Heavy Metal Removal in the Lion Lathe, Making a Roller Stub Shaft From Solid 8" Stock, Big Chips

[@randyhanson837]

Nice work. Keep the chip breaking into those C curls. I'm an old manual and CNC hand myself . Always glad to see someone who knows manual machining. We are a dying breed.

[@구지면흑탄두]

No. I've been operator CNC machines for the past eight years Now I'm in the world of manual machines. Manual machines are fundamental, fundamental, and can never decline. Over the years, I've been questioning why manual machines exist Now that I've experienced both of these, manual machines have to exist unconditionally I think it can create high added value.

[@philipblick8887]

Beautiful to watch (makes a nice change seeing a professional at work) congratulations from Aotearoa New Zealand 👍🇳🇿

[@ccrider5398]

Even on heavy cuts, your lathe SOUNDS good!

[@markchodroff250]

I was a mechanic on forklifts for 50+ years and worked for Clark Equipment for 20+ that old Clark Clipper you own brings back a lot of memories, I used to rebuild those Continental engines and even completely refurbished the whole machine, I was in my 20s-40s a lot of work ,the forklifts switched over to,electric and worked on them intill I was 65 , now retired!

[@bigdave6447]

Get it done right the first time!!!! Truer words were never spoken!!!

[@daleburrell6273]

...that's hard to live up to...

[@erichill5208]

I enjoy watching some heavy turning with big chips. I’m not a machinist by trade. I’m a heavy duty mechanic. I do have a small hobby lathe I picked up used a couple years ago. I have a little fun with it from time to time when I need to turn a little something. So watching you pros whit big machines is enjoyable 👍 cool video

[@whiteyfarm]

I lived in Spooner when I was a kid in the 1950s and one time it snowed in the middle of May and was cold, really cold, on my birthday. The snow stayed on the ground for a couple of days.We usually had a picnic down at the Conservation Station in town on the last day of grade school. That year we all wore our parkas to school and ate our sandwiches in the classroom at Hammil School. I am 76 years old and appreciated your comment about the old. worn out Johnson- band saw that is.

[@OddJobFix]

Freehand inside radius. Love it.

[@TradeWorks_Construction]

That chip pile was insane! You’re drowning in Blue Chips!

[@RG-gk4yi]

Top notch episode. Thanks for keeping us informed about speeds and feeds.

[@randyhanson837]

Keep the feed enough to break the chip, especially with insert drills.

[@KittyDad]

Well, I’ll be dog-gone! Learn a new trick every day!! Makes my week to learn a new thing.

[@allanginger9431]

I was taught to use a four jaw chuck on mill finish products, keep your three jaw for finished surface

[@hacc220able]

Persistence pays off - thanks for sharing

[@darrylmalecki4648]

Great Video Josh that was great seeing the new lathe in action it can definitely take a big cut with that insert !!!! It’s always interesting getting to know a new machine and see what it likes and finding the sweet spot !!! Looking forward to future videos !! Keep up the good work and great content!!

[@metalmansam26]

First, nice job josh as usual. You have popped up on the scene and are becoming one of my favorite channel. Thanks for sharing.

[@TopperMachineLLC]

Thank you. I never imagined this would take off and get popular. Something I never was in highschool. Lol.

[@ronsmith1544]

Great work! Absolutely love machine work!

[@mingthemerciless6855]

That is one well maintained and good looking lathe.

[@GardenTractorBoy]

Great video I really enjoyed watching this project, thanks. The heavy metal removal was cool to watch and the chip were incredible

[@franwilson2097]

hey Josh,enjoy watching you work and I also watch Curtis,you both are quite accomplished machinery operators love the work you both do,then there's Abom 79,all great to watch.

[@elmarqo_3448]

Those were some nice chips. That was fun to watch.

[@steveyoungwirth8574]

great job on all your video i really enjoy watching them I plan on going on the train that you work thank you

[@janudholm]

Thanks for upgrading your lightning, much better videos now. ✌️

[@TopperMachineLLC]

Actually I haven't upgraded the lighting yet. It's on order. Just better camera settings. Thanks for watching

[@edsmachine93]

Nice work Josh. The Lion lathe is a hoss. Very heavy duty. Nice to have Nice equipment. Thank you, EM.

[@thomaschandler8036]

Love your work Josh, looks like the final shaft should be a little bigger for that size roller, just saying...

[@chisdalton9652]

I seem to remember a long time ago a tool company came to us to test out the new ceramic inserts. The cutting came off just like butter scrapings, more to the point though all the heat was contained in the cuttings, quite remarkable even cutting very heavy cuts the job still remained cool. I caring help wondering if such inserts are availed today ,

[@fredboat]

Thanks, Enjoyed the video and humor, Home shop machinist here.later from Hot Texas.

[@kentuckytrapper780]

Now that's some impressive chips, great video Josh, keep'um coming.

[@totalcardetailing2022]

Great job Josh really enjoyed the video. Had a crane for the mill and large. Someone broke into our shop and stole our Yale and tools boxes also

[@MyLilMule]

Video looked and sounded great. Enjoyed the content.

[@shaolinshaotse]

Absolutely wonderful work Josh, love the channel, the shop, the content, and your presentation style. To help with some of the flicker on your slow motion shots make sure your fps and shutter speeds are set to a multiple of 60 - Thanks so much for all you are teaching us!

[@TopperMachineLLC]

I'm using the GoPro at 240fps. Not sure what is going on, but will keep working on it. Thanks for the kind words.

[@rosewhite---]

I was making and balancing rollers 60 years ago. I'd have made a push in piece about 4 inchs long with one side turned to the stub shaft sizes. Then I'd weld the 4inch end into the tube and drill about four 1 inch holes round the tube to fill with weld to ensure the piece didn't flex and loosen.

[@TopperMachineLLC]

I had this discussion with the customer. They didn't want it done that way, that is why I did it the way I did. Do what the customer wants, not what you know is right. Thanks for the input.

[@rosewhite---]

@@TopperMachineLLC I went into Time and Motion and was amazed at how fiercely so many people ignored what was best to what they knew!

[@mabmachine]

Love those chips, that Lion is impressive.

[@tristanhali8252]

really like your videos mate, please keep them coming!

[@nunomiguelrodriguessilva3028]

Really impressive. Thank you for sharing.

[@seamusbolton215]

Love seeing the new lathe in action Can I make one suggestion, it would appear to me that if the part is not failing where its been welded or joined to the tube the problem is the shaft is too thin where it runs in the bearing and it needs to have a larger diameter with larger bearings, just my 2 cents Thanks again

[@TopperMachineLLC]

They have been failing everywhere. Not just the shaft. The last one I did is working great so far, but they adjusted everything in the system. It's always been one end. By going solid, we are hoping to rule out weld fatigue. Unfortunately they can't increase the bearing size. I suggested that the first time. There is one more method to try that I was just made aware of by a friend. He had a similar situation and finally came up with a solution that works. So if it fails again, that will be the route to go.

[@imysteryman]

@@TopperMachineLLC seems to me the roller large diameter is to far away from the bearing.

[@TopperMachineLLC]

@@imysteryman I agree, but I have to make it to the specs the customer wants.

[@mikecabral1579]

I would agree that is a nice saw.

[@ValiRossi]

Nice chips. You should play a heavy metal song like that Kennametal ad that shows up all the time. :)

[@deanehill9730]

Liking your videos and camera shots are just great. That cutter sure can carve off some metal in a pass. Thanks for the video.

[@TopperMachineLLC]

I could have used a different tool. I was cutting good, but it definitely could have been better. I could have been able to take almost an inch total with the right tool. Thanks for watching.

[@radketim]

This is like a more sophisticated red green show

[@jamiebuckley1769]

a1 bud on your camea angles and shots. you are a really good down to earth good gye machinist and i really love your channel being a home hobby machinist with a 14x40 precision lathe and a 9x49 bridgport mill and a 6x12 harig surface grinder and all the stuff to go with machining at a home leval basis. thanks josh thumbs up to you and your channell.

[@rodneykiemele4721]

Excellent video, very enjoyable. Thanks a lot love the new lathe

[@alwynlinde9574]

We made rollers nearly the same size as yours , only difference we never welded the shaft on outside plug. Never had a problem . carried one ton plus fabric.

[@TopperMachineLLC]

This one is the idler for a steel screen, about 300' long. I think they said it was 3-4 tons. I hope this is the cure.

[@danielpullum1907]

Good Job!!!!!!

[@bcbloc02]

Nice chips!

[@mikeduhm5325]

Made plenty of those rolls for McDonough rollcases. Always ran the shaft all the way through. Taper lock with a weld on hub worked very well on shorter( 4' or so rolls). Must be a metric bearing with the odd sized dimension ( close but larger than 1-15/16"). As for the weather, 4-5 years ago we had over 3' of snow and cold on tax weekend in the Stevens point area.

[@d.graydraftinganddesign361]

I also sometimes use my Johnson outdoors.

[@ghl3488]

Hi Josh, I've just come across your channel and enjoying your back catalogue, some big stuff going on there. When I was doing my apprenticeship ( in a coal mine) we had a compressor that was rated a 6500 CFM, 4 of them actually, 2 on duty, 1 on standby and the other in maintence. Each of them was as big as a house so I had a little chuckle about your fan being rated at 3000 cfm. Looking forward to going through your videos.

[@TopperMachineLLC]

Those had to be awesome compressors. Big difference in CFM when you consider pressures, if you don't factor that in it seems way off. My bathroom fan is 145 CFM and my trailer air compressor is 60 CFM, yet totally different outputs. I'm glad you found my channel. I hope you enjoy the old stuff. The new stuff is getting way better with every video.

[@iancraig1951]

Good stuff Josh

[@johnrenk2672]

Nice job. All you need are a couple steel ducks, they love chips.

[@leopold7148]

awesome video Josh! Film quality really increased! 24:22 POWAAAAH! maybe a chip of the week candidate? cheers, Leo

[@donteeple6124]

G Morning Josh, Weather here in Northern NY sucks too....snowed 2x last week, still a cpl of snowbanks hanging on.....ABSOLUTELY LOVE your new Lion lathe.....my PM 1440GT is a light weight compared to yours, but does serve all my needs. Slugging that roller with the solid stub shaft looks like it will more than fit the bill. Just too bad you dont have the freeze fit capability a la Kurtis @ CEE Australia. Excellent content and skills in filming and production above and beyond the machining. Keep up the great work.

[@KittyDad]

Wow, that was some incredible chip making!!! :))) I wonder what the tool tip pressure had to be….

[@daleolson3506]

Great video👍

[@pearidgefarmer]

I got an old johnson too.

[@bostedtap8399]

Steel isn't getting any lighter 😕, yes looking forward to seeing your take on a machine part crane? New lathe working very well, long may it reign 🦁. Interesting failure mode on rolller stub shaft, I assume the bearings are a self aligning type? Great work, and better photography Josh. Thanks for sharing 👍

[@TopperMachineLLC]

I ordered a rolling gantry since I'm struggling to get free time. Been crazy busy this year.

[@routeman05]

lollollol....."Not bad for an old worn out Johnson". I find myself saying that exact same thing a couple of times a month.

[@Bob_H]

All old worn out Johnsons could use a little support. OK how many bad dad jokes can we make?

[@ЖелезнаяЖизнь]

В этот раз качество видео было намного лучше чем раньше ,спасибо ! И токарный станок действительно очень крутой💪

[@Randysshop]

Hi Josh, the video is looking good and the new lathe is cutting with ease. For big turning jobs you could use a chip conveyer. LOL Have a great weekend.

[@workingovertime4429]

G’day mate just an idea for the crane jib I would sling the winch to that till I could get the overhead crane going

[@edwardswiderski4137]

I hope you're able to document your crane as I am going to be doing one in the next 8 to 10 months and any inside information would be greatly appreciated great content

[@TopperMachineLLC]

Actually I ordered one as I'm running out of free time for these projects.

[@andrewshoebridge1673]

Great work, buddy. In my opinion, if room available I'd go for 4" split bearings so much stress in a short space.

[@basbh1782]

Be careful with sparks with the rust inside the rollers I know of a paper mill that had a rust dust explosion on a roller during a repair. Dude had career ending injuries glad to see you using coolant when cutting

[@carlkulyk366]

That’s where Keith Fenner’s chickens went!

[@mfc4591]

Nice chips

[@mikesmith2696]

Did you try c1045 it works well and if you weld on it post heat it after it colder off up to around 450f

[@dannywooster8166]

Watching on 6th May 8pm first cool night here mid north coast of NSW Australia 11c

[@TopperMachineLLC]

We are finally getting above 50 during the day here. Been ridiculous trying to get outside time.

[@bigdave6447]

April,when do B adgers come out of hibernation? You do nice work!

[@swanvalleymachineshop]

Good one Josh . The new lathe seems to be doing it's thing fine . I would fit a larger size coolant pipe for a higher flow of sud's to keep that smoke down . 👍

[@TopperMachineLLC]

It's performing better than I had hoped. I don't think more coolant would curb that smoke. A lot of heat coming out of those chips.

[@haroldparker3487]

Did you really cut .50 per pass, I'm impressed.

[@jameswood7712]

When I was learning to be a machinist it was said you should never chuck rough stock in a three jaw chuck it would damage the accuracy of the three jaw scroll .you should always first turn rough diameter stock in a four jaw chuck?

[@xl000]

Times have chanhed. Chucks are better made those days

[@philliplopez8745]

You don't know chickens until you have lived with chickens.

[@tjbennett7281]

Man that Lion lathe sure can hog through that material!!

[@glennmoreland6457]

Good

[@davids.682]

Good work Josh! I've repaired some broken roller journals also. If I can make a suggestion, try to have absolutely the shortest small diameter shaft extension before the bearing center position (where the balls are). This will have the biggest effect on stresses and breakage. I like the radius and taper transition to help distribute the stresses (NO SHARP CORNERS), but the closer you can keep the bearing, the better. If it uses pillow block bearings, try to maximize the roller hub length and mount the locking collar or setscrews toward the outside. Even that 1/2"-3/4" will make a difference.

[@TopperMachineLLC]

I've tried to talk them into redesign on this one and they just won't go for it. I have a few options that would fix most of the issues, some you suggested, and some of my own. Just have to do what the customer wants.

[@isbcornbinder]

Perfect

[@ellieprice363]

That Johnson is a work horse. I used one for twenty years with no problems. The only things we ever changed was the fluid and blades.

[@TopperMachineLLC]

Same here. I have no idea how much steel this thing has cut.

[@hobtink]

Welding & machine shop I worked at in high school 72-74. By my senior year the bios was sending me out on jobs alone. He had came across a scrap metal dealer that made him a heck of a deal in some 4” diameter cold rolled steel PRE-WWII that he had already bid on and was awarded a job that our machinist needed the steel to complete. The bar was the main upper drive for a sawmill built some time after WWI. THE ROUND STOCKBWAS ANOUT 25 ft in the overhead and the floor a dirt floor was littered with sharp sections of angle iron, I beamChannel and other sharp angle cuts of various pieces of steel sharp ends up. There was about 2.5-3 ft between the roof rafters the pillar block bearings and the roof. And, to top it off the under roof area had hornet nests the size of huge beagles with hundreds if not thousands of huge orange and brown hornets buzzing about. It was the middle of a hot Mississippi summer and all of the ceiling planking was largely rotten so I could only safely step and stand on joists areas which I had to find through about 1-2” of sawdust and dirt dust. The round stock had about 10-12 huge pillar blocks and 4-6, 1-1.5 ft diameter 3-4” wide old cast iron pulley wheels for leather drive belts. The boss had told me do MOT cut the round stick which was about 25ft long. Well I got the rose bud and cutting torch head and pulled about 75 ft of the oxy actyl hose out to get to the overhead that was as close as I could get the truck and trailer to the job. There wasn’t a single can of penetrating spray or wasp and hornet spray in the truck. So I headed to the business office to see if they had any wasp and hornet spray I could have or buy from them, nope. You got a water hose I can pull up there with me to put out any smsust and sawdust fires that started or do you care if a fire starts and the old building burns, no to the water house, yes to caring if the building burned as he had also sold the shiplap and tongue and groove 109 year old virgin heart wood cypress to someone else. So I went back up to heat the nuts and bolts on the bearing caps to try and get them free to lift the shaft out to what I don’t know as there was nothing yo rig to that wasn’t rotten in the roof itself. While heating the nuts in the bearing caps I was continuously having to roast hornets that were getting entirely too interested and too close to me and stopping to snuff out fires. So I rolled up my oxy actyl hose and head back to the shop to tell the boss. He called me a few insulting name then I asked had he went and looked where the round bar was and no ability to rig to anything. He said no, I said well you need to go look. He called me a few more insulting names and said I just get the other crew to go get it. I heard him tell them not to cut the bar as he needed the full length uncut. Well a few hours passed before the other crew a welder and his helper pulled up to the shop and the boss said you get it he said yeah but we damn near burned the building down and the scrap yard owner was pissed. About that time the boss headed to the trailer to see the prize purchase and find it in 3-4 ft lengths. He went ballastic and other than knowing he suffered from high blood pressure it was s as l most comical as that welder told him the same thing I had told him to include that he would need to hire a small crane or trackhoe and coordinate with the man that was buying the lumber from the building and wait until he disassembled the rotten roof and use the crane or track how to lift the bar and the flat pulleys probably near or exceeding 2 tons from the ceiling it was mounted on to get it in one piece. The welder was not neatly as easy going about the bosses insults that he threw at me as I was as a teenager. 25-30 ft of cold rolled 4” pre-WWII sterl bar he needed in one piece that was brought back in 3-4 lengths. LOL.

[@Tahimate]

I thought for a moment that the roller was a solid piece and heavy.

[@williamhoward8319]

railroad jacks used them for lot of odds and ends

[@wendell454]

Would they be anyway you could use bigger bearings so you could make the shat bigger

[@WireWeHere]

7:32 Tappity, tap, whacking the tube 90 degrees from the pinch points can distort the tube enough to free the core... when it feels like cooperating.

[@graeme8755]

Josh I have one small comment, at the 11:30 minute mark the rear roller (of the steady rest) is not touching the work.

[@MICHAEL-ys3pu]

You best go back and have another look and this listen to what Josh has to say this time. 🇦🇺

[@petegraham1458]

Nice work ! I am a retired engineer my first thought when you were explaining the failures and the period between them was “ the roller is flexing and causing stresses concentrated at the shaft to vertical intersection”? You were way ahead of me , next is see how long it lasts with the cone to distribute those loads across from roller to bearing? The next question is now the bearing is going to have more load if the shaft is more ridged ? You may want to advise them to replace the bearings and monitor the temperature?

[@randyhanson837]

My thoughts were that there was a sharp corner where stress would be concentrated. A generous radius with a very fine finish would prevent the propagation of surface cracks leading to failure.

[@bigdave6447]

That cut would scare the man from Down Under!!. Blue #6 chips is a heavy chip,no steelwool allowed!

[@philliplopez8745]

Did you ever consider trepanning and parting ?

[@oldiron4135]

I may be wrong, but that seems like a ton of money just to put a shaft in something. Way back, when we made big augers,, like 18" diameter on flights by 20 foot long, we did them in 3 pieces minus the flights. The tube the flights got welded to, a big sleeve that went in the end of tube, then a shaft that went into the sleeve, then it was all face welded. The sleeve, was just a thick walled tube they happened to find was like a .003" press fit. With that sleeve, we just had to bore it out to large diameter of shaft, if i remember right, about 5.25" in diameter. I think it was 10" long. The shaft that went into tube was obviously 10" long but hung out for the bearing another 10" or so, bearing side diameter of shaft I think was a tick over 2". When shaft wore or broke, mostly wore out as it was over 3800 pounds, we cut the welds, pulled the shaft, made a new one, slid back in, welded and back out the door. They really thought about any easy way of replacement when it happened, and lasted for some time.

[@kwinterburn]

Just seeing this , from the picture the failure was a stress fracture , the usual way of doing this is to use a length of round bar axle the right diameter through a plate with a length of axle inside to a plate so there is no weld at the stress point it's inside the drum , it's how roller shutter rollers are made and the ends don't drop off them

[@ronwilken5219]

Hi Josh, that machine sure can move material. I'm not sure if its possible but can you drive both the x and z travel at the same time. I know you did it manually but can you use the auto in/out of both axis to get your curved face. There's probably some logarithmic sequence involved so it might not be possible to have a curve as you've done without CNC. Would a 45° "shamfer" achieve the same stress relief. What I'm suggesting could be done if you can drive both axis at the same time. Just a thought. Camera work's definitely improving.

[@nickthorp1624]

at 29:57 if you slow the playback speed down you can see the cutting tip glowing red hot, I wonder if there was a coolant feed coming in behind as well as on top if it would make any difference? catching up on all your videos :) like what I'm seeing so far tho, keep it up

[@MrArtVendelay]

Thrilled to see you take out your Johnson. It is impressive and should be taken out regularly for sure.

[@hiscifi2986]

My first thoughts are that the design is faulty. For an 8 inch roller you should have 8 inch bearings. Trying to use 2 inch bearings increases the loads by 4 to 1.

[@gregarioussolitudinist5695]

It is not safely Spring in Virginia until May 15th, we have had more than one severe snow storm in May, and the danger of Frost is not safely past until May 15th. Virginia is a southern State compared to Wisconsin.

[@StuartsShed]

Sorry for the late comment - in the video you end up at a “3/8 depth of cut”. Just curious - that is 3/8” on the radius of the part per pass - i.e. 3/4” off the diameter each time?

[@SillyPutty3700]

Do you have a way to check that the 2 spindles are in line or true to each other?

[@TopperMachineLLC]

No, that is always something I think about but they are in floating bearings, so should be fine. The customer found severe adjustment issues and has corrected it.

[@robhawthorne6892]

They give you the whole tool, use the whole tool….😉

[@mjk8710]

Hey Josh don’t be worrying all seems good sir! Golden videos of the one’s that I’ve watched keep this sh1t up sir!💯👈🏻🇬🇧

[@aintskairtolskol9520]

take a piece of shim stock and cut out a H in the middle of it,your chips will fall in the pan instead of the floor, the top f the h you will be able to see your part take it on and off as you please thats one tip for you,the second tip i have is never use your hands i dont think they are really shaving hooks ,i had to fast foward the video because i didnt want to see you cut a finger off, the tip of my thumb never grew back if that tell you anything

[@KittyDad]

Does all the chips get recycled or something? Seems like to me at least so much good material had to be cut away.

[@willydoitbettydont9100]

At 26:36 and other parts of the video would be a great sound effect in a science fiction alien movie. Machine is working well.

[@BrucePierson]

The weather sure is crazy lately. Here in Australia, we've just had the wettest summer in decades, with severe flooding in the Eastern states. A couple of years ago, it was a bad drought, with terrible wildfires. Who knows what will come next. There's no stability anymore. Hope your weather warms up for you soon.

[@TopperMachineLLC]

Today was the second warm day. Last night we were ordered a total fire ban. Not even a campfire. It is so dry and windy that forest fires could easily happen. So, now I can't even play with my steam engine. 😭