Horizontal Boring Mill: Cutting a Spline on a New Blank End for the Cross Slide Lead Screw

[@markobeck6927]

Hey Keith, one small correction. That was not a "Quick and Dirty" . That was a well planned, well engineered, and well executed repair.

[@canuckloyalist4681]

Nice to see somebody give vintage machinery the respect they deserve instead of sending them to the scrap yard!

[@richardsurber8226]

Not a machinist, but that operation of producing a shaft and cutter to finish up that spline was well worth the price of admission. Thanks Keith

[@johnmcclain3887]

I've been working this trade since the late sixties, had to transition into "digital" in my last years, and have been working out of my own, small shop, retired for over a decade. It's good to see old machines, big ones, being set back up, put back into working condition. I left a shop of that size a couple decades ago, with similar age machines, and four new CNC machining centers I helped set up and put to work in one of my last jobs. That shop has been around about a century, contrast between the old and new reminds me of my youth, when the old was older, and the new is now old. Thanks Keith, nice work.

[@aarongarney2118]

Mr. Rucker. You’re a gosh darn national Treasure!

[@deathk26]

For those in the last video saying the tool needed to be offset in the arbor so the leading edge was centered on the shaft, see this video. It doesn't matter in this case because the resulting offset from center is so minimal. Nice work Keith!

[@paulcopeland9035]

@Current Batches So, do you feel better now?

[@horsepants5848]

@Current Batches unnecessary and a bit nasty

[@erickieffer8440]

@Current Batches This man fits producing these episodes into, probably, an already busy life and I’m sure many find this a rewarding educational experience which extends beyond just running a machine, such as how to behave like a gentleman.

[@cschwad559]

@Current Batches he doesn’t usually need to do work that requires tremendous precision. Do not say beware to anybody about such a good man as Mr. Rucker

[@Stupha_Kinpendous]

I've never used a lathe in my life, but holy shit, I want one. I could watch stuff like this all night long. Love your channel.

[@allangoodger969]

Late on a cold and very wet Friday winter's night on the east coast of Australia. Enjoying your video.

[@RobertBrown-lf8yq]

Me too.., 👏👏👏 Regards Robert (Sydney)

[@nivlick]

Me too bitterly cold here in. Redcliffe Queensland.

[@allangoodger969]

@@nivlick you would have to be beter than 10 deg at Jervis Bay mate.

[@grntitan1]

You Aussies don’t know what winter weather is. But I’m ok with you pretending. 😂

[@allangoodger969]

@@grntitan1 yep but we do know what a week of 45deg C feel like

[@jackpledger8118]

The interesting part is coming up...the weld up and turning to final dimensions. Can't wait to see that accomplished.

[@BedsitBob]

Whatever that steel is, it machines to a beautiful finish.

[@erickieffer8440]

Thank you for making these episodes repairing vintage machinery, you’ve inspired me to attempt the same.

[@wwtrkr3189]

I am not a machinist so watching your good self and Abom79 in particular, is educating me as to what's possible. I'd never come across a horizontal milling machine until you got yours. Never seen a dividing head until you did your restoration and never seen one used in anger until about 30 minutes ago. I never really considered just how certain parts are made before a couple of years ago when I found your channel. I started by watching your Wilton vice restoration. Now, you're number 1 in my subscriptions watch list and I always look forward to your new content. I've had to give up my own workshop for the time being. Needs must and everything has gone into storage for a year or three while I live in a semi-truck and get something permanent sorted out, so these videos at least provide a vicarious satisfaction I miss from not being able to build and restore things myself for the time being. This was one of the most satisfying videos yet. I actually clapped when your single point cutter made the first cut. It's been weeks coming since you first showed us your problem and I'm just thrilled to see this one coming together. Very, very well done, sir. I laughed so hard at your "quick and dirty" comment. This is not "quick and dirty"; this is a fine engineered repair. I tip my hat to thee. Stay healthy, Keith. It's good to see you back.

[@MikeBaxterABC]

16:30 AWSOME set up Keith ... I'm not one to give out random praise, and I'm often kind of critical, BUT this machining project and the set up?? You are making the horizontal mill do tap dancing!! LOL I love it! .. Great job!!! you make it look so easy, and frankly, it's not that easy :)

[@jimzivny1554]

That high speed steel did a great and yes the load on all 3 sides would be considerable. Nice job

[@rickpalechuk4411]

Worked perfectly Keith, good call on the single point cutter. Cheers

[@billrotundo7814]

So glad you are at 100% again. Have a great day!!!

[@buidelrat132]

Bravo on the efficient creative process! Gorgeous result. Thank you for the high speed shots with multiple cameras angles! Hooray horizontal milling machines and custom cutters!

[@Daniel_cheems]

The horizontal milling machine is a life saver!

[@organbuilder272]

Interesting process Keith. You are certainly correct in the statement - If you need it - make it. That is what machine shops are fore - invention of fun tools and things they can make. Thanks for the show, Keith - educational.

[@railfan439]

Thanks for the video, Keith. Glad you are feeling better. Sorry you missed the Bar-Z Jon

[@williambramer8217]

Nice video as usual - looking forward to seeing the horizontal borer in action

[@thomaschandler8036]

Keith, you're the man. Only person I know that can run a spindel counterclockwise and the cutter going clockwise.... Like in the Westerns, the wagon wheels always run backwards. Enjoyed...

[@FunkFPV]

That’s a cool little work around 👍🏻

[@adeeponionbrah]

Nice move roughing it and creating a one tooth cutter. Flexibility and innovation.

[@dermotkelly2289]

Good job! Takes me back a bit.

[@grafixbyjorj]

I was just reading about gashing last night, and lo, Keith gashes the splines before applying the single point finishing form cutter

[@FredMiller]

Great video Keith. I have a small horizontal mill and never even thought of making a single point cutter (great tip). I liked your approach to the overall repair, and I have done that myself. When I can I turn a small indexing and guide pin into the new part and then bore a hole to receive the pin in the main shaft. It is a helpful aid when welding keeping everything aligned. Looking forward to the next video. Keep up the great work,, Fred Ontairo, NY

[@elsdp-4560]

Thank you for sharing. Enjoyed.

[@tinkmarshino]

Always a lot of fun Keith..

[@The_DuMont_Network]

Keith, in your spare time... I would love to see an in depth demonstration of the index head. History, manufacturer, etc. What a wonderfully complicated piece of gear! Can you imagine calculating and laying out the hole pattern before computers (and likely before slide rules...)?

[@ellieprice363]

Short introduction. Most index heads are geared 40/1 reduction and supplied with five or more hardened index plates. With the correct index plate an infinite number of divisions are possible.

[@Jeremy-iv9bc]

It's not as complicated as you think.

[@The_DuMont_Network]

@@Jeremy-iv9bc Pray expand...

[@wwtrkr3189]

Check out his restoration of this dividing head. It's buried in the collection somewhere. He does his usual strip down to component parts and excellent explanation.

[@johnsherborne3245]

Fair comment, but a quick google and slide rules are supposed to be invented in 1622, I’d have guessed at Napier, but I was wrong. In its time I found slide rules could do a pile of things a calculator struggles to do, but I’m no Luddite, I was saved by calculators, after all they like slide rules, are no better than the idiot operating them.

[@jeraldware1518]

I enjoyed this. Would like to have seen your grind set up for the cutter and the finished/installed piece. Thanks and please keep posting!

[@StreuB1]

That wasn't quick and dirty. That was literally the correct way to do a custom one-off like that. Well done!! And you didn't need a flexarm, gib crane, or a new kaeser air system to do it!

[@oleran4569]

Keith actually could use a nice crane though!

[@bigtrev8xl]

Nice work again Keith 👍

[@jeffo881]

great series, keep going.

[@johncloar1692]

Thanks for sharing

[@oldschool1993]

Waiting to see how the threading works on an interrupted cut- never tried that before.

[@mdouglaswray]

Neatly done!! Great angles on the video too. Thanks Keith, can't wait to see the final assembly, sure it will be mint.

[@RASAllusion]

The welded attachment point you describe at the start of this video has me picturing a tapped inch or three and then a threaded inch or three shaft to twist in-and then weld the outside. It will be interesting to see your actual attachment point strategy.

[@mgsperformancerc]

was thinking something similar. Possibly threaded/loctited/cross pinned. Not sure if that's more or less work than welding but I'd be worried about warping that shaft doing a weld.

[@RASAllusion]

@@mgsperformancerc i think leaving extra material is great experience in play to account for heat issues from the weld. Your point there about the heat is a good one. Say the stock used was too short for such a threaded end we are talking about… well, what about a tapping of the part being repaired as well as a tapping of the repair itself and a threaded rod mating the two prior to the weld? This would help with truing it, strength, and cut way down on the heat/weld issues all while adding improved strength. I tend to over build, cuz I really do not like Re-Work. However, i submit that in this example,the damage being repaired was from a moving of the equipment. This to me represents a unknown danger zone, plus already attempted repairs add another layer- like what kind of heat and cool has that steel been thru already? A flux core weld or some such puddle maker will surely mate the repair to the damaged end, but it just seems to me that high end specialized tasks like this one need as much or more finesse than brut force. Aye, a couple more steps it is to add this idea into the build, but totally worth it, imho.

[@mgsperformancerc]

@@RASAllusion yep agreed. The extra to true the repaired part is fine but the original part could warp. I’ve watched Mr. Fenner straighten shafts so it can be fixed either way I suppose. Mr. Rucker knows his stuff too, I have confidence in his approach, maybe in my case it’s more indicative of my own confidence :)

[@RASAllusion]

@@mgsperformancerc absolutely!! He has talents well beyond mine that is for sure. My lathe is a dewalt in a vice and a die grinder 🤣😂🤣😂😂. Looking forward to seein him finish this upgrade repair. As an aside, i was thinking about the threads that exist from the former repair. I find myself pondering a type of castle nut there that would mate with the turning tool. Be well.

[@jamesupton143]

Good morning. Always look forward to your videos.

[@iangriffiths9840]

Are you going to machine a hole in the back and a spigot on the main shaft to aid alignment?

[@ydonl]

Spoilers! Patience, sir. :)

[@floridaflywheelersantiquee7578]

Nice job thanks for sharing

[@rjkee5157]

What about those threads on the original? Were they part of the old fix?

[@shadow83blk]

Just an idea from watching Cutting Edge Engineering attaching new hydraulic ram rod end eyes. In order to align the new piece with the lead screw before welding maybe cut a spigot on the mating end of the new piece and bore a hole for a slight tight fit in the cut end of the lead screw. Then press the spigot of the new piece into the hole in the cut end of the lead screw and it will then be closely aligned for welding. Just a thought that you may already be planning to do.

[@CraigLYoung]

Thanks for sharing 👍

[@kentuckytrapper780]

Another great video Keith, keep'um coming..

[@timziegler9358]

Keith you do excellent work! Best wishes.

[@SciPunk215]

That looks great !

[@lesmansom7817]

Turns out that Keef can count to five👍😎

[@kaydog2008]

Keith did you machine an alinement pin on the weld end and center bore in the shaft? 🧐

[@RB-yq7qv]

Keith I do hope you are do a bore a female peace into the for the cross slide shaft and a male on the new part and a 30 degree edge for the weld to have maximum strength. The male and female fit up will ensure go alinement and the correct gap for welding.

[@InverJaze]

That was fun!

[@johnalgar4747]

Love to see quality machine being repqired and restored. That what they were meant for. Buy one, and keep it maintained - it will last a lifetime. Long before some bright spark cottoned onto "planned obsolescence" and creating a throw away culture. Sad. But thanks for your videos!

[@The_DuMont_Network]

I'm 75. I just finshed using my Grandfather's table saw, jointer, and an actual table jigsaw. And his bandsaw with the big Woods Open Frame motor. Which, I might add, has never been nor needed rebuilding. If you care for your tools, they will serve you well for ages.

[@johnalgar4747]

@@The_DuMont_Network So true. @Doc DuMont. With everyone these days complaining/commenting on waste, single use this & that destroying the planet, and they're right, maybe we should go back to making things that are maintainable and repairable. Cheers.

[@rickswanberg4995]

No, it will last several lifetimes if cared for.....

[@MatthewTinker-au-pont-blanc]

It is an ideal way to do the job, entirely in house!

[@johnlee8231]

Good solution to a one time problem

[@robinmartin4464]

Nice job Mr. Rucker. I am glad to know there is more than one way to skin a cat, on a budget.

[@premierd8988]

Turn a sigot on the shaft .. drill the splined replacement part with a corresponding bore .. slip together and it will be true .. now weld ..jobdone ....

[@curtisvonepp4335]

Show your welding process

[@ericmiller5559]

Keith, I have a handle that might be similar to the original for that. How can I get you some information?

[@StanislavG.]

btw Keith, you do not have to weld it, i think silver soldering it would do the job just fine without all the fuss

[@HipocratesAG]

This is soo cool!!

[@briansmith1514]

I'm assuming that the splines are not as deep as the final diameter of the smaller shaft end given you turned it larger than the finished diameter?

[@MadMotorDoc]

What became of the steam stoker engine, last I remember it was going to Florida for some milling? ???

[@mathewmolk2089]

Yo Keith. Like the single point tool solution. (I did that for a bevel gear I repaired for an old Buffalo Camel Back) - You got machinery that I couldn't even dream of....Maybe you might want to look at a tool and cutter grinder. HGR in Euclid Ohio has KO Lees come up all the time (Got ours in pretty sad shape for $140. (Got it working fine now) I even got a powered work head there for $80 and do small ID/OD grinding on the KO. ... Check it out. You might even score a Brown and Sharpe #3 universal. You can grind your own lathe spindles on that thing. (I have seen them there for under a grand) Keep up the good work, though. Cant Waite to see the Lucas making chips.

[@clydedecker765]

Keith, I follow an Australian Machinist at Cutting Edge Engineering on KZbin who has bought a machine he needs info on. Can you help? Its a 1950s-1960s era Kitchen and Walker Type P1 Horizontal Facing Borer machine. You can see it on his website. It purpose is so "out there" I can't imagine a manufacturer making one.

[@truracer20]

It's more likely that the 1.560" shaft is 1-9/16"(1.5625") nominal than being metric which would be a very odd nominal size at 39.624mm.

[@johnsherborne3245]

Wasn’t the bearing a metric part number,? even in 1918 SKF would probably have made metric and imperial. It’s a curious thing but the worlds oldest standardised thread system was metric, based on even older Swiss metric system. Whitworth devised his system based on the mechanical properties of the available steel which is why they are a bit agricultural and chunky.

[@lnchgj]

Are you going to drill a hole in your part and a corresponding knuban on the old shaft to align the two parts concentrically before welding?

[@dzarren]

Why no cutting oil for most of the cutting today?

[@dcviper985]

But how do you reticulate the splines?

[@Ambidexter143]

I love the precision measurement: "I'll go a tad bit more."

[@ydonl]

Precision sharpie. :)

[@patrickcolahan7499]

Seems as thought the spline cut depth into the diameter should have been to the final diameter of the smaller shaft diameter? Once you remove the additional diameter material to final, won't the spline depth be higher than the smaller shaft diameter? Maybe it is an insignificant amount and it is so hard to tell on videos. Thanks very much for sharing. Always learn something new when I watch your videos.

[@oleran4569]

Look at 1:45 in the video. The tool seems to have plenty of clearance.

[@nobuckle40]

The single point cutter worked beautifully. Could you have used a longer piece of HSS and ground the profile on both ends?

[@ydonl]

Uhm... oh! To turn it into a double point cutter? Think about... how to make the ends exactly the same shape (by hand, at the grinding wheel... ugh!), and how to get them perfectly aligned in the boring bar. Arbor. Whatever. It might end up more trouble than it's worth. Single-point cutting as a concept has some strong advantages! Nothing to sneeze on. :)

[@nobuckle40]

@@ydonl Yeah, you're right. it would be difficult. Perhaps grinding it on the surface grinder would help with the accuracy.

[@ydonl]

@@nobuckle40 I think it could be done, but agree with you that it would require some jig-or-fixturing. The alignment would be hard; I always notice that a slitting saw blade always seems to be off-center a little bit, cutting only one side, "gruhn... gruhn... gruhn..." That kinda thing. Doesn't take much off-center!

[@catfishgray3696]

FEITH, TELL EVERYBODY HELLO, PET THE CATS AND DOGS, SEE YOU ALL NEXT TIME...

[@TERRYB0688]

Hi Keith Terry from Scotland, just a wee question, could the hs cutter be made with two cutting surfaces one at each end an perhaps one end a slightly different profile to start the cut and the other to finish the cut ?.

[@henryD9363]

I guess I'm the only person who really wanted to see him put that handle on to show the fit.

[@paulcopeland9035]

Did you listen to the video and learn why it couldn't?

[@MikeSmith-lu2xe]

if the smaller diameter shaft is oversized, how is the bottom of those slots not oversized as well?

[@LambertZero]

Are you going to cut the interrupted thread? That'll be fun.

[@dtoad48]

hopefully he drills a hole in the end and turns down the old end to make a press fit before welding.

[@piperjohn_3]

Clever hack.

[@DaleDix]

That's pretty flash.

[@juz4kix]

Why not weld it on first to guarantee concentricity?

[@debeeriz]

could it not have done on a vertical mill, seems a lot of work went into making that bar

[@ydonl]

The arbor is general purpose; I think this was just an excuse to finally make it. :) So he's wanted it before, and will want it again. Anyway, more tools is always good! Come to think of it... does he ever use a vertical mill? I don't remember seeing any wimpy Bridgeports around... maybe I missed it.

[@tacticalrabbit308]

That part looks like an input shaft on a manual transmission

[@nashguy207]

Keith whats up with the stoker engine?

[@paulcopeland9035]

YES!!!! I knew there would be one!

[@nashguy207]

@@paulcopeland9035 LOL I am curious I live in Nashville and am looking forward to taking a ride when the steam engine is finished.

[@vaalrus]

This is giving me deja-vu… I had a 50’s swather that snapped the spline off the the drive end of the shaft that transferred power to the swather head. Not having a mill, we cheated, and using our worn out chinese baby lathe drilled and tapped the ends, threaded them together with a stud, and welded the whole works together.

[@robertbamford8266]

Interesting. A question: I know it’s unnecessary, but (how) could you square up the ends of the castle grooves (If it were wood, chisel)? An end mill would just leave vertical curves. Just curious.

[@ellieprice363]

In wood a chisel as you guessed. In metal an electrical discharge machine (EDM) with shaped plunge type electrode would work but very expensive.

[@tiredoldmechanic1791]

I'd have made that piece to thread onto the original then weld it. That might be your plan too.

[@johnnyholland8765]

I like making stuff "new again"...

[@garyrhodes7089]

Just my opinion but when a part is to be welded you need to know what steel it is to avoid potential problems

[@WobblycogsUk]

They must have really been cranking on the handle to break the original, good work on the fix though.

[@RASAllusion]

It submit that kind of damage happens during transport. It sure aint called Heavy Machinery for nuttin. :)

[@lesmansom7817]

I don’t see the need for welding Can you not machine the original part to take the new part and pin it together? That would be the period correct repair. I bet you a penny it would take no longer. It’s only operated by hand at that end. I love your content old mate.

[@bobsandone3108]

What about the threads shown on the old part? They're not needed?

[@Bobs-Wrigles5555]

They're needed, they lock the thrust bearings in place, but you must be patient grasshopper, it has to be welded and turned true and to final dimension before that thread can be cut. maybe next episode or the one after😉😁

[@RobertFay]

*- Makin' what ya ain't got. Might probalee be cheaper than buyin'.*

[@RobertKohut]

Looks "spline" to me... 🙂

[@MHolt3573]

I hate when he drags the tool back across the work. I know it dont hurt anything but it bothers me.

[@mongomay1]

interested if you use kURtis CEE Aus joining method DOWNSIZED