Horizontal Boring Mill Restoration: Milling an End Spline to Repair the Crank Handle

[@dgr8t1]

I want to congradulate you on your weight loss journey! As you've lost weight it has become more visually apparent. I hope it continues to be a true blessing to give you a healthy and prosperous life ahead!! and as always thank you for the amazing content!!

[@glenc90240]

Gotta love the sander power switch without a cover!

[@thisolesignguy2733]

At first I thought "why not just cut the handle off, weld on the back of it, and weld the handle back on?" or "why not just make a piece the full length and weld the handle on that?" but then towards the end, I saw that that's steel and the handle is cast iron and then I had a AH HAH! moment lol. Nice job Keith!

[@kindabluejazz]

Band-Aid should do a sponsorship of all the machining channels. If they put their logo on the bandages, they'd get screen time in practically ever machining video. 😲

[@lodkathree]

Hello Keith, I love your channel and the learnings that come from it. The reason I am commenting is to request please, please, wear safety glasses when you are using machines like the lathe and belt sander. You are a mentor for many people and it would be best practice to set the best example for everyone. The last thing we all want is a video lamenting a visit to the emergency room. You only get gifted one set of eyes. Thanks again. Cheers Lodkathree.

[@bcbloc02]

Cutting pie pieces with squares is surely a challenge but you got it done!

[@passenger6735]

Painting the really useful tools yellow! Sooner or later you have a workshop full of yellow tools, and you're back to square one. That was an excellent demonstration of cutting angled splines on the dividing head.

[@nkelly.9]

Sir, you are an extremely clever and skilled operator. Thank you for sharing.

[@rw3dog]

Nice work. That is some serious math figuring out the 7 slots and the dividing head etc. Thanks for sharing.

[@petegraham1458]

Good lesson on how to make a complex bit of geometry with old school manual machining ! You make it look easy, however I know it takes lots of thinking and time with tables and calculators to get this sorted !

[@peterhobson3262]

The number of engineering hours spent calculating the dividing head circles must have been massive.

[@Barnagh1]

All the work involved in making this small part puts me in awe of the original builders of the machine, long before digital readouts and all the modern aids.

[@paulleffers8217]

and all made in inches. . . .

[@Farm_fab]

Keith, speaking of painting your handle yellow, a teacher who taught at the same school as my mom had lost a contact lens on the floor. My dad, some time later, mentioned to her, that if she had painted the lens red, it might have been easier to find.😁

[@michaelkoch2109]

Really good work! Best regards from Dresden! I am already looking forward to new videos! 👍👏❤🛠🇩🇪❤🇺🇸😎

[@josephsawicki9335]

Wow The way you do math on the fly is impressive Thanks for another great video.

[@edsmachine93]

Great job Keith. Thanks for sharing the process. Can't wait to see the HBM up and running doing the first job. Take care, Ed.

[@benhancock1408]

In order to simplify things a bit, I think I would cut the original sleeve and add a piece in the middle. That would retain the splines you already have, and making it a bit longer would give you room to re-cut the splines in the future if you ever need to.

[@silasmarner7586]

I think his end result (deeper engagement) was perfectly served by his technique.. The splines already needed cutting deeper at the outset.

[@scowell]

Then I would have missed a dividing head lesson! I think the new teeth are better anyway.

[@artszabo1015]

I personally agree with you but that would require two welds increasing the likelihood of misalignment. So technically I agree with Silas Marner on this one. Art from Ohio

[@Henning_S.]

But the old splines didn't fit as well, it seems like someone just milled 7 wide slots with parallel sides instead of the slots with 30degrees included angle.

[@rizdalegend]

My first thought, but then this channel is about doing things differently with a dash of education.

[@junkmannoparts9696]

Hey Keith nice job this reminds me of making a knee 9 spline on Bridgeport mill Mr Pete had a video on how to thanks . JM

[@Sizukun1]

A coat of yellow would match those oiler caps! Nothing wrong with making a tool you're always looking for more visible!

[@evanharriman5352]

Great job as always, Kieth! It’s fun to watch you do so many non-critical “measurements” in one video.

[@davidmitchell7791]

That was a hard one to get my head round 😂

[@RutherfordRyan1]

Great machine Keith and a good man operating and repairing it. How about 4 of these handles around your Lucas…? Less wear on each, hang them around all sides. Thanks for your website and all your videos

[@SciPunk215]

The issue with the handle not clearing would drive anyone crazy. It's great when you can identify the problem and make a solution.

[@dwayneruthig242]

Nice job, Keith. Always fun to see you use the dividing head.

[@BigLapua]

Keith, I just LOVE your videos, the production is great. When your vid pops up, I settle in for about 30 min of great stuff at breakfast. I aspire to do the stuff in my shop that you do. Keep it up!

[@walterplummer3808]

Thanks Keith. Getting closer each step.

[@bulletproofpepper2]

Thanks for sharing. I was so lost there for a moment but my little brain finally caught up to what you were doing. You explained it perfectly I just didn’t get it, but seeing it made it clear. I had one of those “ that’s so kool moments “

[@bobaloo2012]

It looks like your surgery is working well, it's sure nice to not hear you wheezing every time you move. Hoping to have you around a lot longer.

[@HipocratesAG]

how badass ts that belt sander!?

[@ruben_balea]

You can use it as a treadmill too!

[@jackpledger8118]

I always learn something useful from your videos. Thanks

[@davidapp3730]

Nice job on the crank handle. These days it would have to have a spring to push it out of engagement for safety. 100 years ago you were responsible for your own safety.

[@dannyl2598]

Thank you.

[@keithburton7516]

That would have tested my brain, I cut wrongly if I have to turn things upside down. I would have had many cups of tea before I was sure what to do. Many thanks for your content, I enjoy watching them even tough I do not often use such machinery.

[@byronwatkins2565]

At 27:00, the needed y-offset is R sin(15 deg). If the I.D. is 0.8", then y = 0.4" sin(15) = 0.1035". The other side will be -0.1035".

[@sblack48]

The view at 2:00 looks like the cab of a locomotive to me. Which tells you all you need to know about how much I know about locomotives 😜

[@jdmpilot8001]

Couple of newbie questions. 1. When your talking about taking 0.100 off of the diameter, do you fee in 0.050? Do you do the math in your head or are the lath markings setup to allow for the difference in in-feed and diameter? 2. What do you do with all the chips and shavings? Do you sweep them up or use a magnet or what? By the way love your content. Thank you

[@storetrollet404]

Those increments with the dividing plate! Wow - so impressed with the way you kept track! Thank you for sharing!

[@robertsmith4788]

Quite a complicated little project Keith. Thanks for sharing and doing such a good job of explaining the math needed. Bob

[@artszabo1015]

Yeah, somewhere between math and magic, at least to me it was. Art from Ohio

[@stephenmorgan8510]

I love watching as these old machines get put back together.

[@paulkinzer7661]

I would sure need to do a lot of studying to be able to use a dividing head, especially for something like this! Fascinating!

[@noberet]

Today is the day we celebrate the machinist.

[@edwinfriedl2446]

when you were wondering what the material was on the cylinder part. The sparks from the belt sander would have given a clue especially as they were being ground off anyway.

[@Stefan_Boerjesson]

As always, well done, well filmed and edited. Just built and verfied a digital control of a rotating table. 7 steps would be no problem as well as the 15 degree adjustments. A little Arduino UNO, a stepper driver and motor.... 39:01

[@silasmarner7586]

I mean this unsarcastically: You should video it it in action and put it on your channel since I see you do indeed have a channel.

[@Stefan_Boerjesson]

@@silasmarner7586 Thanks! The video recording equipment is either the cell phone, impossible to hold during milling, or a Go Pro hanging in strings, but I'll consider it!

[@patrickcolahan7499]

Fun project with a valuable end product. Thanks for sharing.

[@melshea2519]

Good Morning Keith! 😊

[@jackgreen412]

Always enjoy seeing your approach to and expertise in solving problems.

[@elsdp-4560]

Thank you for sharing. Very nice.👍

[@catfishgray3696]

GREAT JOB, GREAT VIDEO...

[@stancloyd]

Excellent job.

[@kimber1958]

nice work keith Thank you for sharing

[@stevemahrer7097]

Keith, great series, great content. One suggestion, the power switch / contactor on the belt sander has what appears to be open / exposed 3 phase wiring…. Bad idea! I’d suggest a cover plate, before you get electrocuted! Best!

[@whall6101]

Great video!

[@cameraforchristmas]

Great video. Thanks!

[@johnmcdyer7297]

That was a great job Kieth thank you so much for taking the time to post

[@jamest.5001]

Mount a lathe chuck on that thing and a tool post on the bed. And you got one heck of a lathe!😅, Probably not going to have the power needed for heavy cuts maybe mount a external motor, a 5-7hp 3phase with vfd should do it. Spin zhe chuck with a 8:1 reduction cogged timing belt. It would be interesting if nothing else. Growing up we made do with what we had. Often having to make things. Some worked, some didn't. Seems the fun was in trying and solving problems!. I want to build a old stationary, pony/hit n miss, oil field style motor so badly vi can't get it off my mind. I want to start with a pile of scrap, melt it down. Cast the parts and machine them. Weld them until i get a running engine. And i want it to actually be a daily working engin. Used to generate power to charge batteries for my off-grid home. 10-20 hp should be plenty. I'd like to build a boxer two cylinder, a 4"-4.375" bore with a 8" stroke, a engine that can run on diesel or waste oil as well as spark ignition fuels, maybe get a propane/cng tank 500-1000 gallon , maybe use distilled biomass to produce wood gas, or burn used oil , engine oil or cooking oil. After spin filtering . Spin a collection dish at about 1000 rpm inside a bucket with a drain. The oil from a 1/4" pipe running into the middle of the spinning dish. About 8" diameter, 4" tall like a paint can. Having a 1" lip around the top. The oil filling this 1" while spinning. Only the lightest clean oil can escape . It runs out the 3/4" drain to a clean oil storage tank . Attempt to use a 500 or 1500 watt dc motor. With a pwm speed controller to fine tune the speed. It may not require 1000rpm to get clean oil, or it may require a higher speed , and it may require more time at speed to separate the contaminates from the oil. The oil feed speed may need to be reduced to a fast drip to allow seperation time. It could require more like 2000 rpm, and a slow feed rate. Its no big deal to clean the oil. It may also be heated, to possibly 150°f then filtered. Using a head on the engine that can use a plug to raise the compression ratio and be fitted with a diesel injector, or a different plug with a spark plug with reduced compression , 7:1 to 8.5:1 on spark ignition, and being adjustable would be cool. Even if the engine used different heads for different fuels . Would be worth it. Use small engine diesel injectors, with about 20:1 compression. And use either the exhaust or the engine coolant to heat the fuel before being injected. Use a electronic governor for both fuels. Because id probably have fuel in batches for possibly months at a time . Converting to a fuel is simple. Usong injectors for two 10 hp engines running from the cam shaft. And the ignition system running off the cam of the other fuel types. Maybe wood alcohol is produced. And the 20:1 compression can be used with the methanol/wood alcohol, only a ignition timing adjustment may be required, and the engine producing much more power. The rpm will be low . The tq high. Using two 50-100 lb flywheel. ,About 16"-18" dia. Use a dc motor to start the engine. Using a belt drive and possibly one way bearing. The peak RPM would likey be 1500-1800 rpm and normal operating rpm being 900-1200. After some math and figuring maybe 600 rpm would be normal operating rpm, and peak rpm being 900-1200. A 8" stroke is uncommon these days. Id want to use commonly available bearings and valves. Possibly pistons. I'd want a minimum of 4" bore. And 6"-8"+ stroke. I want the long stroke , low rpm. the long stroke should be a quiet engine the ignition long over when the exhaust valves open. The low rpm the engine firing at a slow rate. It should be a quiet engine to deal with , a loud engine running at 3600 rpm all day gets old fast. This engine could possibly idle at 100-150 rpm, if it can produce 500 watts at idle awesome, let it idle all-day. And 2000 watts at 250 rpm, or 6000 wattsat 325'rpm, 10kw at 750 rpm awesomely awesome.. especially if it cant be heard in the house, place the engine inside a building, with quiet car muffler on it basically making it silent while spinning 4, 150 amp HD alternators with it as quiet as a new prius or corolla idling, unheard in the house. The use of a modern 10 hp diesel engine , can produce much noise, even inside a quiet box. Id build a plywood box with labyrinth inlet and cover the inside with foam padding and used carpet. Atleast two layers of each . And still be heard. The thing would shake zhe ground , the boxer being perfectly balanced. Should be smooth and silent!.. sorry to ramble. Its a dream i love building things . I do not have access to the equipment to build my engine.. and definitely cant afford to pay a shop to build it. I gave experience building many engines . Just no equipment to machine them .. have an awesome day love the videos !

[@petemclinc]

Perhaps another way would be to swing the ram 15 degrees on your mill and offset the table in the X axis the required distance then crank the dividing head for the 5 spaces.

[@tomnorman5461]

As always, well done, well filmed and edited.

[@patrickmazzone9066]

God Bless you i have learned a lot from your channel still trying to get a hang on the dividing plate turns to degree you know count holes then move dividers thanks keep it up

[@WilliamTMusil]

Hiya Keith

[@RobertKohut]

Looks like you got a good 'handle' on things.... 🙂

[@TgWags69]

Hi Keith, the name of the arm on your dividing head is a sector arm...not sceptor

[@georgewoodzell1315]

Excellent work, Keith - and a very instructive video. Well done!

[@johnrice6793]

I’m impressed. A most excellent job. You do excellent work. Good on yuh.👊🤜🤛

[@rustyshackleford928]

Keith, this was great. I wanna take you out for a burger my man, you ok? Thanks for this.

[@user3141592635]

A funny thing about English. When I visited the USA, my host asked me about using the word "gonna", instead of "going to". I told him it's the way we are told in television, haha. Yes, I am Scandinavian / Swedish. Swedes does not generally dub films, but they are viewed with text or subtitles in Swedish. An extremely funny example, is in the Movie "Blues Brothers", in German: "Und wir haben Sonnenbrillen !" "And we have sun-glasses". This film was viewed in Germany by a Swede I know. He laughed, because the fun of it got totally lost in German :)

[@kindabluejazz]

Most native speakers of any language will have shortcuts/contractions to common words and phrases. French even formalizes it. Le + amour == l’amour, vois + là == voilà

[@johncloar1692]

Thanks for another steep along the way. Thanks for the effort you put in these videos.

[@PhotoArtBrussels]

As a European it is amazing that people freely chose to work in fractions; 1" 7/8 ... 47.625mm; and at the same time everything around you is decimal. But ... why not, it is a free world! :-) Thanks for all the great content!

[@bw3506]

I was discussing with my wife yesterday about how when I was in grade school (Which would be early 70s) They pushed us hard to learn the metric system because we were supposed to convert to it soon but it never happened. She's a few years younger than me and didn't learn it at all. I liked it and thought it was far easier in all aspects. Guess they figured it was too much stuff to change and too many opposed it.

[@monkeyboy4746]

It's not 1/4 inch, it's 250 thousandths, so we already think in decimal, our inch is our "meter", since they work to the nearest thousandths, they do not have to think in fractions.

[@ellieprice363]

Fractions are strange critters if you’re not used to them. Most Americans learned them in the fourth grade so they’re easy for us.

[@kindabluejazz]

The metric vs imperial discussion is so old and tired. Like 100 years old and tired. When will people understand units don't matter. Any decent machinist should be able to do a job in any unit system. Just get the job done in whatever units you want.

[@johnkingston7244]

As an Englishman I learned all three systems - Imperial fractions, Imperial decimal and Metric. I work in all three quite happily, using whichever system is most applicable, sometimes blending them together. It’s good brain exercise and I like aspects of each one. Restricting oneself to one system only seems a little limiting to me….

[@BedsitBob]

I'd have probably put a close fitting pin through the hole, to keep the two parts aligned, while it was being welded.

[@robertlevine2152]

I believe he did just that. When he was at the lathe he showed fitting the old handle onto the new end. The end stub acted as a chill ring for the weld.

[@darmah1959]

Curious as to why you did not just make a extension on the other end and reweld the handle to it?

[@bw3506]

Sure but then nobody gets the education on how to actually make the splines.

[@darmah1959]

@@ralphgesler5110 The handle looked like it was already welded on, the splines probably needed to be deeper, just wondering why it was done this way as making a round bushing is a whole lot easier.

[@kindabluejazz]

He wanted new teeth.

[@ronwilken5219]

Hi Kieth, that was some dance step with the dividing head. While youve got it set up why not turn another, longer one and make a second handle for the other end of the table. You're also going to need a longer boreing bar. Josh Tupper at the Tupper engineering site just made a five foot one for his different Lucas HBM. Might give you some ideas. Regards from Canada's banana belt. 🤞🇨🇦🍌🥋🇺🇦🕊️🇺🇲👍

[@themikebray]

Great job Keith!

[@scottvolage1752]

Love the Videos Keith. Keep up the good work. Thank you for making the trades great again.

[@buckinthetree1233]

I think I would have cut the splines off, weld in an extension, and reweld the existing splines back onto the extension. Mostly because I'm too lazy to figure out how to cut new splines. I am however grateful you made this video incase some day I need to make one from scratch.

[@johnfriend240]

How many crank handles would have come with the mill? Three would be useful, one at headstock, one for the table and one for the tailstock end...

[@6NBERLS]

Yet another excellent video.

[@richardsurber8226]

very nice thank you

[@shanewalker9564]

i would make the adapter for each shaft with a grub screw to protect the original shafts and to eliminate ware slop

[@sjmazzoli]

fantastic keith...thank you

[@propulsar]

Interesting video.

[@benpress8884]

Love watching you figure out the math and setup of the dividing heads/rotary tables, etc, but wouldn't it have been easier to just cut the splined end off and extend it with some tube stock?

[@paulcopeland9035]

It would be "easier" to not have a hundred+ years old machine to restore! However, restoration is the function of his "Vintage Machinery" shop!!

[@geraldharkness8830]

excellent job well done again keith!

[@victoryfirst2878]

How accurate is this dividing head Keith ????? Keep up the great work Sir. vf

[@georgefager3772]

Job well done as always Keith

[@Craneman4100w]

This is the machine to do that old steam box job, if it's still waiting.

[@LanceMcGrew]

36:05 7/8 REAMER safer option?

[@mgmoody42]

It's only just started and I'm hoping you'll take advantage to make the spine pins longer than what looks like 1/8" on the current handle. Good, .300 should be plenty.

[@lecnac855]

Excellent as usual. Well done. 👍⭐

[@phlodel]

Grinder and paint makes me the welder I ain't.

[@johnb6763]

Thanks!

[@Daniel_cheems]

Looking good Keith. That gastric bypass operation has really helped you shed some weight. Is it the Stoker steam engine that will be the 1st job for that horizontal boring mill?

[@paulcopeland9035]

Who said it was "gastric bypass"?? The bottom line is, that it is none of your business.

[@Daniel_cheems]

@@paulcopeland9035 What else can it be and why do you care?

[@brucewright5061]

G'day Keith, Great video as always. I am wondering why you are not making a 2nd crank handle, so you have one at the front of the mill and one for the back end. Obviously, one for each position would be again causing issues of interference and a serious case of overkill.

[@WesW3187]

I love what you are doing but I was wondering why you couldn’t just extend and bend the handle. Does it create a leverage problem?

[@geneard639]

Great work as always. Now, me? Yeah, I would have sat down, done a drawing, sketched out order of operations, gang machined pairs of cog ends, machined new handle shafts and bent them, lathed out new handle axels and grips, put them all together, kept two, offered up the others for sale and used the money to pay for my parts and labor. I admit it, in weird that way.

[@stancloyd]

You can see where the handel was welded. Make new toothed sleeves the right length, then weld the handle back on. Less work, better crank handle.

[@paulcopeland9035]

*handle

[@glennmoreland6457]

I've a small high speed lineshaft driven radial drill that uses similar handles with a castelation... They were very common... ☹🇬🇧

[@isbcornbinder]

God job

[@kindabluejazz]

'inconventional' is an unconventional word. 🙂

[@ralphpavero7760]

Omg my brain hurts I need to make one myself thank you for sharing BTW is that a HHS end mill or carbide

[@THEIRONWORKER]

Make an extra one of those you will need it on a HBM and you are all setup to do it

[@sunnysaini9475]

gteat job sir

[@garybrenner6236]

Is the Boring Mill ready to go?