Changes Made On The Robotic Welder Parts Job - Lessons Leaned Since The First Parts.

[@arthurjennings5202]

Practice! Practice! Practice! Words of wisdom from my piano teacher. It is true that smart people learn by watching and improving processes. Work smarter, saves time and money as well as parts.

[@bcbloc02]

Projects breed projects! Being able to do the jobs faster and more efficient is a win win!

[@brian_2040]

Man you aren't kidding about the head cutting better. Its hard to believe what the chages did for it. Good job Mr Josh.

[@BrucePierson]

Great modifications to the process there Josh, making the job easier and the finish nicer. You can always learn with repeat jobs by assessing the current setup and looking for ways to make it better.

[@jylmachineshopvb]

Love you’re videos! Keep your great job going!

[@BruceBoschek]

That multi-purpose stop is a great idea.

[@mikep1085]

I think the wooden box that the Starrett came in, is as much of a work of art as the 123 calipers!! Its gorgeous! Can you imagine when it was new? 😄😃🤩

[@TopperMachineLLC]

I agree. The box needs a little attention, but it will clean up well.

[@stevechambers9166]

Josh that caliper it’s just a work of art and that cutter was definitely way better ifyou didn’t see the chips coming off you wouldn’t know it was cutting😂

[@ron827]

I admire a craftsman who is still willing to learn and does not profess to know everything as does a KZbinr in the NE. Go Josh!

[@TopperMachineLLC]

Never stop learning.

[@gofastwclass]

Great to see the learning process still happens for you. I completed a multi-part job in my home shop using knowledge I gained watching your videos. I had several of the same part to make and used a series of stops to set the length and clock them properly. I was able to hold a tighter tolerance than I ever have which was far better than required. Thanks for the great videos.

[@TopperMachineLLC]

Glad it worked out for you. You never stop learning

[@lerkzor]

Twenty thousand dollars new? My goodness, they are sure proud of that caliper!

[@TopperMachineLLC]

Yes they are.

[@ChrisArnold-h7q]

Ran the exact same size Lucas as an apprentice brings back memories finish looks good we were taught to cut against the positive stops and the table. Had one journeyman who would make you tear down your setup and make you start over till he approved made a lot of apprentice mad but was a great mentor

[@TopperMachineLLC]

Since I was only using the angle plates as a location stop, I had no problem with this setup. Cuts were light to make surface finish.

[@alungiggs]

Thank you Josh. Nice bonus video for a Sunday morning. 👍🇳🇱

[@TopperMachineLLC]

Something went wrong. It was supposed to be Tuesday morning. But it works.

[@kristyskirt9015]

That “Starrett” vernier caliper matches the quality of work you do Mr. Topper. Great score on that caliper. 😊

[@mikebarton3218]

That’s a whopper, Mr. Topper 😂

[@claudelewis5026]

after watching your channel and working on repair most of my life ,,, i see where i could have benefited from time in a shop like yours

[@GardenTractorBoy]

It is always good to make improvements on a process

[@johnmcanulty7341]

Honey, I am getting larger tool chest to store my new caliper... but, I think may need the 96 inch, just in case. Gerstner, please take note. Great video.

[@TopperMachineLLC]

I just need a bigger shop. Lol

[@watwsplace8614]

Love the box the caliber is in.

[@scottthomas5999]

Good setup. Love the caliper.

[@MrMojolinux]

Nice work Josh and nice Starrett Vernier Caliper! It's so big you can actually read the lines without a magnifying glass!

[@seasaw40]

Hey Josh @TopperMachineLLC I just wanted to comment and let you know how invaluable the videos you make really are. I saw a video of yours, about 6 months ago, working on a precision ballscrewvfor a viewer, and you had mentioned he wanted you to film it to get younger people interested in the trade. I've only been working as a machinist for about a year and a half in a family owned job shop, and they took me in with zero experience just because I was so willing to learn. Early, early 20's when I started and I can't help but think about your apprentice Connor and I being so lucky. My highschool never offered such a class, and I could never afford a technical school, so I really do applaud those who are willing to teach us who work hard and want to learn these skills. Thank you

[@TopperMachineLLC]

Hi, thank you so much for this comment. I was somewhat taken aback by what you wrote, and I really don't know how to respond. I wish you all the best and will give you this advice. Keep learning, get dirty, do whatever it takes. You will go far! I created a community tab post of your comment. I hope you see it. I have asked my viewers to give you encouragement and feedback. Thank you again for making my day!!!

[@tomeyssen9674]

What a nice Starrett, I'm glad you got it!

[@NorthForkHollow]

I really liked this video. It's one thing to watch a video of someone doing machining, or anything really. But when someone makes a video like this, it's invaluable. You can't always tell all the little details that go into a setup or tool selection. But watching a video about what lessons I learned and why I changed it is an amazing teaching tool. Thank you for making this video to help out those of us that don't know as much.

[@TopperMachineLLC]

Glad you enjoyed it!

[@jeffvalero]

Now you need a "I have 72 inches and know how to use them" T-shirt 😜

[@jamesreed6121]

It is amazing to see how a person's mind works. The more you work with a process ideas appear to come out of nowhere to make it better. Some to save time others to make the product better and sometimes just to try something new. As a hobby machinist The learning process is what keeps me from getting bored with machining. KOKO! (Borrowed from ARW)

[@alanm3438]

Thanks for the update. If you can figure out a better way, then why not. You are always learning. Great video!!!!!!

[@kristyskirt9015]

Yes the Lighting that can make or break a complex machining process. I had a small auto repair to do replace ignition lock on a car equipped with tilt telescoping steering wheel and boy O boy, that lack of lighting almost trashed the whole steering column. Yet I fixed the lighting and got it done the first time right. PS no auto repair shop would take on this job. 😊

[@danrabenhorst2549]

Very impressive caliper I don't think I could lift it anymore thanks for the video

[@joannepeterson2631]

Your channel and cutting edge engineering the best

[@luksan_swe]

Thank you for another interesting video. The lid on the caliper box is like a wooden door.. impressive.

[@dennisleadbetter7721]

Hi Josh, when you have multiples to do and continuing orders for the same product, it makes it worth while to make fixtures and/or jigs to do the job, and they can be very simple yet achieve worthwhile time reductions, adding to the bottom line. That face cutter did a nice job. Those verniers are in good condition, who needs to go to the gym!! Regards Dennis

[@hasletjoe5984]

Josh, I like this revisit/lesson leaned type content. Nothing wrong with the regular stuff, but this hit the spot. Thank you

[@TopperMachineLLC]

Glad you liked it. It was supposed to be on Tuesday, but something went wacky with KZbin and daylight savings time.

[@BrucePierson]

Daylight "saving" a a total pain. We don't have it here in Queensland Australia, but many of the Australian states have it. When I lived in New South Wales, I had to get up in the dark to go to work and then go to bed in the evening with the sun still up. Totally stupid idea.

[@donteeple6124]

Josh, This was a GOOD ONE !!!!! Visual and oral explanations outstanding and easy for all to understand...I could tell just from the sound that that cutter was going thru that like butter.....BTW...that vernier is the biggest Ive ever seen......you now need to modify your shirt to this...." I have a BIG JOHNSON and a BIG TOOL. !!!!!!!".......LOL......even just showed the wife your big tool....she was IMPRESSED...........waiting on a guy to come over for a welding job, simple one for a square tube base for a heat pump to raise it off the ground.....we are under a WINTER STORM WARNING.....forecast is for 10-20 inches of heavy wet snow tonight thru Monday noon.......ughhhhhhh....then back into the 50s next week.....ground is thawed and mushy so any plowing will rut up things.....scowls and asks if you put away your snowblower good luck charm and caused this.....LOL......just kidding.... I really liked this and the series this sets up on things..... Don

[@TopperMachineLLC]

LOL, yeah it is big. I am the envy of all of my machine shop friends. Even Abom doesn't have a big one. LOL The snowblower is still ready to go, it is just blowing it your way. I will go turn the chute away from you, we'll see if that helps. LOL

[@donteeple6124]

Why is it customers are ALWAYS late........LOL@@TopperMachineLLC

[@TopperMachineLLC]

@@donteeple6124 Or don't show at all!

[@haroldchoate7497]

Sadly customers of machine shops rarely check out the shop’s tooling and business practices. They accept the shop’s bid and wait for the results. These videos should serve as incentives for your customers to send you more work because they can see your efforts to do better, more efficient work. The investment you have made in measuring tools (calipers, 2 axis DRO) are expensive and have to be paid for somehow. The answer is more work. I was happy to hear you say you’ve been able to use the 72” calipers on a number of other jobs. You are quickly becoming an eagerly awaited source of information and entertainment to me. “Now get out in your shop and do it right the first time!” 😊

[@TopperMachineLLC]

Tooling and machine investments have driven a lot of work the last 2 years. When I bought the Lion, things turned around for me. Even being in a depressed region, I started getting work from all over the country. You need to keep investing in order to grow.

[@haroldchoate7497]

I agree, you’re either going forward or backward there is no standing still. I enjoy the videos where your intern is involved. There is always a special bond between a young man and his mentor. I hope that is the case with your two.

[@wmweekendwarrior1166]

Big difference in surface finish, nice!

[@geckoproductions4128]

I always pick up little details from your videos...like putting a coupon underneath the toe clamps on top of the square tubing. Thanks!

[@TopperMachineLLC]

Focuses the clamping force where I want it.

[@procyonia3654]

That starett looks significantly beefier than my 82" mitutoyo Cool, wonder if it resists deflection in the bar better for a more accurate reading

[@oldreliable303]

Thats a very nice starrett bar clamp... or a very big ajustable wrench...

[@RossiDeakin0406]

And the bigger toe clamps ....👏👍Great job

[@Bob_H]

When you pick that caliper up it looks like you're holding a broadsword ⚔ laddie.

[@frankerceg4349]

Thank you Josh!

[@blitzkrueg07]

when i ran HBM we were taught to put angle plates so the cutter pushes into them. so personally i would put angle blocks on other side of part. also i would use wire springs under the clamps so they stay airborne. love the videos

[@TopperMachineLLC]

The only reason I didn't so that was for setup speed. The angle plates are only there as a rigid stop. I wasn't pushing hard enough for movement. I was going for surface finish. You may not have seen it, but I did use a small pad under the clamp bar to focus the clamping force to the center of the tube.

[@StuartsShed]

I really like to see fixturing set ups. These jobs are very much about that - and when you can create one that has a lot of potential to work with other jobs that have / may come in that's a huge plus. I am inspired by (rip off 🙂) a lot of fixturing that I see and use it in my day job and my own shop. As obvious as these seem after the fact, they don't always spring to mind at time of need - or my own ideas tend to be a bit over complex at times. Plus - big face mills and chips is always good to watch. Cheers!

[@TopperMachineLLC]

Setups can get crazy, especially on the first setups. They do get better with time.

[@gregmarchegiani6656]

No more cardboard protection for chips? I love your channel man, humble, down to earth and professional. Great guy

[@TopperMachineLLC]

Started it on fire. Time for a new plan. Thanks!

[@rupunzel6299]

Nice example of how tooling and set ups evolve and become more refined with passing batches of parts. Carbide insert tools like to be run hard as they rely on heat produced by friction at the "cutting edge" to mov metal. Getting the best and most out of carbide tooling means rigid/stable set ups coupled with enough spindle speed and feed rates to get the specific carbide insert into its proper operating range. Long as the set up is rigid/stable, push the spindle speed and feed rates up enough to achieve a good rate of metal removal, good surface finish and insert life.

[@TopperMachineLLC]

With every new or repeat job, there are challenges. Since this face mill was new to me, learning it's sweet spot was critical. I found a happy medium for tool life and surface finish. The parts came out better with each batch.

[@kentwgazlay]

I think it would be better to put the angle plates on the other side of the tube. When cutting you would be pushing to them instead of pushing to the hold down stud. Just my thought. Nice work Josh

[@TopperMachineLLC]

I am not putting force into them, only using as a definite stop. The cut was light enough that I had nothing to worry about. If I ran the other way, I would get a shower of chips, if I put the angle plates on the other side, clamping would be a pain. I chose the best option.

[@hacc220able]

A master at work - thanks for sharing.

[@HorsleyLandy88]

I did think the cutter was a bit slow in the last video, I have a 4" cutter like that on my mill and it gives an excellent finish.

[@zedostenso3069]

Josh you need a protective cover for the x axis scale before something bad happens. Love your videos. Cheers Zed

[@TopperMachineLLC]

The cover was damaged years ago. I am actually installing a new scale on the back side of the table as I reply to you. Along with the third axis. Gotta keep upgrading.

[@skwerlz]

I've always written down any problems, possible solutions, changes to make, etc... on the back of the work order. That way next time the same job comes around I can look at my previous notes so I don't have to remember exactly what problems I had, just that I had problems.

[@ypaulbrown]

Josh, don't you know it is 2 am here n Florida, and you are keeping up all night...... cheers my friend.....wonderful episode on the mixing and drilling earlier, Paul

[@TopperMachineLLC]

Something went wrong. This was scheduled for Tuesday morning

[@stevenslater2669]

I’d like to see the machines Starrett uses to make that giant caliper…

[@NavinBetamax]

...also if they make/made them any length BIGGER !!! Yes, please

[@dcraft1234]

Any tips on how someone could measure that length reasonably accurately without a caliper like that?

[@TopperMachineLLC]

Buy a caliper. LOL. Ok in seriousness, you could use your DRO, but I don't think that would pass if your customer stopped to check progress and compliance. There are cheaper versions of this caliper out there. But in reality, having the tools for the job is the most important.

[@glennmoreland6457]

Good video ☹️🇬🇧

[@lwilton]

Now the one thing I immediately wondered on the previous video is if you came up with a jigging and clamping setup to let you do both the end plates and the side plates without having to reset angle plates and the like.

[@TopperMachineLLC]

I considered it, but the time to make it outweighs the setup change time.

[@michelecrown2426]

If you take a flat bar and add a tab up on one end and a tab down on the other, (like a straight Z) you can hook it over the end of the part and hold the vernier on the other. As long as you machined or ground it accurately, it will give you perfect measurements with a shorter vernier on longer parts. Make the distance between the outside faces of the tabs a convenient length for easy adding to measurements.

[@TopperMachineLLC]

I considered that, but owning a big Starrett caliper is cooler. Lol

[@michelecrown2426]

Definitely way cooler@@TopperMachineLLC 😎

[@willfriar8054]

a simple tool is a squaring bar that you bolt down to the bed. it has matching holes where the tea slots go! indicate an 18 inch long bar to within 1,000 and tighten the hell out of everything! anything you lay up against it will be square to the cutter! it makes squaring up plates and square tubing really easy. with a real good setup if you have to do lots of them you can set your stops square up the perimeter with an end Mill and then switch tools and cut the bass. that way you get repeatability.

[@TopperMachineLLC]

It is on the list of things to build. Way easier than using the angle plates for everything.

[@ssboot5663]

Now that is a REAL no B.S. CALIPER!!!

[@billsmith8739]

I was wondering why you was running the cutter so slow?? Looking good!!

[@TopperMachineLLC]

surface finish. It is all about the finish.

[@schorse1000]

I'm just wondering, seeing the direction of cutting, wouldn't it be even more ridgid when you put the angle blocks on the other side? Then the cutter woud press the workpiece against it.

[@TopperMachineLLC]

I would have had a harder time reaching everything for setup the other way. It was clamped well enough that it didn't matter

[@ianstewart1188]

Thanks

[@TopperMachineLLC]

Thank you very much.

[@jsn1970]

I'm impressed with your work. I wonder if you ever considered to relocate your Lucas machine in such a way that you can work on both sides of the worktable; in my view you can set up a workpiece on the one end, while the workpiece on the other side is getting milled? I would love to do some measuring with your super caliper :)

[@TopperMachineLLC]

Ive thought about moving the mill, but my shop is too small to make anywhere else function as good.

[@CatNolara]

Doesn't look like it's been an issue but I'd have had the angle blocks set up so the cutter pushes the workpiece against them instead of away from them. Maybe even clamp them with two bolts instead of one only. Just for good practice.

[@TopperMachineLLC]

It wasn't an issue. I considered it, but I would have had a harder time reaching the parts. I did have 2 holding for milling.

[@johnpfaff7328]

I don't imagine the first foot or 2 of scale markings get used very often on that caliper!

[@TopperMachineLLC]

I'm guessing first 3-4 feet. Lol

[@MrWhatnext]

One thing you did wrong was your positive stop ... angle iron ... is on the wrong side. The pressure of the cut is being taken buy the clamp. Two two piece vises keyed to the table with clamps on the top is how i would have done it. A positive stop for the length is the only way to go.

[@TopperMachineLLC]

I did nothing wrong. The job got done and there were no issues with the setup. I did it the way I did so it was easy to reach.

[@tiredoldmechanic1791]

I was wondering if the plates couldn't be drilled and tapped prior to welding them on and a jig setup made to hold them in position to weld. Then the plates would only need to be surfaced after welding. It would be much easier and faster to make the holes and the plates could be made in a stack. I guess it depends on how many of these welders they are building.

[@TopperMachineLLC]

It's never a good idea to do this. There are just too many variables. Doing it all after welding is best practice.

[@shogormachine]

So how much did the Starrett 72" cost ?

[@TopperMachineLLC]

I showed current price in the video. What I paid is between myself and the seller.

[@SHADOW.GGG-]

learned

[@phillipharris8277]

I would have put the angle blocks on the other side of the part so that the cutting forces would be into the "fixed jaw".

[@TopperMachineLLC]

There were no real forces. It was just a precision stop. Slow enough feeds for surface finish. Swapping my "stops" around would slow setup of each part.

[@candicebeebe6688]

How do you set the cutter bit height ?

[@TopperMachineLLC]

Video coming later

[@dale5898]

Josh your opening moments are comedy gold? You are a lonely beacon of restraint. It would be too easy for me to get demonized. As they say, No good deed goes unpunished. But you got to laugh last all the way to the BANK!!!

[@TopperMachineLLC]

Thank you, I am glad you caught that jab at those know-it-alls. I was laughing so hard when I thought up that opening.

[@kodiakmagnumtlm1634]

Why not cut towards your angle block?

[@TopperMachineLLC]

They are only a stop, not there for force.

[@stevebarnes766]

Just curious. How do you compensate for the shorter length of the part against the end stop once you have milled the first end? (Assuming you have to finish both ends of the part...) The part is now shorter, so the end stop won't set you out where you need to be vs. the first end. How do you get around that? I'm assuming you are having to mill both ends of the part. Thanks!

[@TopperMachineLLC]

I don't think you watched the entire video. It was all shown and explained.

[@stevebarnes766]

@@TopperMachineLLC Ok. I must have missed it. Thanks!

[@davekarch5668]

hey josh, where did you get that air powered chamfering tool? saw something like it on cutting edge engineering. also those 74" starrett verniers are freaking awesome! i love my 123 12" its my favorite measuring tool. the shop just bought a 52" long jaw 123 for a specific repeat job, they are real sweethearts also deadly accurate almost as good as a micrometer! love the videos! never miss one

[@TopperMachineLLC]

I think I got them from KBC Tools. Absolutely love them for chamfering. So fast and reliable.

[@robertskelton2576]

Was there any reason you got this job over who ever did the first few?

[@TopperMachineLLC]

First place lost their machinist and nobody knew how to run the HBM. My reputation was what they heard about and sent it to me. They said I hit better accuracy than their guy did.

[@funone8716]

Over the years, when I've made 'too many' improvements on repeat jobs, they've all gone away just about when things were most efficient. Almost uncanny occurrence. I'm wary about spending too much time or money to make jobs go quicker. It seems it's the nature of the job shop business.

[@TopperMachineLLC]

I tend to plan on the job disappearing. Buying the caliper was justified because it's a lifelong investment. Everything else of this job was basic setup and operational changes.

[@joell439]

👍😎👍

[@scottjones7279]

Do no know how many robotic companies there are in in your area but the com that I work for bought one from a Wisconsin based company. The legs and frame work are great, the rest of the equipment not as great.

[@TopperMachineLLC]

Most of them are not in my part of the state. There is almost no industry in my region. I am fortunate enough to have companies willing to truck stuff to me.

[@trialetcompagnie4481]

💪💪💪💪🤩🤩🤩🤙🤙👌

[@oldschool1993]

Makes you wonder why someone would pay 20K for that caliper when a 500.00 DRO display and scale will do the same job to a higher resolution and work in either inch or metric.

[@TopperMachineLLC]

So, by this logic, nobody needs any measuring tools? You still need precision tools to verify the accuracy of the DRO. Case in point is the Newall DRO on my Lion Lathe. It has failed 3 times since I got it. If I had relied solely on it, I would have scrapped a $3000 part the first time. After that, I never trusted it again and was correct in not trusting it as it failed 2 more times on expensive parts.

[@oldschool1993]

@@TopperMachineLLC A DRO is a measuring tool, you can verify its accuracy against any number of standards. In your instance you could verify it against your 48" caliper. Any tool can fail, but in my experience when a DRO fails it gives a very clear visual warning- either the display begins reading erratically or it stops reading altogether. I think you are comparing the validity of all DRO's against what is clearly a defective product from Newall.

[@TopperMachineLLC]

@@oldschool1993 You are correct, but you also never want to rely on just one measuring tool. Sure the DRO will do the job, and you can check to standards. But being able to physically measure the part on and off the machine is important. I can mill the part, relying on the DRO method, but how would I verify it to the customer if they paid a visit and wanted to check the parts on the pallet before shipping. I guarantee they want to see an actual measurement. Now, that said, what is to stop someone from building a DRO based caliper or micrometer? That has some significant possibilities.

[@oldschool1993]

@@TopperMachineLLC That is exactly what I was talking about- a single scale and a display is just a caliper. All you need is a stop on one end of the scale and a stop on the reader head- bring the 2 together and set zero.

[@TopperMachineLLC]

@@oldschool1993 Gottcha. This may be worth exploring. But I now own the coolest vernier on all of KZbin. BTW, I paid nowhere near $20K. Not even a tenth of that, I got a smoking deal, and don't regret it.

[@swanvalleymachineshop]

Lol , so the old '' it's not how big your tool is but how you use it '' thing , myth busted !!! 👍

[@sicstar]

That's not a caliper. THAT'S a caliper!

[@robertginther9248]

Josh, what was the tolerance on the job length? (If it required a couple thousand for the vernier, how many jobs to recoup the cost & still make a profit to buy the groceries)?

[@TopperMachineLLC]

+/-0.005. Tools like this are just part of the cost of doing business. They are taken out of profits. Just like a new machine purchase. This job required them, but now I own them for any future jobs.

[@mikebarton3218]

That’s a whopper, Mr. Topper 😂