sometimes called .drawing.. template ) pattern or a guide "or la#ing out or machining to a speci"ic shape or "orm. tensile strength The propert# o" a metal which resists "orce applied to pull it apart. thread ) helical projection o" uni"orm section on the internal or e(ternal sur"ace o" c#linder or cone. )lso! the operation o" cutting a screw thread. throw The crankpin on a cranksha"t. )lso! the length o" the radius o" a crank! an eccentric! or a cam. tool steel ) general classi"ication "or high-carbon steel that can be heat treated to a hardness re*uired "or metal cutting tools such as punches! dies. drills. tapsA! reamers! and so "orth. truing The act o" centering or aligning a workpiece or cutting tool so that an operation ma# be per"ormed accuratel#. )lso! correcting the eccentricit# or out o" round condition when dressing a grinding wheel. T-slot The slots made in the tables o" machine tools "or the s*uare-head bolts used to clamp the workpiece!! attachments! or workholding "i(tures in position "or per"orming the machining operations. two-lip end mill )n end milling cutter designed with teeth that cut to the center so that it ma# be used to "eed into the work like a drill. ,a#s The "lat or --shaped bearing sur"aces on a machining tool that guide and align the parts which the# support. wheel dresser ) tool or device "or dressing or truing a grinding wheel.

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work ) common term "or a workpiece or part being machined. )polog#! this came "rom a unknown engineering site.

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