Machining Large Sprockets - Boring And Keyway Cutting - Manual Machining

[@pastortomolson]

I love having your videos on as I work on projects. It is like having a friend with me and an inspiration to do my work well. I am fortunate to know you in person as a friend!

[@MrArtVendelay]

The excitement shows on your face when you pulled that spade bit out of the box.

[@TopperMachineLLC]

I hate drilling holes, but spade drills make it fun.

[@larryvollmar8763]

Even my wife was amazed at those chips! Hehehe

[@jangoofy]

I was just about to comment on that, such pure happiness in his eyes :-)

[@jsr3793]

Martin rising their prices is one of the reasons I have my job now. I'm an automation and robotics engineer, and being able to run a lathe is a priceless skill.

[@atfthestore1313]

i do this stuff all day at work, then for some reason come home and watch more videos about work

[@ChuckNorriz1122]

I could watch slotting and broaching all day. Those cogs don’t look cheap. I would be a nervous wreck working on one. Nice work Josh!

[@TopperMachineLLC]

@troyfortune4124 it is nerve wracking, but worth it in the end.

[@danielgriffith7694]

I’ve personally installed several of those sprockets on a drag out conveyor. Usually they are indexed or timed together so they align perfectly on a shaft

[@TopperMachineLLC]

I was never given any specs on timing the keyway, but I always orient them the same.

[@dalebailey1844]

I love the fact that there are no filings/chips anywhere except for the work that you are doing.. I worked in a shop that must of had them all over from the MID 30s. What a mess. that was in the sixties. HAVE A GREAT DAY

[@Joe___R]

With the casting being so hard, you might want to try ceramic inserts instead of carbide.

[@MrBanzoid]

Hi Josh... It might just be me but I find something soothing about watching reciprocating machines like your keyway cutter!

[@samrodian919]

Nice job Josh! I love watching that More Vertical slotting machine. It's so hypnotic!

[@pablocardoso777]

Do not forget to record a video when you use the sawmill. We are missing it. @Engelscoachshop is restoring a wagon similar you use to spread the sawmill dust. Regards from Uruguay.

[@TopperMachineLLC]

We have been too busy this year to even saw. I'm hoping when the weather cools a bit, carl and I can start dropping trees and sawing again.

[@seantap1415]

Another great channel.

[@petegraham1458]

Nice addition to the shop tooling library , hope the job pays out well for you. Thanks for the video!

[@edsmachine93]

Nice work Josh. That Spade drill is awesome. That slotter machine is awesome. Need to get some smaller radius insert for that big boring bar. Maximum rigidity!👍 Very good video. Have a great weekend. 👍

[@TopperMachineLLC]

I actually bought a different boring bar that I can easily get inserts for.

[@Joe___R]

A fuel pump in a 5 gallon bucket of coolant would easily fix your flow through coolant issues. A regular would let you easily adjust the pressure so it isn't too high and making a mess. Most electric fuel pumps put out 60-80psi.

[@25vrd48]

Difference in metal hardness differences is tough to machine . Great explanation and machine work .

[@thomasgrimes922]

I love your presentations because they are practical, open, and informative. Thank you very much.

[@IslandHermit]

As someone who has never run a metal lathe, that spade drill surprised the hell out of me. I would have thought it would require so high a tool pressure as to stall the lathe.

[@kristyskirt9015]

Oh sure you’re having fun with all the new Snazzy tooling. I too enjoyed doing hogging and finish boring, on time too. Must say Mr. Topper you do do it Right the First Time. Hopefully a certain company with a non working space capsule is watching this video!

[@TheAyrCaveShop]

LOL

[@MrMojolinux]

Just getting up to speed on your most interesting sprocket video. When I was an apprentice, one of my jobs was running a Keyseater, which is like an auto broaching machine that you could swap out different single width cutters on different dia. bars depending upon the job at hand. We would usually first layout the desired keyway on the gear or sprocket's etc. bore face including the depth of cut to finish, and then generally feed in the table that the part sat on by hand, though it did have an auto feed, but that caused more trouble sometimes than it was worth due to deflection of the up and down cutting action in and out of the bore. BTW the part was generally NOT clamped down, but just sat on the table inside a provided and adjustable central 'V' like a combination square's center. That said, I don't think our keyseater had the capacity to handle that large dia. sprocket of yours, but it could cut up to an inch keyway after first cutting out the majority of the keyway's meat first with smaller bars and cutters, building up to the finish 1 inch keyway.

[@EL34XYZ]

Wow, love that spade drill with the coolant inlet!

[@Frank-Thoresen]

Absolutely. The Lion lathe just needs a stronger coolant pump for the spade drill bit.

[@TopperMachineLLC]

Coolant pump was big enough, just restricted by the small tubing. It has been corrected.

[@Frank-Thoresen]

@@TopperMachineLLC That is money saved 👍

[@emmp8760]

ever thought about doing any vlogs on family vacations? exploring that town would have been a good one!

[@andrewdalgarno5322]

When I saw the title and thumbnail, my first thought was "new drive sprockets for the dragline crane!" Not quite. But exciting, none the less!

[@TopperMachineLLC]

Sorry, no new sprockets for that. Too odd and obsolete to replace.

[@jamesharrison6201]

I enjoyed the math involved in choosing the gear sets and cutting head for the gear hob I ran

[@Marcuscalafatty]

This bloke is the real deal .

[@luksan_swe]

Another excellent video. Have you considered making a barrier with tape around the outside of the center hub to force the oil to flow through the bore instead of over the outside edge?

[@TopperMachineLLC]

I was actually hoping to get some playdoh to make a dam.

[@brian_2040]

Hey Josh, i can back you up on Martin's sprockets going up. One of the ag machines deals with them, and its stupid crazy how much they went up.

[@MikeF1189]

Ok. You win. That drill bit is no joke.

[@e.scottdaugherty8291]

Man, you get to play with all the nifty stuff, jealous. Good project, thanks.

[@zoltannagy1813]

Changing to a smaller radius on the carbide insert did the trick, but did you try using a positive rake insert to prevent chatter?

[@GardenTractorBoy]

That twist drill is impressive but the spade drill even more so. This was fun to watch, especially the keyway cutting, thanks

[@Mike.Lehmann]

Really like that spade bit. Looks like you scored a good job there. Nice video Josh.

[@stevenslater2669]

I really like how you describe to us what the job will be used for. Many of the other machine shop channels will start an episode by saying, “I don’t know what this thing is used for but the customer gave me these dimensions…” There’s a truism in the engine manufacturing business, “A cylinder block (or head, or crankshaft, or intake manifold, etc.) drawing does not tell you how to make the part.”

[@TopperMachineLLC]

Most of the time I have no idea what a part does. Some I have great knowledge of. Especially of parts that I helped design or troubleshoot.

[@bostedtap8399]

Nice additions to the shop, as you state, coolant flow is a little wanting for through coolant tooling, even on a manual lathe. Great work Josh.

[@charlesemmer8856]

The largest spade drill I have ever seen personally in operation was at Ladish. They were boring a through a large hole on General Electric commercial jet landing gear. I was in the process of calibrating the axis position feedback scales at the time and I would get a path error on the laser every time it broke through the hole.

[@charlesemmer8856]

The scales were being set up on a traveling column boring bar that was at least one hundred feet away

[@jamesreed6121]

that spade drill is awesome! I will be sure not to miss next week. KOKO!

[@jrmintz1]

Great video, as always. It might not be a glamorous video, but I'd like to see how you clean up the slotter after doing a job like that.

[@TopperMachineLLC]

Putty knife to push the oil to the drain. Let sit a few days and magnet to puck up chips.

[@mikesnodgrass-de8ln]

it's a good practice to key those large table sprockets on center of a tooth. you never know if they have attachments on the chain that need to be timed.

[@TopperMachineLLC]

That's exactly what I try to do.

[@jpenny01]

I sure appreciate your videos. Now that bit can move some heavy metal bro.... and PS, I'm glad you showed your excitement when you open that box up. And pulled that bit out.

[@fricknjeep]

hi there good job wish you were closer , need a key cut in a largr pulley for the saw mill , best to all john

[@TopperMachineLLC]

Shipping isn't that bad these days.

[@MrAnon-ee5jt]

i used a cold gun and connected it to the inlet of the insert drill and it was the best/loudest "dry cut i ever made.

[@AmateurRedneckWorkshop]

Glad to see that you have some new jobs. Thanks for the video keep on keeping on.

[@williamhoward8319]

elevator sprocket ours were mounted at botton with traction wheel on top

[@jonstaszak2426]

Awesome job Josh, hoping to add a lion lathe to my shop someday soon. Keep up the great work!

[@TopperMachineLLC]

New or used? I love mine, bought new. Best business decision I ever made.

[@jamesriordan3494]

Nice one Josh; knowing that you are doing it all, machining and filming, really appreciate your time making these. Definitely asking Santa for a spade drill !

[@kehrer1993]

I have seen people mount the big drills to the crossway, so they can use the power feed for boring. Do you ever do that?

[@TopperMachineLLC]

If I have a lot of them to do, yes. Problem with this big drill is that I only have a 4mt tool post holder and a 5mt drill.

[@robertchapin3683]

Thanks for another informative video. Those pieces look like Track Steer drive hubs.

[@RalfyCustoms]

Good job Josh, that keyway cutter is a beauty, thanks for sharing buddy

[@donteeple6124]

Morning Josh, Great seeing you scoring a nice big job like that. Dropping down to that 432 was a good choice along with reducing the speed to fight the chatter. I just absolutely LOVE that Lion lathe of yours..........gotta do a cut n profile and chamber job this week for a friend, he found an antique and the replacement part is unobtanium new or used anywhere.....so gotta make it....all of which I get to do after finishing the honey-do of painting the kitchen trim for Momma !!!!!!!!Great vid as usual. Don

[@TopperMachineLLC]

Thanks Don. That Lion is a workhorse! Hopefully you'll get to see it soon.

[@willgallatin2802]

Well, the next upgrade will be a higher capacity pump for the lathe. The look when you opened the new spade bit was priceless.

[@tomtd]

@@willgallatin2802 it’s that Christmas Day look.

[@TopperMachineLLC]

Actually the pump is plenty big enough, I had to upgrade the tubing size. Works great now.

[@carldaniel6510]

Love that Moery slotter!

[@BrucePierson]

The jobs keep rolling in and keeping you busy. Great for the business, but less time for your own projects. It must be hard getting things balanced so you get the jobs out and hopefully have a bit of time for your own projects. You certainly have a lot of interesting hobbies.

[@TopperMachineLLC]

My stuff keeps getting pushed back. I'm actually getting frustrated that I can't get the draglune done or bore the steam engine cylinder.

[@BrucePierson]

@@TopperMachineLLC I know just what you mean. I'm retired now, so I don't work (at a job), but we have so many projects to do here at home that it's taking forever to get through them. That means that my car project and a couple of other projects that I really want to get done are in limbo, while we're getting other projects and routine maintenance out of the way.

[@82ndguy5]

Wow! A total of 11 to do. Very interesting issues that you explain very easily. I enjoy your videos. Thanks!

[@kd5byb]

When the spade first went in...those chips...so amazing!

[@BurnAndHackett_RC]

Glad to see you are still making a living doing a job that you love. As a certified armchair machinist, I thought that the sprocket was barely held to the lathe chuck. I was fully expecting you to bolt some sort of retaining clamp to hold the work into the chuck jaws as well as the 'normal' clamping force applied.

[@keithmonarch447]

Hi Josh, haven't really seen you, while. In my area, we have been getting 😂 warm days around here. I'll finish watching your current job. Take care now..

[@randydobson1863]

Hi Josh & it's is Randy and i like yours video is Cool & Thanks Josh & Friends Randy

[@number2664]

Spade drill went quite well considering the pilot hole, they don’t usually like that. I thought you already had a spade drill? Or not one that big?

[@TopperMachineLLC]

I have several smaller sizes. This is my biggest to date. More larger sizes to buy when needed.

[@marossgnv]

You have an entry for the chip of the week contest.

[@TopperMachineLLC]

I've won it once. Never thought to enter these. Lol

[@steveunland8079]

You should always skim cut the outer end of the hub after you bore to be double sure that your key is dead square to the bore. If the original face is out of square to the bore, so is your key by setting up on a face as you do with the parallel bars.

[@bobhudson6659]

I think Josh knows enough about machining that he would have checked that the bore is perpendicular to the table before he started the keyway. Give him credit for knowing what he is doing. But I am sure you meant your comments for people who are new to machining and have their own vertical slotter.

[@TopperMachineLLC]

A lot of things get cut from the video. Indicating all surfaces for deviations is critical.

[@steveunland8079]

@@bobhudson6659 Yes that is a true statement, these type of machining videos are for everyone to learn from and yes it helps to share concepts so that someone that may not be aware of it can learn for their future endeavors.

[@buckinthetree1233]

That's a pretty good tip. It sure would make setting it up in the slotting machine easier.

[@wallaceknifeworkshomestead]

That drill is awesome!! Great job!

[@James_Scheid]

Today Spacely Sprockets, tomorrow Coggswell Coggs!

[@TopperMachineLLC]

Ruhroh! That sounds like a lot of work. Lol

[@bcbloc02]

Interesting looking sprockets, must be some odd chain.

[@eyuptony]

Brilliant to watch, Josh. Interesting. Cheers Tony

[@TheUncleRuckus]

I love AT as cutting fluid it makes it look like your using the blood of your enemies as cutting fluid. 😂 Great video as always Josh!👍👍

[@rogarmadz]

Enjoyed watching you work, GETTING IT RIGHT THE FIRST TIME!!😀👍

[@TheDistur]

A new tool and a job well done. Good times in the shop!

[@richb1334]

Hi After watching the video, to protect the lathe when changing the part put some wood on the ways.

[@Grandpa600]

Josh, how did you get to where you are today? Did your education motivate you towards Engineering, or was it a conscious decision early on in your life? I continue to appreciate your videos, and I wish you, and of course Conor, all the. best.

[@TopperMachineLLC]

I think it was a lot of bad choices and an unwillingness to give up.

[@mikedyson7330]

Excellent manuel machining video this is what we want. Thank you Josh.

[@TheMetalButcher]

That seems like a great project to hone to finish since the material is differential. I bet if you did enough an old sunnen or similar would be worth it.

[@teaches2010]

My little twist drill......❤❤❤

[@paulsto6516]

Say hello to...

[@wallbawden5511]

Hay Josh like seeing the Lion in action and now you have a kick arss chuck for it bigger better Then you show off your big tool of a drill bit only to pull out a more better version The tip can you go bigger for it or is that max size just need to sort out coolant pump now Big boring bar is nice as you say more better tip will sort it out for sure good that you had the back up one on hand bit smaller but got it done in your get it done attitude Also love the Slot machine has to be one of my favourite machines to watch in action its a beast for sure Cheers from North Queensland Australia

[@TopperMachineLLC]

Lots of new tools for this job. I actually bought a better boring bar after filming. The spade drill can take much bigger inserts.

[@ThePottingShedWorkshop]

That spade drill seemed to produce 3 distinct chips per "flute". Is this by design of the cutting edge? I'm really enjoying your videos. Please keep them coming!

[@TopperMachineLLC]

Yes it is. Actually there are serations in the bit to break smaller chips. That is how they feed so fast.

[@alanm3438]

Was that Rocky, in the background, keeping a eye on you????? You are never less than interesting!!!! It is incredible what you are willing to do to help your customer. Equipment and tooling are so expensive; I sure hope that you were able to make money. It is something how you, a one man shop in the middle of nowhere, is able to come to the rescue for so many. Good job on both the video and the project.

[@TopperMachineLLC]

Tooling is just part of the job. Now I am better equipped for the next job. I did ok on this one even after all the extras purchased.

[@TalRohan]

I am going to make a lifting hook like that for my swage block, I can't move it by hand so I just bought a really nice old chain hoist but using slings is a pain in the rear ...a hook like that would go through the centre hole nicely...I may make a hook for lifting it off flat though...will try that arrangement of yours and see how it works I can't help wondering what uses sprockets that big...theyre huge and obviously made to a pretty fine tolerance All good fun Thanks for sharing

[@michaelweatherhead9470]

Nicely done Josh great job 👍❤️❤️.

[@TheAyrCaveShop]

Those are some serious sprockets 💪💪

[@TgWags69]

Used to have a surplus store near me that had a bin of those spade drill inserts for $5 a pound. I grabbed a few just to grind for special tooling. But too bad, they closed and everything went to the scrap yard

[@TopperMachineLLC]

That's a shame! It's hard to find great deals like that.

[@jst.hilaire354]

Does the tailstock have a powerfeed. If not, can you latch the tailstock to the saddle? Just thinking!

[@dutchgray86]

Need a carriage mounted drilling bracket for power feeding drills, like what Dean Smith and Grace provided on their lathes.

[@TopperMachineLLC]

There is a provision on the Lion to pull the tailstock with the carriage. It had to be removed to accommodate the DRO. I will eventually find time to make a new "Hitch" for it. Someday, I hope.

[@ChrisChandler-dj1wy]

I caught the hot chip wrist flip while you were boring the sprocket, I think every machinist knows that move. Do you find that the bore closes up any from the keyway material removal?

[@michaelcothran4064]

Josh, why not consider a morse holder for your lathe so you can use your lathe feed

[@JonesMetalCraft]

Love that keying machine.

[@justinjenkins4337]

New subscriber here. I bought a kbc mill about 2 or 3 months ago just south of you, in Haugen.

[@TopperMachineLLC]

KBC has some nice machines. I have a customer in Haugen and friends who lived there. Know it well.

[@justinjenkins4337]

@TopperMachineLLC your customer might be who I bought it from. They use to machine thier own parts to fix their machines but the guy that did it retired and they don't have anyone who knows how to anymore.

[@TopperMachineLLC]

@@justinjenkins4337 I'd bet it is. Lol.

[@alandawson2813]

Awesome video Josh, been looking forward to the next installment. From kiwi land

[@louisbigelow1866]

Before I retired when I had a boring bar that was approximately half in and half out of the holder, I would put my small drill press vise on the far end to change the frequency that once the vibrate at quite often it would deaden the vibration and I could continue machining at the higher rate...

[@TopperMachineLLC]

I tried a bunch of things to dampen it. The nose radius was just too big to give me a good cut in this material.

[@richardhallatt5285]

Can you get a holder for the tool post so you can power feed the spade drill? I've thought about buying a couple for my shop that's all. Cheers Richard

[@TopperMachineLLC]

I have some for 4mt, but this big guy is 5mt. I haven't found a holder yet.

[@richardhallatt5285]

@@TopperMachineLLC Ah I see, yes 5mt might be a bit on the big side. Take it steady and keep up the good work Josh.

[@donanything6816]

Nice new drill bit! Heavy sprocket, makes me wonder . . . . How much does a key weigh?

[@TopperMachineLLC]

7/8" square key. It's got some weight.

[@donanything6816]

LOL!! Thanks for that. My brain had me thinking about the old joke when the lady asked "What's a henway" the answer being "about 2 pounds". Thanks for the video.

[@The_Foolish_Fool]

Allied machine makes amazing spade drills, I have nearly every size of the TA they make

[@TopperMachineLLC]

I've only got a few sizes larger to get.

[@spikeypineapple552]

Hi Josh, where do you get the cutting edge in your keyway tool from?

[@jamesbonnema1041]

What size hole gives spade drill advantage over twist drills?

[@TopperMachineLLC]

All sizes. They come in a variety of sizes and out perform twist drills in every way.

[@Marcelo-56]

Gran trabajo de mecanizado, prolijo, bien explicado y para sus años de experiencia, muy profesional. Aquí estoy en el sur de América del Sur, aquí no hay nieve pero el viento sur es enfermante. Mi hermoso jardín semi tropical? (destruido por completo por el frio) 😡🤬🥺 Así es vivir en Argentina 🤷‍♂️

[@davidmosscrop2374]

Morning Josh! The slotter is such a beast. Why a shrink fit AND a key way? Have a great week Be Well

[@TopperMachineLLC]

These are known to spin and slide off. The shrink fot has proven to eliminate both problems. Welding also failed in case you were wondering.

[@candyjanusch3716]

once you rebuild the feedbox on the slotter so it feeds correctly is there a "stop" that can be set so you can walk away from machine somewhat while it works? kinda like you dont need to babysit the planer on long cuts so much

[@TopperMachineLLC]

Yes, there are stops I can set. Looking forward to doing that repair hopefully I can get a break from work to tear into it.

[@seldendaniel8819]

Quite satisfying!

[@eegaugh]

So far as I recall the Lion has no tailstock power feed. How do you feel about hand winding that superb spade drill?

[@TopperMachineLLC]

Feeds super easy actually.

[@johnlee8231]

Did the twist drill or the spade drill need more force to turn in? Also why is it always the last couple of finish passes on a bore that give us all the most trouble? Always good to see a post from you.

[@TopperMachineLLC]

Spade drill for sure worked the best.

[@ssboot5663]

I learned a LOT here today! How do you suppose the sprocket cogs are cut out so nice? waterjet or laser sprot cogs?? Just wondering- - NICE DRILL BITS!! ***LIKE!!*** does the slotter use a "clapper to relieve the back drag friction on the back stroke? "Thanks for sharing!

[@TopperMachineLLC]

The sprockets look to me to be flame cut. Probably similar to my copy torch that I have videos of. There is a clapper, but I find it doesn't help on these long cuts. It actually pushes away.

[@TalRohan]

Its a good job that cutting oil doesnt dry out ...the surface area of it you have all over the slotter is huge lol

[@seantap1415]

Is there any reason why you don't keep your cross slide either parallel or at 90% to the carriage. You should give yourself every advantage you can.... love the videos

[@TopperMachineLLC]

@@seantap1415 a very good reason that I have covered before. I will also address it in this week's follow-up video on Wednesday.

[@frankerceg4349]

Thank you Josh!