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

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

[@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!

[@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!

[@nkelly.9]

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

[@noberet]

Today is the day we celebrate the machinist.

[@kindablue1959]

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. 😲

[@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.😁

[@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 😂

[@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.

[@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.

[@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.

[@josephsawicki9335]

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

[@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.

[@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.

[@Sizukun1]

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

[@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.

[@kindablue1959]

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.

[@dwayneruthig242]

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

[@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

[@walterplummer3808]

Thanks Keith. Getting closer each step.

[@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!!

[@HipocratesAG]

how badass ts that belt sander!?

[@ruben_balea]

You can use it as a treadmill too!

[@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 “

[@dannyl2598]

Thank you.

[@storetrollet404]

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

[@stephenmorgan8510]

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

[@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

[@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.

[@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.

[@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.

[@jackpledger8118]

I always learn something useful from your videos. Thanks

[@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!

[@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 😜

[@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!

[@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

[@phlodel]

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

[@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.

[@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

[@rustyshackleford928]

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

[@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.

[@jackgreen412]

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

[@catfishgray3696]

GREAT JOB, GREAT VIDEO...

[@johnmcdyer7297]

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

[@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.

[@kindablue1959]

He wanted new teeth.

[@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.

[@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.

[@georgewoodzell1315]

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

[@TgWags69]

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

[@stancloyd]

Excellent job.

[@WilliamTMusil]

Hiya Keith

[@RobertKohut]

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

[@melshea2519]

Good Morning Keith! 😊

[@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. 🤞🇨🇦🍌🥋🇺🇦🕊️🇺🇲👍

[@michaelkoch2109]

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

[@patrickcolahan7499]

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

[@elsdp-4560]

Thank you for sharing. Very nice.👍

[@whall6101]

Great video!

[@cameraforchristmas]

Great video. Thanks!

[@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!

[@kimber1958]

nice work keith Thank you for sharing

[@themikebray]

Great job Keith!

[@johncloar1692]

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

[@georgefager3772]

Job well done as always Keith

[@lecnac855]

Excellent as usual. Well done. 👍⭐

[@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...

[@scottvolage1752]

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

[@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!

[@6NBERLS]

Yet another excellent video.

[@scrotiemcboogerballs1981]

Great job thanks for sharing

[@geraldharkness8830]

excellent job well done again keith!

[@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 :)

[@kindablue1959]

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

[@sjmazzoli]

fantastic keith...thank you

[@johnb6763]

Thanks!

[@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".

[@johnrice6793]

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

[@richardsurber8226]

very nice thank you

[@propulsar]

Interesting video.

[@shanewalker9564]

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

[@Craneman4100w]

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

[@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.

[@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

[@isbcornbinder]

God job

[@mattyt9999]

Wouldn't have been easier to remove the handle ands add the extension to the back?

[@bw3506]

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

[@kindablue1959]

He didn't want to have to weld onto the cast iron arm. Someone else already did that part.

[@danielnorman8595]

right off the bat I'm wondering why you just didn't cut off a handle and add it to the back then rewelled the handle? You save yourself a lot of machining

[@kindablue1959]

He wanted fresh teeth on the handle.

[@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!!

[@sunnysaini9475]

gteat job sir

[@kindablue1959]

'inconventional' is an unconventional word. 🙂

[@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.

[@THEIRONWORKER]

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

[@weswright3187]

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?

[@tiagomendes8818]

Sabe demais

[@glennmoreland6457]

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

[@victoryfirst2878]

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

[@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

[@TheUncleRuckus]

For the algorithm 👍👍

[@Poppi2006]

I vote for masculine pink.