MAKING LINEAR BALL WAY CAGES

Design and build of linear ball way cages for my Mitsui surface grinder rebuild. Including special clamps and rail system for long thin parts and a precision die for cutting reticulated foam
Paypal donation www.paypal.com/cgi-bin/webscr...
Support through Patreon / robrenz
I am "robinrenzetti" Instagram lots more content there!
"SHOP NOTES" contributed by brs_workshop
• Overview of the old ball cages, condition and design considerations
• Switching from grease to oil lubrication
• SolidWorks(?) explanation of design.
• @7m ""Just enough of a drawing""
• Delrin to wood transfer adhesive test. A study quick-and-dirty workholding of awkward pieces, fully explained and tested with a force gage.
• 3M 467 Adhesive Transfer tape:
McMasterCarr (60yd): www.mcmaster.com/#adhesive-tr...
Amazon (.5 in/20yd): www.amazon.com/dp/B007Y7CQ1S/
(other sizes): www.amazon.com/467MP-Performa...
3M's website: www.3m.com/3M/en_US/company-u...
• 3M F9460PC Adhesive Transfer tape: (not to be confused with others that contain the same number)
McMaster (.5 in/60yd): www.mcmaster.com/#7628a52/=1e...
Amazon (.5 in/5yd): www.amazon.com/3M-Tape-F9460P...
3M's website: www.3m.com/3M/en_US/company-u...
• 3M Plastic Adhesive Transfer tape:
Not sure which one is shown, probably 9482PC (2mil) or 9485PC (5mil)
McMaster (PPE bonding): www.mcmaster.com/#adhesive-tr...
3M's Website (9482PC): www.3m.com/3M/en_US/company-u...
• Wagner FDX Force Gages: www.wagnerinstruments.com/prod...
• NOGA Ceramic Blade Plastic Deburring Tool, CR 1500 or 2000:
McMaster: (CR2000, maybe): www.mcmaster.com/#6074a36/=1e...
Amazon (CR2000): www.amazon.com/NOGA-Ceramic-D...
KBC (CR2000): www.kbctools.com/products/ABR...
Noga: www.noga.com/Products/cera/Cer...
• Notice the 'fence' or alignment pins in this fixture are deburring tools.
• Explaining ball deflection, Hertzian stresses in a ball way.
• Making improved clamps from ViseGrips.
ViseGrip 9LN 9 in. ""Long Nose"" (Made in China):
Amazon: www.amazon.com/Irwin-15-9LN-8...
Harbor Freight (also Made in China):
www.harborfreight.com/hand-to...
• Tip about evenly wearing your abrasives by watching the spark pattern.
• Nylon Deburring Brush Wheel:
McMaster: www.mcmaster.com/#4901a56/=1e...
A number of other brands available from retailers.
• 3M Strip Caulk 08578:
Amazon (20yd): www.amazon.com/3M-08578-Black...
3M's site: www.3m.com/3M/en_US/company-u...
• Apprentice = broach catcher
• Haircell finish plastics
• Ever wonder what that application pressure is? Well, from 3M's datasheet on 467MP it's 10-15 psi.
• Tapping head is a SPV (Spintec) SA-0E. I can't find the model on their website.
• #0000 Stainless Steel Wool for Deburring hard plastics
• Creating a foam die cutter
• 100 pore-per-inch reticulated (open cell) foam.
• Techniques for facing accurate rings of triangular cross-section. Cubic Boron Nitrite turning tool reground.
*Not affiliated with any distributor or manufacturer. Links for reference & convenience only.

[@ThisOldTony]

always world class! not to mention, this probably THE best video i've ever seen on building Mitsui ball way cages. ;) keep 'em coming, Rob!

[@ROBRENZ]

Thanks for watching Tony! I pick these obscure topics just so there is no competition, easy way to be the best :-) ATB, Robin

[@shirothehero0609]

Im positive a man of your stature would have seen many a ball way cages in his time. TOT = the quintessential authority on cages for balls. Er. Right.

[@nageshmadhukarchavan5814]

@@ROBRENZ ppp0p0

[@jmcg2518]

it really makes you think on a more quantum level, like....how small of tolerances are possible? And can tolerances be brought down to a subpartical level? Oh, man, I think I just blew a God partical fuse in my head.

[@superspecialty5169]

Anyone who says the “uh, umh or ah” is not world class.

[@PracticalRenaissance]

I love how you demonstrate that precision has no limit; Building multiple tools to help make jigs to cut a part to help rebuild a machine, all to ensure that potential deflection is in the single digit micro inch range. As always thank you and I can't wait to see more!

[@StefanGotteswinter]

Simply entertaining and educational. 50 minutes went by like nothing. Love the cbn turning tool (Or should I say reground cbn insert - Thats a great tip you gave some time ago, just to regrinding worn cbn inserts.) Also very much enjoyed walking trough the design in Cad. Poor forcegage, had to laugh *help* :D

[@ROBRENZ]

Thanks Stefan, glad you enjoyed it. ATB, Robin

[@Metalloys]

36 years a machinist and I feel like a 4 year old in kinder garden watching with jaw down a David Copperfield show !

[@ROBRENZ]

Thanks for the kind words and glad you enjoyed the content.

[@sharkrivermachine]

Your attention to detail is amazing. You are going to have the best surface grinder in the industry. Thanks for sharing.

[@robertcorrie6737]

Sir: you are lite years ahead of most of your viewers. But in saying that watching you work and explaining things as you go teaches us and gives us something to admire and strive for. Thank you for your time and teaching , you are a true master.

[@kingcrunch85]

You Sir are a madman and i mean that in the best way possible. The foam wicks blew me away! Absolutely awesome!

[@user-tw9io9nz2m]

50 minute Renzetti video, what a treat!

[@PhilsProjects]

an eye opening experience watching every video. Renzetti University . there is so much to absorb that i have to watch it again and again. Thanks Robin

[@ROBRENZ]

Thanks Phil, you will get to see them in person! ATB, Robin

[@robertfoss803]

The content is great as always, but I feel like the production values of this video is higher than what we've seen before. Nicely done! The effort is very much appreciated.

[@sjoemie_himself]

Never have I seen such detail and thought going into what seems to be a simple spacer for some steel balls. At the same time I think you mr. Rinzetti are the only person who could entertain an audience for 50 minutes straight on such a subject. Time and time again I am blown away by your attention to detail. Thank you for sharing and teaching all the tips and tricks you have put into this (and your other) videos/projects. greetings from the Netherlands

[@duobob]

It must be really nice to have tools and machines that you have personally thought out and carefully made, modified, and designed to support the ideas you personally have for their usage to the smallest details. There is nothing like a custom made tool that fits needs for planned operations and projects for the person who made it. I try to do that, too, but on a MUCH more humble scale.

[@arnljotseem8794]

Great video Robin. Learn something amazing every time. Being a new machinist, for me this is like going to university after just having finished first grade.

[@diegovianavillegas3297]

Only Robin is able to improve a Mitsui grinder. Truly amazing

[@MikeBramm]

Your meticulous craftsmanship is just Awesome. I have a feeling this is how NASA would do it.

[@bugrobotics]

Thanks for taking us along for the ride Robin. Another great primer on a number of subjects. Enjoyed it as usual!

[@kennethnielsen1800]

I have watched a lot of your videos and I am always amazed by the level of workmanship and attention to detail that you put in your work, i learn something new every time

[@joell439]

Another stunning video with so many tips and ticks along the way. Your humbleness and attention to detail is so refreshing. Thanks so much Robin for taking the time to capture, edit and share. Simply awesome....... Joel

[@houseofbrokendobbsthings5537]

Always a joy to watch you work. The list of crucial tips continues to grow. Thanks you for all the time these videos take. Your prep and delivery is top shelf. _Dan_

[@stuarthardy4626]

Only one word Robin WOW

[@arsanzic2161]

I'm always in awe of the amount of work and knowledge you put in to making things right, and always learn something (many things) from each of your videos. Thank you for sharing your knowledge and experience.

[@lornie212]

This video is a master-class in what precision looks like. Thank you.

[@jdm2651]

This is the 1st video from Rob that I watched. He was doing so different from the othersq that I couldn't tell if he was crazy, or to what he was getting to. Now that I have watched a few more, I know that he's an absolute master, but the first feelings are still there.

[@FredMiller]

Great video Robin. It took me about 3 minutes to understand (get my head around) why the difference in ball count per slide but then it made perfect sense. I now realize that you need to work with a different mind set when you are working with pressures at the micron ranges. Very informative and enjoyable... Fred

[@WacoA.I.]

16:05 I'm still working on this myself.

[@larrychamberlain2871]

Impressive, I do like watching a thinking man work.

[@SneerfulWizard]

Everytime you post a new video (like the spindle rebuild) I find myself rewatching many of your old ones and finding new nuances and bits of info everytime. Much appreciated 👍

[@ROBRENZ]

Glad you find the content useful

[@rupertpowell]

As always Robin, your work is on a different level. I could tell in the tone of your voice that when that top cage dropped into place you knew ALL the effort was worthwhile! Great video shots and editing too. Can't wait for the next video.

[@Redmech80]

I enjoy my very early mornings. Enjoying a cup of coffee when the rest of the world is asleep, I then see I can further enjoy buy watching my much anticipated video that I knew was coming. Great video.

[@parnellpollioni]

As usual just watching your videos is amazing what I am able to learn from adhesive’s to foam etc. unbelievable thank you very much for all the time and effort you put into these videos super helpful.

[@techbilly119]

I was surprised to see you put the balls in the cage straight from the bag mcmaster shipped them in. I would have thought you would clean them with alcohol and lubricate them with unicorn tears. 😂 I love your videos, thank you for taking the time to share your skills with us.

[@alexsterling5186]

Beautiful work Robin. You take machining from a science to an art form.

[@michaelschnock3998]

Robin, you amaze every time. Well done my friend. outstanding. Now I​ just have to buy a machine with that kind of rails, to repeat what you showed. thank you very much for sharing your knowledge.

[@lapoint7603]

Very nice video. I can't wait to see your surface grinder when it is finished.

[@timtrott4145]

Remarkable attention to detail. The pains you take for an effectively one off job to make it perfect. You take a lot of pride in your work and it shows.

[@BossWelder81]

Who in the actual hell would "thumbs down" this video?? :) Thanks for sharing Mr. Renzetti. Beautiful work.

[@BobOBob]

Some people make unreasonable demands, like arguing with a creator's choice of music/no music. Their opinions won't be missed when they unsubscribe.

[@globin010252]

Inspiring, as usual ... there is something oddly soothing about your vids

[@AlwaysSunnyintheShop]

Never fail to impress the hell out of me, Robin. Stunningly good work, as usual. ---Aaron

[@TopGearFan29]

As always you have made an improvement on a design and made things run better for yourself and you’re coworkers. You are an inspiration! I wish my boss would allow me to do the necessary repairs to all the machines at my workplace...

[@hodgepodgeenginerd1258]

I didn’t understand half of this video but thought it was amazing the amount of thought and detail. Thanks fir all the work you put into these videos so we can enjoy and maybe learn something.

[@howder1951]

Fascinating Robin , way out of my league but a pleasure to watch and it does go in technique resources files , there is a lot of info that I could use on my own endeavours, cheers and thanks!

[@63256325N]

My hat is off to you for your attention to detail which, by the way, is second to none! A great project that I'm sure will work flawlessly. Thank you for sharing the build.

[@mr.t.807]

I like the video, and your explanation is fantastic. It a sham they don't have machine shop class any more, I believe you make one heck of a instructor!!! Thanks for all the lessons.

[@ScrewDriverxxx]

Damn, I have watched this many times over the years but can only like it once. Over one hundred thousand views and half of them are me! 😜

[@cliffordarrow6557]

wow! your problem solving is an absolute treat to watch!

[@greasemonkeygaragewatson1069]

wow now I no how bad I really am. thanks Robin I could watch that stuff none stop all day

[@fasousa4798]

Mesmerizing. I am subscribed to many other machinists here on YT but you sir top them all. Your attention to detail is even more emphasized than Tom Lipton or Joe Pie. Thank you for taking the time to share it.

[@emiliog.4432]

Your meticulous nature is an inspiration. Even to disciplines outside of machining. Awesome work. Great problem solving. Thanks for sharing.

[@ROBRENZ]

Thank you very much!

[@rogboak]

I have a Harig grinder on its way to my house right now. I’ve been planning what my solution will be for balls and cages upon inspection and had a very similar thought in mind. Of course your execution and end result is superior to what I had planned and really like some of the points you make, and will likely implement if new cages are needed. I priced out the balls in case I see reason to replace them and was quite surprised at the cost of that. One day I will learn that my ideas aren’t original, someone has already done it and probably better. Glad I found this video. Went good with morning coffee.

[@randr10]

I'm so glad I found your channel. This is such next level precision and the thought that goes into your processes is so incredibly thorough. Most people have the tendency to want to slam bang everything together, and that's a negative influence on me. I doubt I'll get to your level but it gives me a goal to shoot for. Hopefully I'll be better for it. You show how it's possible to take your time, be patient, consider all variables, and still get the work done in a relatively efficient manner. I don't think you would have spent much less time if you'd just bored some chamfered holes in the strips like the original cages. Well done.

[@warrenjones744]

Nicely done Robin. You just drove home the point of thinking things through and then taking the time to do do good work. Cheers

[@hdheuejhzbsnnaj]

So many little moments of genius. I loved that reticulated foam die, and the very long narrow bag to protect the finished ball cage.

[@KnolltopFarms]

I too loved the die...and now wonder, was it odd for me to become hungry for calamari rings while watching him undo the cut sections? Mmmm, calamari!

[@stevenmoore7334]

hi Rob, Ive been watching yourself, Abom, steve summers, edge precision, Joe Pie since xmas and haven't turned yous of since. Im a joiner/carpenter 25 yrs and thought working to a half millimetre tolerance in my job was good, but u guys just blow that out of the water. You sir, are a true genius and I'm quite sure the guys that do your kinda work are blessed to see someone like you share your skills so they can learn, i also pick up things from all you guys i can use in my job. love watching your videos

[@philmay7834]

These videos should be compulsory watching for people who want to go into mech. engineering or similar pursuits. Great stuff!

[@donzmilky5961]

Great video robin, its nice to see someone upgrading their machine the proper way and using oil where it belongs instead of smearing grease on it and calling it good enough.

[@literoadie3502]

I love it! Can't wait to see the rest of the rebuild!

[@urrick33333]

That was very useful and educational (and entertaining!), thank you, Robin!

[@stevewilliams2498]

I did find it educational. Thanks Rob. It will help me up my game after 27 years "black smithing" back to where I was when I changed career path after being time served apprentice. Hopefully to make retirement hobby time more rewarding. Steve.

[@triplemiter]

I learn a lot from your channel Robin - thanks for sharing. You set the bar for attention to detail and thoroughness in your work.

[@glennfelpel9785]

Well done Robin. Very inspiring and I did learn a lot from this one. Thank you for sharing.

[@MrSidiox]

I didn't even realize this was a 50 minute video until it was over and suddenly an hour was gone. Amazing attention to detail and completely overengineering the clamping system, wonderful.

[@ianpendlebury3704]

Excellent result and a wonderful insight into how you think things through and then do the actual machining. Thanks for making these videos - they are hugely instructive.

[@5tr41ghtGuy]

Great design, superb execution! It seems that work holding is often the biggest challenge, and I learned a bunch from this video :-)

[@OldIronShops]

wow very interesting video i never fail to learn something when watching you work.

[@Steve_Just_Steve]

I find myself hanging on every word so much that when you cut yourself off I find myself craving the rest of your thought. LOL I understand that you sometimes worry about the lengthiness of the vids , but I would bet my lunch money that none of us watching do. =)Thanks for the vid Robbin.

[@nothermarkgnomex]

Very interesting. Now I know what to look for when designing ball cages. Changing the number of balls to match forces with different geometries makes sense to me but I never knew what math to look for. That is what I like about your videos. Every one teaches me things!

[@chieft3357]

I found your video very informative and exciting to watch. I never knew what was coming next. I sure didn't see this coming, those vice-grip pliers being re-made into machine clamps. Awesome!!

[@camelazo]

A lot of knowledge contained in this vid!!

[@DRrandomman22]

a nice belt grinder in the shop is really under rated. there super handy and a lot of jobs can be done quickly in them like putting radius on keys or chamfers that are not critical

[@geraldrourke5499]

WOW! AMAZING machining skills to say the LEAST!!! I learned a lot! Thanks my NEWEST FRIEND!

[@rasmusb2523]

Those are just beautiful, Robin! Love it when you go through all the design aspects of everything you do, it always gives me new ideas. And on that note, eventhough it's midnight in Sweden, lets head down to the shop!

I learn so much with your videos Thank you from Spain.

[@irfanashraf1238]

Only a true master can remove ambiguity in details . My we remain blessed with your presence.

[@Metalloys]

Rob : great great great ..... great work.

[@davidmott2090]

Thats called craftsmanship

[@than_vg]

Learning new stuff each time, thanks a lot!

[@Anonymouspock]

This video more than anything gives me the idea to take some of the surplus mass quantity of 1 inch ball bearings lying around from an old robot game and use em with 3d printed bits to make casters for new robots. Definitely worth at least an attempt.

[@gatekeeper84]

For a split second I thought you had three hands when you were using that broach. Thanks for another amazing video. I have a feeling we will be seeing those clamps again.

[@465maltbie]

Watch it once to see it, now to go back in a couple of days and take notes...thanks for taken so much time to explain what you are doing. Especially with the different materials you are using.

[@magorkovacs]

So glad i found your channel! I find your style of doing things, thinking things through really inspiring.

[@martin09091989]

sheer overkill on the making of the cages! with this pasion for detail you should work in the rocket industry!!!! but its satisfactory to watch you doing this with this precision, even it really didn't mater this much. hope you have someone you can teach this skills, beside the youtube community.

[@steveh8724]

Did you not see "the apprentice" catch the broach?

[@magnusklahr8190]

Martin L d

[@prestonleeper4814]

First class workmanship! This video illustrates what patients, perseverance, and attention to detail provides.

[@bhein67]

That was simply amazing to watch!

[@aearles7]

Amazing work Robin. Your skill is well beyond what I ever expect to have, but you provide the inspiration to produce quality products and the proof that it can be done!

[@DK-vx1zc]

wow, brilliant ! Looking forward to the assembly Thanks much for all the great videos you share.. They are very much enjoyed and appreciated

[@chaosreigns7386]

Machining that little press cutter for those foam inlays was amazing... Great job brother, learned something valuable here, thank you

[@trajtemberg]

Im new to clamping with adhesives and this was really helpful. Thank you sir.

[@jefferdman5921]

Nice job. I have to build one for my table saw, it is worn and has dropped a bearing. Of course that is not required to be nearly as precise as yours need to be. But you gave me some good ideas. I liked how you have engineered an oi,l bath for the bearings, I think I will try to do the same me with mine. Thanks again.

[@hideyourcables]

watching your videos makes me smile. thanks for sharing

[@wgm-en2gx]

I thoroughly enjoyed this video. Thanks.

[@kristiandelchev4034]

As always, full of great information and knowledge! Thank you!

[@dvdspndl]

Man, that's an amazing video. I'd never imagine how much thought and work you put into things!

[@markgrevatt4867]

Brilliant idea with the clamps you do some spectacular work. Even though this is something I couldn't do. I enjoyed watching. 👍👍👍👍

[@gentharris]

True and pure genius!

[@Ujeb08]

A very nice, long and interesting video Robin! Making those foam rings was awesome. Thanks for sharing your skills and knowledge.

[@Engineer_Stepanov]

Absolutely professional work! Respect from Russia.

[@ROBRENZ]

Thanks Alex.

[@snatchie715]

10 out of 10, Have to give you the highest regard for all the information that you put out through your videos Robin. I am currently going through the beginnings of a Tool and Die Making Career and your videos have been incredibly useful in understanding a lot of precision and machining concepts. Request if you could ever one day do a video of just all the machines in your shop and a brief overview of everything you have done to modify them and why you chose those exact machines and if you would have done anything differently knowing what you know now, I get the feeling that a video like this would bring up a lot of points that a novice hobby machinist wouldn't be aware of in the beginnings of setting up a garage shop. Thank you for everything that you put out

[@maxcnc777]

Great design! I should say re-design. Loved the punch. I've made something similar for foam and rubber. The milling fixture for the cages was a bit over thought..but as long as it works. I use 3m tape the exact same way to fly cut a 6 ra finish on long electrodes for lasers, but have never used that specific tape. Can't wait to try some! Thanks!

[@JBFromOZ]

that is insanely awesome Robin!!!

[@winkworks]

Beautiful work, sir!

[@MilanDupal]

Great performance! Thanks for sharing.