Producing Extremely Thin Wall Parts ---Made Easy

This video will show you a technique for producing parts with extremely thin cross sections. By thin, I mean less than .015 with extreme accuracy. When conventional machining won't get the job done, this technique will. Take a Look.

[@davecross5317]

Damn Joe! I LEARN more watching your stuff than any other source. Please keep it up and keep explaining the why’s and not just the results! Btw, you should sincerely consider doing a machining 101 kind of dvd set. I’d get in line in the cold and rain to buy it.

[@adsomelk5130]

Damn, man! I passed off a job about two weeks ago, to another guy, after getting down to my last pass and it slung out of the chuck. It was almost the exact same set up, same material and everything. I got so mad when I scrapped it I gave it to another guy. Man I wish to god I had seen this before they gave me that thing! Was one of the most frustrating days of my career. BUT, anyhoo, awesome video as usual, too bad I was late on watching it.

[@bro7269]

Boy, I envy you guys that have rigid, accurate machines and sharp tools.

[@joepie221]

Things we take for granted for sure.

[@oddjobbobb]

How in the world can there be 24 people who gave this YT a thumbs down? I mean, for crying out loud, what could they have found offensive, irksome, or a waste of time? This operation was more, pure magic. Thank you again, Joe.

[@tabaks]

Kids these days...

[@rustypanels1917]

There are losers out there, thumb down to everything. It's them, not the video.

[@harryhopkins7798]

Thanks Joe, I know this is an older video but just want to say I am a hobbyist that enjoys making stationary engines. Your channel has taught me many helpful things. Love all the tips on how to make small pieces! I am only KZbin trained but your video's make me feel like I am in a classroom!

[@joepie221]

Thanks. I'll take that as a compliment.

[@cameronmccreary4758]

I used to encounter parts similar to this one and I would machine the inside first then fill with Cerrosafe a Bismuth alloy which expands to the bore and then I would machine the outside diameter to size. Finally, I melted the Bismuth alloy from the bore and then I had a very accurate and thin walled part with no chatter or other anomalies.

[@toddk.5873]

Thanks Joe. I watched this video for fun the other day & by coincidence I needed to make a couple of 0.015" walled x 7/16" aluminium bushings the next day to tighten up some slop on a motorcycle clutch lever housing. It worked like a charm. I just wanted to say thanks again.

[@Critical_Path]

This was a super informative video. I have had issues with parts of this nature in the past, and this technique would have totally worked, I bet. Thanks for sharing! Really love the Joe Pie academy here. Crazy heaps of clever, simple solutions to common issues. Spectacular, thanks for being willing to share this knowledge!

[@joepie221]

Glad to pass it on. Thanks for watching.

[@c0ulter]

Joe, your not only awesome at machining, but your a great teacher as well. Out of all the other channels I watch, you take the cake in both departments. Thanks for putting your knowledge out there!

[@screens1979]

Fresh out of the Marines in 1969, I worked for a Czechoslovakian owned job shop in Boulder, Colorado. They had a job come in, super thin wall and they figured it out. I remember them talking about it, “You can’t sneak up on it, you just have to go for it !!” I think the customer was Coors Porcelain and the material was brass.

[@FrugalFlyRodder]

Awesome, I'm new to metal lathe turning, and I've been looking for someone doing this exact technique. THANK YOU!!!

[@joepie221]

Glad it was helpful!

[@peteramor9810]

Yet again the master demonstrates in way that can be understood by everyone Really look forward to your videos Joe Even thought i was a fitter turner for over 50 years you manage to teach me something every time It's the simple things that can make life so much easier You take care Joe and looking forward to the next one Pete from the UK

[@joepie221]

Thanks for watching Pete.

[@pairdocs]

That was fantastic. I've been looking for a way to make a thin custom bushing. Kudos! from another seventy-something.

[@MrRatkilr]

Been machining a while and learned something new. thank you.

[@Idontwanttosignupist]

Awesome. I had to make a 5mm to 1/4 collet sleeve yesterday and remembered this technique. 27 thou thick - easy.

[@joepie221]

Glad it helped.

[@MichaelLloyd]

I'm just a beginning hobbiest but videos like this one are extremely helpful for letting me know what is possible. The lathe you were using, or at least the lathe that was shown at the very end, was different than what I've seen you use.I'm looking for the "turning small parts" video. I've been very successful with screwing that up :o)

[@johntenhave1]

holy dooley! When you put the dimensions up, I thought this is simply not possible. Had I not seen it for myself, I would still think it was an impossibility. Pucker factor and education 10/10! Great video from Pie university. Thanks again Joe.

[@joepie221]

Glad you liked it. Have you watched the 'Extended small diameter turning' video?

[@johntenhave1]

I did, Joe. I could not believe what I was seeing there either. But I believe it now!

[@PlayAtYaOwnRisk]

Thank you so much for what you do and the time you put out to help all of us.

[@mertonsilliker4858]

Joe, if I did not see this myself, I would not believe it.

[@Rich1ab]

Great lesson! Joe thank you for passing on your experience. Clearly, logically organized explanations. To the point and on time like any excellent machinist exp

[@ChrisB257]

That Joe was impressive! I rather hope I don't need to make quite that thin a wall! Keep the great vids coming .:) Thank you.

[@Freetheworldnow]

I wish I could see the same demo, but this time using hot rolled steel!! Great video and great lesson.

[@ThePsiclone]

Watched this yesterday with no idea I'd ever need it. Then today happens and it saved me a lot of hassle. Had to make two screw on aluminium spacers M12x1 on the inside M14x1 on the outside leaving bugger all in between. Worked a treat. Thanks Joe!

[@joepie221]

Outstanding.

[@novaman68]

I have been following most of the machining channels on KZbin for the past 5 years, and I can say without a doubt that I've learned more from you than all the others combined. This video helped me to solve a problem I've fought for a long time. Thanks and keep up the good work!

[@douglasschwind9905]

Joe, you have made a world of difference in my understanding of work holding. You are sharing more practical machining techniques than any other posters I have viewed. Thanks a lot.

[@joepie221]

I've been in customs and prototype my entire career. I enjoy the challenge of unusual part geometry in both the machining and fixturing. So far, so good. Thanks for watching.

[@cmguitar50]

Just did this to make a 6mm ID /.250" OD bushing in brass for an encoder pulley. The ID was a tad small, but after I split the tube, it fit great :) THANKS FOR THIS GREAT VIDEO!

[@rickveren5502]

Great to have your videos to educate those that are hobbiest like myself but love the trade. I used your guidance to machine a brass sleeve for the tailstock on my jewelers lathe. Almost the same wall thickness of .010”. It worked great! The draw in bar was about .010” smaller than the tail stock casting and I was considering boring it out for a meatier bushing. The problem was it’s hard for me to justify modifying such an iconic old lathe. So I figured I’d give this a try and see if it last. It will allow me to use the tailstock with a small precision as a drill chuck and keep center as I feed it in. Btw, I tried to sneak up on the final size and it didn’t work to your point. So awesome that your share your skills and knowledge. Truly grateful 🙏 Have a blessed new year Joe!

[@joepie221]

Glad to hear all ended well. Happy New Year to you as well.

[@brianlewis6208]

Amazing, I have been watching your videos for a while now,you are a good teacher,keep them coming. Brian Lewis.

[@richardcox3485]

Wish I would have seen this about six years ago, had to install new steering bushings in my lawn tractor, I tried to make them but did exactly what you said not to do (sneak up on it) oh well only 46 cents a piece at the time but of course 6.50 for shipping lol. Joe you always explain things so well. Thanks.

[@teslacoolguy]

I used this technique to make a part with a .020" wall thickness and it worked excellent. As always thanks for the great informative video.

[@robguyatt9602]

Hi Joe, I do a lot of machining Acetal. Great to see many of my techniques are shared by an expert and even greater to learn new techniques. I make go/nogo gauges for measuring production parts due to the difficulty of micing thin-walled parts. I use HSS mostly but I recently busted another small HSS boring tool. So I thought why not try grinding an old 3/16 solid carbide endmill. OMG, it's great. I take heavier cuts than ever and I can't imagine ever busting this little bugga. Yeah ok, I ain't holding my breath LOL.

[@SasquaPlatypus]

Thanks Joe! There are a couple of your setups that I use all the time! Keep em coming!! My favorites are when you show work holding for difficult parts.

[@sharkbaitsurfer]

You're a true Guru and you just won a new fan! Subscribed

[@joepie221]

Thanks and welcome to the channel.

[@HughButlerTallahassee]

By coincidence I'd been thinking of a project with a thin wall like this; a cap to repair the end of a small flashlight. I was foreseeing all the disasters that would happen when I tried it, but after your video I walked out into the shop and turned out of PVC pipe. Right on the button first time out. THANKS!

[@pedalcarguy]

Boy, was that an eye-opener! Thanks for sharing this, Joe.

[@patdenney7046]

You're a real Machinist wow first time I watch the channel

[@daveknowshow]

I needed this video two years ago. I successfully made the part but there were many failures to get one part successfully. log this in my bag of tricks thanks for another great video!

[@buildmotion1426]

Ha! I’ve likely done this goofing around but not on purpose. I feel like this channel is adding to my confidence to open my own shop. Keep’m coming, I feel like an apprentice all over again.

[@dougalan5614]

What an awesome demonstration! I need to make just such a part, and this will help immensely! Thanks again, Joe.

[@joepie221]

Nice. Good luck.

[@wallacesaan]

A really great technique, clearly explained and demonstrated (as always!). Thanks very much.

[@markrichardson239]

Awesome Joe!!! Did a job a few months ago, and if I had seen this before I did it, it would have saved time. The trick is pure common sense. Get the bore in, maybe do a test cut to establisish your OD cutter... And go for it while you still have rigid stock. Love it!~ Thanks Joe!!!!

[@cmguitar50]

Love it! I wouldn't have thought of doing this until I saw the video.

[@SirFlibbertyJibbit]

Good techniques. When turning and boring thin walled PTFE the best way I've found is to have a high depth of cut on both ID and OD. I use a vacuum with the pipe mounted on the cross side to suck up the swarf.

[@joepie221]

Thats slippery stuff to hold securely. I like cutting it.

[@keithscott9774]

Now that's a great technique, and so simple (when you know how). Thanks very much.

[@joepie221]

Glad you like it!

[@jmriph2354]

Just used the technique to make some 1.5 mm cross section x 30 mm thick tubular features in ABS to size in one shot, Thank you Joe!

[@joepie221]

Way to go.

[@AlisRIOSteff]

I just blew this exact type of part in my hobby shop, this is just the video I needed thanks for all your knowledge!

[@corysell6048]

Nice video. Learned this technique from a tool maker I worked with years ago but haven't had to put it to use in quite some time. We broke a punch from a progressive die that had a point diameter in the .075" range by about 1" long. We had a blank in the spare drawer but the tip needed to go from 3/16" dia down to .075" for the 1" length. Using a spin fixture and surface grinder, he took the diameter of that punch (which was M-2 hardened to 61/63 RC) down in one pass. Ended up with just a little taper from the grinding wheel breaking down, but got the die back running.

[@dcw56]

We used to call this using the material as its own fixture. Works great. Neat episode, Joe, as usual!

[@esosoteric362]

Thanks Joe. Very useful technique for making thin walled displaced cylinders in Stirling engine models. Keep up the good work.

[@grahamlongley8298]

I have just been directed to this vid because I have 2 of these to make in delrin with 1mm walls & 80mm long* 28 diam, tomorrow & did not have a clue how to do it. Thanks for that.

[@TonyLeach-airguntech]

Would have loved to be your apprentice Joe, you have possibly the best educational machining channels on YT.

[@joepie221]

Thank you. I have taught many apprentices over the years. Good group of guys.

[@davidwootton683]

Thank's Joe, I have used a similar technique when making hole cutter's for hardwood hole plugs. You machine (M/Steel or S/Steel) from the inside to the outside but only put the bevel on the I/D. Then you cut the teeth. If you have the correct profile you end up with perfect holes and plugs. Thanks for sharing this with us. Kind regards David.

[@AdmitthatijustdiditX]

Wonderful video, I had planned on doing multiple spring passes, but your video clearly demonstrates why that would likely be impossible, thank you for sharing this.

[@AdventuresinFabrication]

Just the opposite of the way I would have thought to do it but once you explained it, made total sense. Thanks.

[@ScottGMerritt]

Excellent, Joe.

[@RoboCNCnl]

Great trick ! I would indeed think to creep up to it... also the pilot stopping for the chuck ! thanks for sharing !

[@davidwootton683]

Thanks Joe, This is amazing! This is one for the books. Many thanks and greetings from Africa.

[@joepie221]

I always enjoy knowing where my material is getting watched. thanks for checking in.

[@yankeemachineworks6115]

This is a very good and valid technique for making parts with this kind of dimension. Ive used it many times to make cylinder bore liners and the like. When you think about it theres no mystery...the thin wall part that you are making is actually the "waste" from your turning and boring operation. With some practice it will work wonderfully.

[@joepie221]

You bet.

[@billcooley5527]

Both the thin wall and the small diameter are just killer ideas. great great great I would have turned down the work because I couldn't sneak up on the number. Wonderful technique! Thank You

[@frankhoose]

Another great video, Joe. Thanks.

[@alexwood020589]

That first plunge with the drill! So satisfying. Awesome technique man. Love the videos.

[@JacobSkriver]

Haven't machined any parts for years but this technique was so impressive!

[@joepie221]

Thanks.

[@jimmyboles3409]

Great tip on the application of very thin parts I really enjoy learning your tips and tricks , from your years of experience a lot of knowledge there 👍 Thanks joe👍

[@joepie221]

Thanks, I see your channel is extremely new. I hope you consider hitting the Subscribe button someday. :)

[@tim9lives]

You’re the best Joe. Really appreciate you passing these tips on to us. Thanks again.

[@James-fs4rn]

you definitely know your stuff Joe and have one of the best channels on KZbin imo! I have inserted a pin in the bore if a skim on the OD was needed and had success. Thanks again and keepem comin. Happy holidays to you and yours!

[@zumbazumba1]

Many ways to skin a cat!(wonder who eats the cats thou ?Maybe that saying came from china)

[@mosfet500]

Thanks Joe, always enjoy your videos. I drilled a 4" plus hole 1/8" bore in a 3/16" piece of 303 stainless. I used a Royal 5C collet in an Austrian lathe.

[@hadcat1]

Nice job! Another way if this does not work is to finish ID and fit a slip fit solid plug inside....Then turn the OD...The plug method is the only way when working with Nylon or Teflon. The behavior is certainly different on thin stuff.

[@clemwyo]

Thanks for a great technique. I had a part similar to the one you made that gave me fits. Now I know how to do it. Sure appreciate all the great tips you share. Craig

[@HawaiiGoesFishing]

Very impressive! Your thinking behind the process makes a whole lot of sense. It's obvious after you demonstrate it. I was wondering about making lens shades and adapters. Now I know.

[@pierresgarage2687]

Hi Joe, You're so right about the approach "Get it right as fast as possible", always worked for me, the hardest one in this thin walled case is UHMW, the chip tends to stay around the part more than the rest of other materials.... Pretty wastefull way to fabricate Beer cans though... lol

[@infoanorexic]

Pierre, we know you can take care of the "waste." By the way, any luck in recovering your missing ingots???

[@cylosgarage]

That was amazing! Great tip joe 👍

[@toddsorensen6504]

What a great teacher you are, Joe. Thanks for your willingness to share your knowledge and experience. I don't suppose you'd like a seventy-something year-old apprentice, would you?...

[@joepie221]

Only if shes 5'10, blonde and well preserved.

[@toddsorensen6504]

Well, I guess we'll both have to keep looking. Wrong gender, what hair's left isn't blonde, not so sure about the preservation. OK on the height, though...

[@gilbertodiaz-castro626]

As always a great video. I know you have a full schedule with your company but perhaps you should become a machine shop instructor at the local community college, many would appreciate it. You don't only possess the knowledge for it, you have the wisdom of how to explain things to make them Lieutenant-Proof... Even an old gizzard like me can learn with you as instructor. (Lieutenant-Proof is a term that comes from when Gen. McArthur was having trouble getting the lowest man on the list to understand his exact original orders so he went and found the dumbest guy he could find in the field, made him a Lieutenant so he could be the "General's Aid" when this guy was able to explain to him exactly what he wanted his orders to convey those were the words used to send the orders down the pipeline.)

[@CO2isplantfood]

i watched this video and had to try this for myself. i used yellow brass, aluminium, 316 stainless and 4140 and was able to get wall thicknesses as low as .008 with some practice. I really enjoy all of the videos you are producing , keep them coming!!!

[@joepie221]

Outstanding.

[@Gottenhimfella]

Just occurred to me that, using stainless, this could be a good way of making a non-standard "Speedi sleeve", or a standard one in an emergency.

[@MrKidkiller159]

crafty guy you are joe !!! awesome! !

[@benkeller3]

AS usual I learned something... Thanks for your Videos Joe...

[@adhawk5632]

Wow, that technique worked perfectly 👍👌🇦🇺

[@joepie221]

It really does.

[@armdaMan]

Hello there Cap'n Wow !!! Was on the edge of my seat. This is superb and a perfect diameter to boot. Definitely usable in our turnings. Like the other Gent says, would be nice to see how U do very small diameters Thanks a zillion for showing and sharing ATB aRM

[@joepie221]

I am editing that small diameter video at the moment. It should post in the next day or two. Stay tuned.

[@jacekbielawski31]

Thank you Joe, you are an inspiration. You are not only demonstrating how, but also explaining the reasons in such a pedagogical way in many of your videos. Greetings from Sweden.

[@joepie221]

Greetings to a fellow "ski" from Austin Texas.

[@netkev92]

Good shop class. Looking forward to the thin parts video later today.

[@Harrzack]

As always - a great learning experience watching a machinist’s machinist at work! I just wonder how you get the time to keep that large shop running AND have time to get these very helpful videos done. ⚙️🛠

[@TadTadd]

As always, I love watching these videos. Like any good instructor, you always teach other details as you are progressing toward the main point. Besides a cool thin wall turning technique, I also learned the simple way to line up my parting tool with the end of the work, using the scale to feel for the edge. I have always used a magnifier to do this visually, but I will try your way next time.

[@CalvinEdmonson]

Smart machining as usual. The other day during lunch I made a small tube for an elderly neighbor to thread line through his wind chime tubes. Drilled a .059 hole 1.25 deep in .375 brass ( I knew the brass would be easy to work). Then I took .300 deep cuts at .090 on the od until I had a 1 inch tube with a 3/8 head to grip. Worked out well.

[@tobydulanski9480]

In honorable mention Dead Sharp Tools that have never seen any metal on Delrin and Teflon. Thin walls can be tricky in milking as well. I use HSS and always CONVENTIONAL CUT as not to suck the wall into the cutter. I make filler blanks for thin metal walls that are .010” . Planning is everything as Joe points out in many of his videos.. As always thanks Joe!!!! 🙏

[@jimmilne19]

Wowzers! Great technique. Quite impressive procedure. Another super video!

[@MrWeelzupamc]

Joe I can't wait to try this. I have a motor coupler in need of a.0125 sleeve. Is gotta be stainless 304 ( food). Thanks for another video expertly presented, giving us the confidence to jump in the deep end of the pool. I've agonized about how to approach this for days. Now I'll look like a hero. Cheers!

[@AgentWest]

Hey Joe. I just watched an episode of "Supreme Skill" (a Japanese TV show) and immediately thought of this video of yours. It would be interesting to see you make that part using the technique you show here. The part is 20mm OD tube with a 60 degree flare to 50mm OD on each end. The whole thing is roughly 60mm long and is made of one piece of material. Wall thickness is 0.3mm. You chose the material, no need to go all out with titanium like they did :) Don't think youtube allows links in comments any more, but if you search for "Supreme Skills! Turning vs. Spinning" it would be right at the top.

[@30000hp]

Love your work. Thanks for sharing your knowledge, today I used one of your tricks in some lathe work. It worked like a charm. If I ever comes to Austin, I'm coming to checkout your shop and buying you a beer. Good job sir. Keep those tips and tricks coming.

[@joepie221]

I accept. My 2 favorite beers are....Free and Cold. Either will do.

[@patricksullivan9951]

Now that was impressive!! Thanks for the tip!

[@conwayjames1]

Just seen your videos on turning and I am truly impressed with your work, truly wonderful to watch and I hope this is some help to you, great work and great to see how it's done.

[@joepie221]

Thank you.

[@martyscncgarage5275]

That was awesome Joe! Thanks for the great tip.

[@donaldvantongeren8385]

Hi Joe, thanks for your always very informative video's! Strangely enough I was looking around for a piece of thin walled plastic, when I you showed this! Going to my shop now :-) Kind regards, Donald

[@clifffiftytwo]

Fascinating - great video. The parting by hand was also new to me. Thanks!

[@joepie221]

I had parts just tear into a million pieces when parting thin wall. Taking a little extra time is money in the bank.

[@ianmacpherson2409]

Hey Joe. Thanks for such an informative episode I always learn something from your work.

[@grayskwerl4973]

Amazing technique to watch - but it makes great sense, and evidently works very good. + Thanks +

[@whatif8700]

Fantastic video as always Joe. Most of us recognize that in this instance, pullng the chip away with your fingers while the spindle is running is not a serious hazard. However, when cutting metal it can result in serious injury. Given that many viewers of your videos are new to machining, perhaps an edit to include a warning would be in order.

[@joepie221]

Good call.

[@johnreese3943]

Joe, thanks for another great video. I used your technique today to make a thin walled bushing. Without the bushing I would have had to remove the apron from my Nardini lathe to reassemble the feed clutch. The bushing allowed me to hold a thrust bearing in place during assembly.

[@joepie221]

Great. I hope it helped you.

[@legesupra4275]

can you make a video on how to make that sharp cut off tool ?

[@joepie221]

Use a regular parting tool and just put a very aggressive nose angle on it. Make it pointy like a threading tool but leave one side flat. That the side that establishes the length of the part.

[@billherreid9661]

Wow! This is super impressive. I'd love to also see counter examples demonstrating what happens when you get it wrong: start with the OD or take multiple passes.

[@TAWPTool]

Yet another great video Joe Pi! Thanks for furthering my machining education.

[@marcellemay7721]

My take on the keys to getting this to work. Use a very sharp tool, HSS is great for this. Bore the inside first. Take the outside cut all at once. This works well because the material that you haven't cut yet , in front of the cutter supports the thin part at the cutter. This is the reason why you cant take a second pass, as there is no support material left.Did I miss something? Great tip!

[@joepie221]

No, your observations are Spot on!

[@SpencerSkelly]

Fantastic technique. Your videos are great, thank you.