MetalworkingFun Forum
Todays Project - What did you do today? - Printable Version

+- MetalworkingFun Forum (http://www.metalworkingfun.com)
+-- Forum: Machining (http://www.metalworkingfun.com/forum-5.html)
+--- Forum: Projects (http://www.metalworkingfun.com/forum-7.html)
+--- Thread: Todays Project - What did you do today? (/thread-727.html)

Pages: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550

RE: Todays Project - What did you do today? - Pete O - 02-05-2016

I think I may have convinced the missus that there are possible uses for all these machines other than making parts for one another.
The transfer case in my Land Rover had sprung a leak (yeah, surprise...), there is an 'O'ring at the rear of the intermediate gear shaft that is very prone to leaking and involves removal of the transfer gearbox to fix it. I have a mate with the same model landy and his was leaking worse than mine, so I offered to do both in my workshop if he would help me, as it's a 2 person job.
The O-ring leaks because the lateral forces on the shaft cause ovality of the bore in the aluminium housing where the head of the shaft sits. I decided on a more permanent repair than just replacing the o-ring.
Enlarged the bore in the case by .600, made a bush from some 4140 with a .001 interference fit in the housing and .001 clearance on the shaft.
[attachment=12665]
Heated the case on the BBQ and cooled the bush in the chest freezer, applied some loctite 620 and a simple puller arrangement
[attachment=12666]
[attachment=12667]
Put all new bearings and seals through the box whilst it was out, lot of work but now it's quiet as a mouse and not peeing oil on the ground. Only downside is that now I have to do it all again on my mates car. Nice to have the gear to do the job properly.

RE: Todays Project - What did you do today? - Mayhem - 02-05-2016

Nice job Pete

RE: Todays Project - What did you do today? - dallen - 02-05-2016

nice job

RE: Todays Project - What did you do today? - Kennyv - 02-05-2016

Nice work Pete exceptional job.
quick Q you mentioned .001 interference fit is that with the new bushing and the case ? Im thinking out loud here but thought should be up to .010 bc of softness of allum no?
now I may be wrong someone correct me if so... cuz if I can rem we used the +.010 tolerance interference but that was cambering's in the journals of an engine again was Long time ago...
all replies welcome TIA
kind regards Kenny v

RE: Todays Project - What did you do today? - Pete O - 02-05-2016

G'day Kenny, been wondering where you got to, good to see you back. The reason I went such a small interference was fear of introducing too much stress in the narrow part of the casing where I have bored out toward the opening for the front output housing- on the left in the top pic. I was frightened of cracking it and ruining the housing altogether. Not having the training that yourself and some others on here have, I just pulled the .001 figure out of thin air. The 620 (if I'm remembering the number correctly- it's a long way from the computer to the shed) is supposed to be a permanent bond and can fill up to .003" so hopefully it will stay put.
If someone is going to tell me that the housing will expand and let the bush fall out, please tell me before I do the second one!

RE: Todays Project - What did you do today? - TomG - 02-05-2016

I took a mental health day and basically just fooled around in the shop. Against my better judgement, I gave Horror Fright another $19 and replaced the impact wrench on my power drawbar. Maybe when I have more time, I'll do a re-design on it and make it more robust.

Tom

RE: Todays Project - What did you do today? - Roadracer_Al - 02-05-2016

In response to Pete O's comment about the pleasures of being equipped to do a job, I'll give that a hearty second.

I ordered receiver hitch -- a class III Curt -- for my wife's RAV4, and when I tried to install it, only 3 out of 4 holes would line up, so I took it into the shop and stuck it in the hydraulic press, and I bent that sucker into shape. The holes lined up right. Took all of 7 minutes "from door to door", as it were.

I love having the right tools.

RE: Todays Project - What did you do today? - johnnyc14 - 02-06-2016

I really miss the quill DRO that came on my PM932 mill so I wanted to add one to the Ferro knee mill I have now. I bought two 6” digital Accu-Remote scales from KMS tools on sale at $30 each and use one on my lathe and the other for this project. I started by making up a prototype bracket from a couple of pieces of aluminum angle and pop rivets.

[Image: 20160203_144855_zpsgcktte80.jpg]

[Image: 20160203_144904_zpsqpsrmtag.jpg]

[Image: 20160203_115008_zpsyz1w0qen.jpg]

I made the permanent versions from a length of 2.5” square 6061 aluminum tubing with 3/16” wall. I marked out the pattern on the tube with a scribe and highlighted it with a sharpie then carved it out on the mill with a ¼” end mill. I painted the final product with engine enamel and baked it at 250 degrees for 2 hours to harden the paint.

[Image: 20160206_133207_zps4jas3pzc.jpg]

[Image: 20160206_133221_zpscvqxabip.jpg]

I had to reduce the OD of the fine feed wheel to clear the thicker bracket so I put a knurl on it as well.

[Image: 20160206_092751_zpsln3dnwmt.jpg]

[Image: 20160206_092757_zpsb2fxr4y9.jpg]

[Image: 20160206_092859_zpsegv989b8.jpg]

I also had to make up a plug to fit into the hole in the quill stop. It has a nose machined on it that fits into the hole and on the other end is a 5mm threaded hole to fasten the bracket of the digital scale. I attached it the quill stop with JB Weld epoxy.

[Image: P2280827_zpsymhexqdu.jpg]

[Image: P5171019_zpscwih8dc1.jpg]



It turned out well.

[Image: 20160206_135928_zpsfouxsyym.jpg]

[Image: 20160206_133437_zpstybyr7cz.jpg]

[Image: 20160206_135950_zpszokxo5fj.jpg]

RE: Todays Project - What did you do today? - EdK - 02-06-2016

Nice work John! Thumbsup

I was just looking at quill DROs today since I want to put one on my PM935 as one of the first modifications.

Ed

RE: Todays Project - What did you do today? - DaveH - 02-06-2016

Nicely done John Smiley-signs107   Thumbsup
Smiley-eatdrink004 
DaveH