Machining Big Holes in thick stainless custom flanges

In this video we machine some custom stainless steel flanges for a research project. We trepann the largest hole and step drill the smaller one, we also do a bolt hole pattern in both.
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[@gav2759]

I know there are plenty of KZbinrs who will always sneer at safety comments, but those dangling hoody laces were giving me the collywobbles.

[@CrimeVid]

Yup, unsafe on a fishing boat or in a workshop.

[@cableup1]

Old boilermaker recalling old boilermaker methods. Layout hole. Carbon Arc party. End grinder with an 80 grit flapper to reduce the ugly from eleven to eight. Hunk of 1" flat CS laid onto flange for mag drill to cling onto. Through drill holes with whatever size gets you there. SS all thread cut for studs. Backweld studs. Lunch / beer.

[@alt-w7130]

Great Vlog, notice you had your hood string loose using your lathe be careful.

[@paultopolski1978]

People don't pick their pets, pets pick their people. Cora is a perfect example of this. You guys are a perfect match!

[@johnschneider3082]

I don’t know if it’s such a good idea to have a pet in a machine shop. Metal shavings and shards are very sharp,the pet could easily get something in a paw, fur, its mouth, or even an eye. I know yah love your pet, but.

[@BruceBoschek]

Trepanning is a very good method, leaving you with a very usable blank instead of a few kilos of chips. I used to really enjoy watching David Wilks in the UK, trepanning "canon bores," probably 30 cm in diameter and a couple of meters long, using internal cooling and a dedicated lathe. Good to see that super DoAll drill press! Thanks for another stimulating and entertaining video. Our GSDs Halgrim and Bella send greetings to Cora Lee.

[@TomokosEnterprize]

I must check this fellow out. Thanks eh.

[@ronwhite6719]

Ahhh drilling, tapping, trepanning and coffee with Steve. Life is good, my friend.

[@SteveSummers]

Hello buddy, I sure hope you are doing well. 😊

[@EVguru]

To stop the large drill wanting to 'walk' and stress the Jacobs chuck, use the boring bar to open a counterbore just large enough for the drill lands to enter.

[@jamesconner8275]

Great show.

[@johnkanaly1242]

Brings back memories of working at EMS and testing parts used for manufacturing of satellite parts. We used chambers that were 6’ square and had to achieve very low vacuum pressures. They had a number of large holes that plates were made to allow us to get test & power cables in and out for different parts testing. Getting them to seal because of the extreme pressure difference was a challenge. They looked exactly the same as yours but I think the surface was more machined so they could seal. Thank you for the memories 😂

[@TomokosEnterprize]

He has that effect on folks. I can relate to most everything he does. A younger me for sure.

[@Streaml1neJMoose]

Congrats, Gramps!

[@waynep343]

I still smile at how nice the shop came out after replacing the wall.

[@petegraham1458]

Cora is a wonderful shop companion! Your both blessed to have connected!

[@garymorgan242]

I am a relatively new to owning a personal lathe but have done some shade tree machinist work be for an been around it most of my life. And I have been helping others with my lathe lately and making a little money at times and nothing supper tight tolerances or anything. but I have never seen a parting blade like that and it will save me a ton of time in the future. because I tend to having a lot of that kind of jobs. and drilling and boring a hole like that sucks on time anyways. LOL even though I still enjoy the time but other things got to get done also. Thank for this video and enjoy your channel.

[@Bigredkarl]

Take the strings out of your sweater if you are going to wear it and sleeves rolled up don't forget safety first

[@mdouglaswray]

Production work! LOVE IT! Knocking em out, gettin those doll hairs.

[@greybeard3759]

Hope everything's OK! We're missing you.

[@scottpecora371]

Every work environment needs a good mutt to complete the feel of a business. An strays make the best because they've chosen you.

[@malliz1]

Thanks Steve I enjoyed that

[@Ideasite]

Steve, you're among the few machinists who seem to regularly run their cuts at sane speeds. I'm amazed at the number of KZbin videos I watch where the machine is screaming at an insane speed. I realize that too low of a speed will destroy a cutter, but I know from experience that reducing the speed allows for a far butter cutting experience. Really appreciate the time & effort I know you put into these videos. Please keep it up & thanks!

[@TomokosEnterprize]

I know there is a formula for cutting seeds. Cutting speed (100 for high speed and 400 for carbide tools) times 4 over 2 (something like that. It's been a long time) but always found it far too fast. Generally the finish and what looks right was the way that worked best for me.

[@frankfreeman1444]

Hello again from Thailand. Cora just keeps getting sweeter. I don't know if you or she lucked out the most, but either way you two are a glorious match! Thanks for sharing her again in this video.

[@matambale]

It's been a while Steve, hope things are all ok with you and yours.

[@stompbox64dtown9]

I am worried based on the tornado on the 9th that hit TN and Kentucky.

[@raymondhorvatin1050]

Thanks for sharing nice dog

[@philipcable437]

A nice example of manual machining. Thanks Steve.

[@Uncleroger1225]

Happy Saturday Steve, Cora, and Grits! Good, basic machining video. Always educational and inspiring. Thanks for sharing, God Bless.

[@bboomer7th]

Thank you Steve. Informative and entertaining. And yes, I do have drill press envy.

[@johnmccanntruth]

That was a nice change of pace for the shop. Happy Thanksgiving!

Parabéns pelo belo trabalho 👏👏

[@crichtonbruce4329]

Saturday morning + Machining with Steve + coffee = contentment.

[@SteveSummers]

😁👍

[@deemstyle]

I know you have to do what is needed at any phase of your life, but as a long time patron- I’m really glad to see some machining again on this channel. I’ve stuck around because I think you seem like a really phenomenal person- the kind of guy I’d definitely want to be friends with- but I’ve really enjoyed your machining content the most. Also- I am so so so very jealous of your DoAll drill press!! That thing is freakin awesome!

[@TomokosEnterprize]

They really are nice and have a great owner that cares for them.

[@mdvener]

Another great Saturday morning with another great video. No machinist here but it's always so interesting to see how parts are made. Manual machining is for me is more informative than CNC. Being a hands on type of guy it's always a pleasure watching you putting a plan together and go for it. We'll done and looks great, so till we meet again take care.

[@chrisjackson9978]

Another interesting video Steve. Thank you. Glad to know Cora has settled in well. Her turning up in need of TLC was meant to be. You have both gained and benefitted from her adopting you!

[@SteveSummers]

😁👍

[@kimber1958]

Great to see you in the shop. Thanks Steve

[@ypaulbrown]

great stufff......cheers from an old guy in Florida, Paul

[@elmarqo_3448]

The automatic feed on your DoAll drill press is great. I stops the feed and retracts the quill at the same time.

[@bulletproofpepper2]

Thanks for sharing.

[@dutchgray86]

I have done smaller stainless pipe flanges with annular cutters in the lathe, I have up to 64mm dia cutters. Works well, better than boring it out. 17/32, got a 13.5mm drill its so close you wouldn't notice the difference.

[@robertschauer376]

The power feed on the drill press is very nice

[@srtautoworkz]

Get yourself or better yet make a spring-loaded tap guide, they're awesome

[@NightsReign]

Did Cora forget her safety supervisor reflective vest at home? 🤔 We won't tell OSHA if you don't. I went through a number of possible applications for these flanges in my head, and since it isn't intended to pressurize, the one that jumps out at me makes me wonder if they're planning a hefe, pilz, dunkelweizen, or IPA. 🤤

[@robertfountain4856]

So good to see you back on the machinery. Let me just say that your shop is looking good with all the banners and signs up. You made the right decision to put in those windows instead of just more blocks. They add a feeling of comfort knowing just what the weather is doing.

[@geckoproductions4128]

neat trick Steve, thanks

[@bearsrodshop7067]

Spray on marking dye,,, great tip. I am back out a little more in my shop this month, and soon will get back on the Big Powermatic drill press restoration that was started before the cancer. It has the MT 3, and have a MT 2 adapter, so will start looking for Mt 2 drills. Nice quick project Steve, thx for sharing, and make sure Kora gets some turkey next WK 👍🤔

[@georgesweap7]

Been a machinist since 1972, I never knew that is process was called trepanning…we always called it circle cutting. How dumb am l! I learned something new today!

[@opticaltrace4382]

Oh Steve, you've really triggered some sort of OCD in me that you've not centred the inner bolt holes exactly between the outer ones! 😂😂

[@SteveSummers]

😄

[@elsdp-4560]

Thank you for sharing.👍

[@josephstlouis]

Thanks for new video! The wrench for 4 jaw chuck is pretty long. With the jaws fully extended I'd suggest the cross handle clear the jaws by 1"-1 1/4". All the best to you and your family. Take care, Chuck

[@erniemathews5085]

Thanks to you, my work is better. I know some things now that really help.

[@justagig46721]

Steve you’re like the Bob Ross of machining! Do not start saying “light happy cuts” though. It’s gonna hit different.

[@TERRYB0688]

Steve one thing I’ve found that work good on both the lathe and milling machine for large holes are Mag drill bits, you need to make an adapter

[@RB-yq7qv]

Nicely done

[@boblister665]

Cora is lucky to have found such a good home. I have worked in auto body and fab work for 49 years but never machine work. I enjoy watching the precision involved

[@glennmoreland6457]

Good video

[@gregdawson1909]

You can make a simple drill grinding jig out of angle iron for use on your surface grinder to even up your cutting edges, we get good enough results to use in a cnc mill. Its just a piece of 1-1/4" angle with an adjustable back stop. its welded at your desired point angle and primary cutting edge relief, and stuck on your mag chuck. Then you give it a finger so you can index the cutting edges. once you get a nice even grind on teh cutting edge you hand grind your reliefs and thin the web. little practice you can get very good results.

[@gavinmclaren9416]

In my shop, those holes would be nipped out right fast with a plasma cutter. No CNC here, just a gear-reduced variable speed rotator that can turn slow enough for this sort of cut. My shop tour for those parts would have included a visit to the drill press for a piercing prior to the plasma cutter. Also, I reckon that I would have straddled the holes on each flange just out of habit, as it is (B31.3) code. However no criticism is implied or intended, Steve! You do you. I did not see a big 'ol plasma machine in your shop that would punch through the inch-plus of an 8" 150# blind flange but your lathe worked a treat treppaning that hole, and I'm sure it was bang-on centered. The loyalty of a stray dog that you adopt, like Cora, is second to none. She will stick with you through thick & thin for as long as one or the other of you is alive. A great friend and companion, and a great shop supervisor. A win-win for both of you in the life-lottery, if you will.

[@bud-in-pa589]

Probably doesn't matter for this experimental setup but by the ANSI standard (B31.1) you would scribe center lines on the 8" blind flanges so that the bolt holes straddle the center lines and then orient the smaller flanges so the their bolt holes also straddle the same center lines as well.

[@gavinmclaren9416]

@@bud-in-pa589 Yup, sounds exactly right.

[@annacalise8336]

I was glad to see you using a clamp drilling the larger holes, can't be to careful and having fingers is nice lol, love the shop dog, beautiful dog!

[@honorharrington4546]

Steve, It is great to see someone treating a drill press with the RESPECT it deserves. I would argue that the drill press is the most dangerous tool in a home shop because of operator error. It is easy to see the danger of a bandsaw, or belt sander, or lathe, or torch. The drill press is 'just' a drill motor in a mount so how dangerous can it be? If they try to drill a 3/4" hole in the end of a 2' section of flat steel with the excess hanging off the right side of the table then they and the Ambulance Medics and the ER Doctors may all get a first hand look at the damage.

[@TomokosEnterprize]

Large radial drills will remove an arm if not respected. Just as these would do. Any disrespect will not be a good thing at all.

[@TomokosEnterprize]

Hey Steve, It's great to see you on the machine tools at home again. It has been some time eh. I always liked to get the 4 jaw chuck off it's rack when I was still working. It is one of those projects that made me think a tad harder. I made a few of multi hpled rounds like these but larger. 29 " as I remember and 25 threaded 1 inch holes. The mating plate that holds the feller buncher head to the stick on the machine. Who ever did the hand on that 7/32 bit nailed it. When both sides are making identical chips you are as perfect as they get eh. I envié you with both those Do-All presses. They are a really good drill that makes them a treasure in the shop and you have two of them. WooHoo, LOL. I was fortunate to have a radial arm drill with a 12 inch post. I can't remember a day it was never used. Old, tired and well loved. I made it into an almost milling machine by drilling the quill and made it able to hold tools with any chattering so that the morse bits wouldn't vibrate out. When the Logging business shut down and the shop and equipment went to auction my heart sank. Nearly 20 years of fixing, Making and building one off things now a sweet memories. It's always good to see you post Steve and I eagerly await what ever Cora the security boss says you can post eh, LOL. Take care eh !

[@SgtCude59]

Cool I think you chuck key looks so cool .

[@SteveSummers]

It's made from a old concrete drill👍

[@CraigLYoung]

Morning Steve 😅 Thanks for sharing 👍

[@kylelawrence5541]

Those old morris twist drill tap handles are the best ever made. Lucked up and found one. Still looking for the A tho.

[@scottpecora371]

BTW Steve, thanks I learned some things with this project. Also when you find yourself in an improvement mood, take those big step down shank drills put it in a rotating Collett and mill a flat spot every 120 degrees and they won't spin in your drill chuck any more.....

[@RustyEast]

This is the type of content I want to see but I will take what I can get 😂

[@salmonforever6088]

Yea Cora!🎉🎉🎉

[@JM-hy2ve]

At the end of the video it may have been the angle of the shot but between the draw string on your jacket and your beard I thought this might be Steve’s last video

[@mathewritchie]

Of all the trepanning videos I have watched this is by far the most recent,it was also one of the least dramatic except for an English shop that specialised in poking big holes into big bars of refractory metal mostly with big annular cutters on old turret lathes with pressurised coolent to push all the chips out.

[@pukkimi]

What channel was that? I haven't got recommendations from that channel for ages.

[@phalanyx3478]

David Wilks

[@pukkimi]

@@phalanyx3478 Thank you!

[@ch4611]

Part of me want to chastise for not two hole aligning those bolt patterns, but not knowing what they are used for gives me pause. I did want to recommend to you, tho, tapping sockets. I got a set from lisle. Take a button-less ratchet add a center, and you have yourself a one handed tapping wrench. One hand on the on the quill lever, one on the wrench. Also made myself a “dead center” with a straight shank that slips in the drill chuck for alignment. Honestly, best way to tap when working off a drill press. Felt like passing it along.

[@tda2806]

We metric guys would call that a 110mm diameter hole, 55mm radius, no calculator required 😄

[@johanneslaxell6641]

What "radius 55mm"? My DRO works directly in diameter 🤭😂...

[@scroungasworkshop4663]

Ohhh, you mean the rest of the planet 😂

[@jakebpau2396]

The metric system...... 7/8ths of the world can't be wrong!😂😂😂

[@scroungasworkshop4663]

@@jakebpau2396 Ha, I’ll pay that👍👍

[@johanneslaxell6641]

@@jakebpau2396 Well, ⅞? That is about 22,225 😂

[@charlieromeo7663]

Enjoyed the vid, Steve. Looks like it’s cold in the shop already. Happy Thanksgiving. Cheers from Florida’s Space Coast.

[@markwood5382]

Cora could not ask for a better family either Steve. She is lucky that you both were meant to be together.

[@teddrosenthal]

Science!!!!!

[@RyanDoesAll]

Steve watching those hoodie strings swaying next to the spinning chuck made me anxious. Pull that string out before the lathe does it for you!!! 😂

[@MeUK-s7l]

Hi from Dorset, UK 👋

[@jamesdrayon8733]

Try using a angular cutter for bigger holes

[@marcellemay7721]

You have a lot of tooling that I don't have. But I have some monster drills that take carbide inserts that'll go all the way up to 3.5". They only fit my 20" lathe tail stock but they've enabled me to whip out some pretty big jobs on my lathe. I also have some mongo carbide insert boring bars, up to 2" diameter and 16" long and tool holders for those. They came as a package when I bought the lathe from a guy. The tooling that came with it is easily worth more than what I paid for the lathe. It's paid for itself in side jobs but I'd like to find more work for it, it's a money maker.

[@billgilbride7972]

Three things... Your lathe is sooo quiet; I'm very impressed by the drill press; and I did not realize how useful slow revs can be at cutting very well. Thankyou!

[@blankroomsoup666]

My concern with trepanning would be that the slug wedges itself as it breaks off and that breaks the tool, side stepping was a good idea. I like that lube you used on drilling, much less mess than oil!

[@johanneslaxell6641]

I do some trepanning and my recipe for steel/stainless: ~100 m/min, feed 0,1-0,15 mm/rev, coolant and stop 0,5-1 mm before going through. Knock out piece in center and make a finishing pass or two. And when centering larger pieces (both in three jaw and four jaw) i usually make a centerpunch and then I hold the piece in place with the tailstock live center as I tighten the chuck. If some of the names went wrong my native language is Swedish, not English. I am not just being "stupid" 🤭😁.

[@Hoaxer51]

@@johanneslaxell6641, It all came through well, I understood everything that you intended. And no, nobody thinks you’re stupid, thanks for sharing.

[@StanislavG.]

Cool video! I've seen trepanning done with a tubular drill setup, kind of like a hole saw but with two carbide cutters on opposite ends; Now i wonder whether these cutters are offset to allow for chip clearance, like you did with sidestepping your parting tool

[@benjaminshaw80]

Honestly, on the little hole I may have tried a hole saw. I have used hole saws in 1” thick stainless with good results. The surface finish is garbage but it pulls a usable slug out of the material.

[@funone8716]

CNC plasma cut to rough size. Even manual plasma with a simple template.

[@jamiestotz2516]

Could you have used the band saw, since it has a blade welder?

[@SteveSummers]

Yeah, it would have been more work but definitely doable 👍

[@genejasper4091]

Two easier options include a pvc coupling and a reducer bushing and 8” blind flanges are available in PVC.

[@tonybell1597]

Nice and simple.... good job, and we love Cora! 🙂

[@jackyoung42]

wish I could find carb cleaner that cheap I think the last one I bought was closer to $☹ 7.00

[@cyberhornthedragon]

the valve co. i used to work for made tank bottoms out of those flanges adding weir type valves to them we loved the 304 as it behaved well while machining but the 316L was a monster ate cutters cold welded chips to itself UGH

[@aserta]

A custom cut brazed tool works a bit better, especially since you can make it so it cuts on the chunk side as well, thus ditching the need for side stepping. It does give you a truncated cone slug, but being able to dip it in one go without any other movement is good.

[@aserta]

16:58 you should get the puck variant pair as well. The rectangle format is good for its side, but for more detailed work, the pucks are the kings of the shop. Being able to grab them in that hand well gives you a lot of control over what you're doing. 25:47 dunno how it is on your end of the pond as costs go, but you can use two other things: 1. contact cleaner or 2. anti graffiti spray. At least here in Europe, i can get it cheap, cheaper than i get a can of decent quality spray paint.

[@p52893]

It’s Oatys for me

[@ALSomthin]

Hi Steve. Cabide tipped hole saws and carbide tipped annular type hole cutters also work really well making large holes then use a boring bar to get to size and surface finish if needed . Its probably a little faster. Cora is a great pup. I miss my pup he was poisoned by some crack heads awhile ago.

[@alanbrown4446]

Could chain drill a circle then clean up on the lathe.

[@DolezalPetr]

Hi, do you have a video on your chuck keay? That thing looks awesome, is it made from an old drill bit?

[@PatrickKQ4HBD]

Would a plasma torch and circle jig be a viable option for roughing in the holes?

[@MrMojolinux]

The smaller the hole, the more difficult it is to trepan. There are specific limits of hole size dependent upon the type trepan tool used, but smaller sizes eventually becomes impossible due to the tools inside radius rubbing an ever decreased size.

[@llapmsp]

Nice video Steve. How is the DoAll horizontal band saw coming along? I haven't seen any videos of it lately. Give Cora a scratch behind the ear for me.

[@danhoag373]

Also, what happened to the do all horizontal saw? Good job 73 dan

[@somebodyelse6673]

Kinda curious what they're doing that requires an inch thick cover, but doesn't have high pressure?

[@MrJohnnaz]

Bandsaw it out? (blade welder required) What about the lowly holesaw

[@bkoholliston]

A fella like you with a big bandsaw with a built-in blade welder could have also drilled a pilot hole, welded the blade through the hole and cut out most of the waste. Finish on the lathe. Probably faster than trepanning but not as good a video--thanks for the good video!

[@rogerscottcathey]

What's the research about I wonder . . . 👍🤓

[@user-gy9qv4ml5y]

What’s that you are using on the tips of your drill bits when drilling?

[@user-gy9qv4ml5y]

The white compound. In the small short open top container?

[@scootertrash3807]

Steve, I’m not a machinist nor do I know about how to measure strength of a part, I only think and see it might be stronger to off set the holes of the internal flange from the external holes of the stainless flange. Is this correct thinking or have I got it all wrong sir?