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  #21  
Old 18-09-2024, 06:23 AM
RodW (Rod Watkins)
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Very impressive Stefan. I take it you made the ball joint components in house?
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  #22  
Old 18-09-2024, 07:23 AM
Stefan Buda
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Yes. I made them without a CNC lathe by generating the spherical shape on the milling machine. I did not take photos.
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  #23  
Old 01-10-2024, 07:23 PM
Stefan Buda
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I had to take a break for a while from this project, but I'm cutting metal again.
I'm making the front ring out of a square plate, and I had to start by making a jig for holding it on the lathe.
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  #24  
Old 01-10-2024, 09:04 PM
Saturnine (Jeff)
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Thanks for the update on progress, watching with interest the techniques you are using. Have done similar jobs when wanting a largish and disc or ring, getting some plate and cutting to a rough circular shape, making an adapter to bolt it to and spinning in a lathe and machining it circular.
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  #25  
Old 02-10-2024, 08:40 PM
Leo.G (Leo)
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Wow, did you have cigarette foil clearance on the lathe bed?
What size swing?


That's an amazing looking job but I've seen some of your other items and they all look amazing!

What size plate is that you are using?
Final dumb question (sorry).
The way you've cut the plate, I'm guessing not with the milling machine so it's been a decent size band saw?

I have a plasma cutter, only a cheap Aldi thing which will do 10mm steel and maybe slightly thicker aluminium, with the aid of a circular guide I can get an accurate blank in minimal time with minimal fuss, not that I have the guide but if I did. I reluctantly used it for the first time some time back to cut an old gas hot water tank in half to use as the slag tank for my plasma bench I'm yet to get to, I have everything here to do it. I was going to use an angle grinder till my son asked why did I bother buying the plasma cutter. I hadn't used one since I studied fabrication engineering at Young TAFE and didn't get to play much with the TAFE's expensive machine (no student did). I've fixed the electronics in a couple for friends but didn't have a compressor to play with them.
They are so fast, clean, effective and less overall scrap/waste.


Saying I haven't made the cutting table, I haven't welded the frame (stand) for the milling machine which came as a package deal with a combination lathe I bought my son, 3 years ago (health doesn't always see me getting to what I should get to). I got the separate table, vice, tools basically everything but the MOJO to weld the stand.

https://www.machineryhouse.com.au/k149?s=k149

Migraines and moving/mowing/welding/doing most average things don't mix so I'm just an old has been.

Last edited by Leo.G; 03-10-2024 at 11:15 AM.
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  #26  
Old 04-10-2024, 07:38 AM
Stefan Buda
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I had about 12mm clearance between the disc and the lathe bed.
It will be more difficult with the other truss ring which is 20mm larger in diameter.
The square plate was 307 x 307 x 16 and weighed 4kg. The finished ring's weight is 690g.
I still need to drill some radial holes and that will require another fixture.
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  #27  
Old 04-10-2024, 09:30 AM
Leo.G (Leo)
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Your work is always so impressive!



And the furnace to cast the waste?
I have some fire bricks and a gas rig here with intentions of maybe setting it up one day for quick, rough castings. Whether health permits it or not I don't know and won't till I get home from my doctors in 2 hours if I don't end up in hospital.


My engineer friend locally would often ask if I wanted bits of steel and alloy to play on the lathe, varying grades. He'd pull them from his scrap bin after someone changed the design on 100 something or others he'd manufactured for them, high grade steels of varying hardness. One day he mentioned he needed new pins on his backhoe at home and I asked "wouldn't this stuff you're throwing out fit?"
Well, problem solved, a prefect fit without the slightest modification.
To be fair he was/is in the process of clearing out his workshop and taking everything home to work from there in a huge shed he has and he has so much stuff and bits and pieces.
I avoid going to the shop too often because he keeps insisting I take stuff, things I know which have cost him a lot of money and I don't want to be that friend, I always offer him cash. I did take a few collars he was dumping, again, a hardened steel and said they'd be ideal for my 12 tonne workshop press. He then decided to take a set for himself (he'd normally just machine one on the day if needed) and also grabbed a bunch of them to give to his workshop neighbour. He didn't see the practical use till I mentioned something. Though for him to throw it out and buy steel next time he wants one and it will be charged out I guess is no big deal financially, for me, wow, the materials and gear he's given me.


I was shocked the other day when I bumped into him and he said he's had an offer of $3,000 for a lathe, a HUGE lathe which runs near the length f his workshop. I asked "didn't you spend $10,000 on the last chuck"?
Yes!
He said he'll get $3,000 for the turret lathe with multiple chucks and steadies included. Unbelievable, I spent more than that on a small Chinese thing.
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  #28  
Old 04-10-2024, 12:33 PM
RodW (Rod Watkins)
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Nice work Stefan.
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  #29  
Old 05-10-2024, 07:43 PM
Stefan Buda
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Thanks Leo and Rod,

I got the back ring of the truss machined too. This one weighs 20g less than the front ring.
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  #30  
Old 08-10-2024, 07:25 AM
Stefan Buda
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The front ring now has its radial holes done too.
I want to get the truss rings sandblasted before anodizing.
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  #31  
Old 08-10-2024, 01:23 PM
Leo.G (Leo)
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Do you do your own anodizing?
I have a few things I've done or had done I must get to myself if I can find my black food dye. I used to do zinc plating and anodizing for a living at a place in Silverwater (Westwood Winters) back in the early 80s, back in the day of sulphuric acid only 2 tanks away from the cyanide tank, fun job, don't breath the dust in and hose before you sweep.
I never missed the big rubber aprons, gloves and boots when I left either.
They no longer use cyanide in zinc plating I believe.


Sorry, probably a stupid question (I have lots of them), do you sandblast to increase the overall surface area for a better finish or is it just for the matt finish and better grip/feel?

Last edited by Leo.G; 08-10-2024 at 02:26 PM.
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  #32  
Old 08-10-2024, 02:11 PM
RodW (Rod Watkins)
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Ditto, I'm also curious as to why you would want to sand blast your beautiful machined finish. And isn't sand on aluminium a bit harsh? Thanks Leo for asking.
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  #33  
Old 08-10-2024, 02:36 PM
Stefan Buda
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The sand blasting is only for cosmetic improvement. It hides the machining marks.
The anodizing is a bit of a problem in Melbourne as there are only two places that can do it. One is very unreliable, quality wise, and the other has a minimum charge of over $400, although they work to military specs and I never had a problem with their quality.
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  #34  
Old 08-10-2024, 02:47 PM
Leo.G (Leo)
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Quote:
Originally Posted by RodW View Post
Ditto, I'm also curious as to why you would want to sand blast your beautiful machined finish. And isn't sand on aluminium a bit harsh? Thanks Leo for asking.

While often refereed to as sand blasting it's actually bead blasting with various compounds and grades of beads available to suit different tasks/materials.
In a past life a company I was at we sold the cabinets and equipment to do the blasting and I did a couple of old rocker covers for a friends V twin Japanese motorcycle and they came out looking better than new. I should have bought a cabinet then but now own a little hand held gun, cheap Aldi thing I haven't tried yet and a suitable compressor.
I may yet build a cabinet for it, I'm sure I have the steel and only need the Perspex and gloves though I won't expect too much of the unit.


EDIT: I was replying here when my sick cat had an accident and I had to clean it up.


Quote:
One is very unreliable, quality wise, and the other has a minimum charge of over $400, although they work to military specs and I never had a problem with their quality.
I know the gentleman who used to do it at the small arms factory locally (now Thalis I believe). He's said he may be able to get small things plated for me (he's now retired) but I haven't asked. When it comes to plating I'd expect if time permits it's better to save a few smaller jobs up and have them done at the higher quality place though anything urgently needed it's pay up.
This may also explain why a company I recently contacted somewhere in NSW didn't bother replying to my contact, not worth it to them to do the small slide projector parts. The amount of small one off's I did back in the day, all legit (down to a single bolt and nut, often free, just thrown in the rack with other jobs (huge tanks)), the old boss was a never say no person and wasn't a thief either.



I may be wrong in saying this, Joshua Bunn has in the past mentioned to me he does all of his own anodizing, perhaps it would be worth having a word with him but I just realised he's in WA and I think you are in Melbourne, postage would probably cost more than the job locally. but there maybe safer, better options available, I haven't looked. My son and I have played with a circuit board tank to nickel coat contacts on a circuit board and I'll be buying or making a smallish fish tank to do my own slightly larger projects.The chemicals are usually the dearer part but I've seen mention black food dye is quite suitable (and other food colourings). Play with scrap and the other important thing to remember is timing is everything.



https://www.dragonmetal.com.au/blog/...-need-to-know/



Quote:
The sand blasting is only for cosmetic improvement. It hides the machining marks.
We've all seen your glass dome and I'm sure no one here really believes you leave machining marks, LOL


Sorry, not a sycophant, in awe of the end results of both you and Joshua with the work you've both shown here (I worked with some VERY bodgy machinists and some amazing ones too).

Last edited by Leo.G; 08-10-2024 at 03:18 PM.
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  #35  
Old 08-10-2024, 05:36 PM
Stefan Buda
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I can anodize small parts, but these are not small.

The expensive anodizer here in Melbourne has a lucrative contract related to the F35 program and can't be bothered with small jobs unless you are prepared to pay the ridiculous minimum charge.
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  #36  
Old 08-10-2024, 06:29 PM
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Peter Ward
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Quote:
Originally Posted by Stefan Buda View Post
I can anodize small parts, but these are not small.

The expensive anodizer here in Melbourne has a lucrative contract related to the F35 program and can't be bothered with small jobs unless you are prepared to pay the ridiculous minimum charge.
I feel your pain.

The CSIRO had a cold deposition mirror facility that I was prepared to pay for, (as I would not have to ship the optics offshore) but they point blank refused to service "external" (read actual $ paying) clients.

I digress. I am in awe of your work.
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  #37  
Old 08-10-2024, 07:01 PM
Stefan Buda
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Thanks Peter,

Yes, I don't know how we can compete with the Chinese, given some of the business attitudes around here.
Recently I dropped in to a fasteners place, on my way home from the northern suburbs, to get 4 M12 bolts, only to be told at the sales counter that they have a minimum charge of $20. I thanked the two men on the other side of the counter for explaining and then I let them resume their casual chatting.
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  #38  
Old 08-10-2024, 08:31 PM
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multiweb (Marc)
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Originally Posted by Stefan Buda View Post
Thanks Peter,

Yes, I don't know how we can compete with the Chinese, given some of the business attitudes around here.
Recently I dropped in to a fasteners place, on my way home from the northern suburbs, to get 4 M12 bolts, only to be told at the sales counter that they have a minimum charge of $20. I thanked the two men on the other side of the counter for explaining and then I let them resume their casual chatting.
There's a place in Wetherill park in Sydney called WDC. They do all sort of fasteners and also stainless steel. Over the years I bought small bits and pieces from them. Always so helpful. They sell by bulk. Read 100s. When I come for 10 or 5 and go to pay they say don't worry about it. I always leave some cash for maccas for them.
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  #39  
Old 08-10-2024, 08:36 PM
Leo.G (Leo)
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Our local bearings and industrial supplies is much the same as what Marc mentioned. I often walk out with half a dozen stainless button head bolts for a gold coin when they don't even bother checking the price. Nice bunch of fellows.
Failing that I'd be going online but freight is often the catch and it's of no benefit when you're in the middle of doing a job and need them then and there.
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  #40  
Old 09-10-2024, 07:13 AM
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Hi Stefan,

I don't know where in Melbourne you are located, but I've had good dealings with "Bayswater Bolts" on Canterbury Rd (Between Boronia Rd and Dorset Rd).

Usual disclaimer - not associated with them in any way shape or form, other than as a satisfied customer.

Cheers,
V.



Quote:
Originally Posted by Stefan Buda View Post
Recently I dropped in to a fasteners place, on my way home from the northern suburbs, to get 4 M12 bolts, only to be told at the sales counter that they have a minimum charge of $20. I thanked the two men on the other side of the counter for explaining and then I let them resume their casual chatting.
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