Making Press and Hammerforming Dies

[@johnalexander2349]

It's videos like these that remind us just what's possible using only the tools we have and a bit of knowledge and ingenuity. As always, thanks, they're inspiring.

[@andrewwilson8317]

Have had good success with forming bearing shields for classic motorbikes using a technique I was taught as an apprentice. The shield material is sandwiched between the former and some tough rubber sheet. The former is pressed into the rubber using the shop press and the resistance of the rubber gives a nice gentle flow form. Handy for shapes that are not round or have a taper on them. Thanks for the great video Tom.

[@oxtoolco]

Hi Andrew, That process is called Guerin forming or rubber pad forming. Works well for stuff like this also. The die would need to be different and the support for the rubber would need to be kind of cup shaped. That would also work. If I had a lot of these to make rubber pad forming would be a good option. Best, Tom

[@andrewwilson8317]

oxtoolco Thank you Tom, did not know that was its proper name. I used the technique recently to make some formed panels in aluminium for a restoration job. The shapes were irregular and lent themselves readily to the technique.

[@scottwillis5434]

The Guerin process is good for one-offs because you only need to make one die, and there's no need to precisely align dies.

[@alistairhosie652]

Hi when I was around fifty four I developed a form of parkinsons disease and I retired and built myself a wonderful large woodworking shop quickly followed by a nice but smaller single garage size machine shop. These shops have been my saviour I attended a retired engineers club for around five years one day a week every Friday where I learned all the basics in machining . Watching you and some others here have been a great inspiration to me. Anyway I wanted to say I love watching your videos and wanted to thank you brother. God Bless your unseen pal Alistair in Scotland on the Holy Loch God bless and as they say in the states keep-em-comin-bro, LOL

[@oxtoolco]

Hi Alistair, Thanks for the nice comment. Its always cool to hear folks get inspired and are empowered to take on those projects they have been dreaming about. I'll have a snort of some single malt that came from somewhere near Argyll and toast your nice note. Thanks for the comment. Cheers, Tom

[@moh5463]

Fonctional art. I have been watching your channel for years, you never cease to amaze me. Your are an inspiration to mankind. Respect.

[@craignicholson505]

so simple but so much brains behind it Tom this is why u need to be on KZbin to show how to do it right

[@davidmicheletti6292]

I think what I love about your show is just how much care an attention you put into every project you do. Your group of other you tube machinists friends leave me in awe. I just I would have to say I've been Awesomeized,

[@brucethomson2049]

Worked well. What I have done in the past is make the bottom tool with a thread in it and used a bolt to hold the top tool in place. You can slip a tube over the head to press it first , then tighten the bolt down to hold it in place for hammer forming. Then put the whole shooting match in a vice. That way you can hammer form the edge all the way around without having to swing a clamp out of the way. You can use the bolt to pull the depression into the metal first as well, as long as it is of sufficient size. Handy if you don't have a press!

[@jmwarden1]

Tom, that was very educational and a neat way to make a bearing shield. Thanks for your great video's, I have learned a lot from them, even at 73.

[@hermannstraub3743]

Very nice. Thoughts: The bearings have had a open inner side because the hub had to be filled with grease at any time. so the fresh grease would press through the bearings under the washer and drive any dirt outwards. Also i might have considered to give the outer rim of the cup an slight angle. so dirt could be thrown out and would not stuck in the corner. Very, very interesting though. My attempts in formig sheet metal always end in wavy scrap.

[@jusb1066]

i was thinking to use silicon to adhere it, any grease will still get out along the hole of the shaft, and overall would seal it even more?

[@oxtoolco]

Hi Hermann, You are correct. That would mean the maintenance guy would have actually had to do his job. I prefer engineering solutions that take into account just how lazy I am. Thanks for the comment. Cheers, Tom

[@larrysperling8801]

you are a real craftsman tom. not many people would have have made a forming die to create a shield. i'm going to have to make one of those platens you used to bore the hole in the shield, i can see a lot of applications for one of those. happy new year and thanks for everything you do for the metal working community.

[@billlee5307]

Thanks Tom for a year of interesting, informative and just plain fun videos! Best wishes to you and your family!

[@littlerick3]

I was a machine designer for many years and the suggestion I have would be to add a simple labyrinth seal with a sheet metal washer. Turn a small step on the outside of bearing housing for a lite press fit of the washer. The OD of the washer can be made very close the inside of the cap since the is no relative motion between the cap and the washer. I enjoy seeing how you design and fix problems.

[@JunkMikesWorld]

Nice job on that part Tom! I often use hammer forming to make rust out repair pieces for car bodies. Typically my dies are made from pieces of scrap wood so there is no problem working the edge with a steel hammer. I do appreciate the tip about using a soft hammer when working with a metal die. I likely would not have thought of that until I had screwed up my part. All the best! Mike

[@oxtoolco]

Hi Mike, You know I screwed up more than one part before I figured that out. Thanks for the comment. Cheers, Tom

[@bobbergman9467]

D'arcy Saw has a lot of parts for old Marvels saws. John is a good resource to talk to. Marvel is a great American classic tool. Nice video. Bob

[@bobhorton4750]

Thanks Tom. I have been pondering on how to make a similar set of forming dies and this video really cleared things up for me. I guess there really isn't anything new under the sun Mr. Wizard. Take care. Bob

[@cliffordfender1159]

Tom, don't forget about that sleeve that contacts the inner races and goes in-between the two bearings. Great work and video, Cliff

[@chukkyup]

snap an o ring between cover and wheel to remove gap, nice to see more marvel action.Thanks for the videos

[@Bookerb2004]

What a treat... It's never the product, it's always about how you get there, Happy New Year Tom & Fam

[@wyattoneable]

What a great tip about not forming the edge with a metal hammer. I did not know that. That answers a lot of my past project problems.

[@63256325N]

Another Oxtoolco job well done. Nice attention to detail. Thanks for all the videos you produce.

[@davidmotoman4956]

I was looking to do the Same Last year for a Dust Shield on the rear wheel bearing on one of my Motor Cycles i was restoring. Time was of the Essence and Settled for boring a Hole in the middle of a brass Welsh plug polished it up presto. But Now i Know how to make a Die for the next ones :) Cheers Tom keep em coming

[@bradapprentice1397]

Tom, Once again you break new boundaries in what is fresh and new, in the world of “KZbin Metal-Heads”. And, as always, ya did a good job of it! Brad

[@reideichner8597]

Very nice, Tom! That shield will definitely save the bearing. I love your approach to solving a problem! Thanks!! Happy New Year! Take Care, Reid

[@PeopleAlreadyDidThis]

Super. The award for "most delicious sound on KZbin" should go to those resonant "clocks" your headstock gear shifts make in your acoustical concert-hall of a shop! I could watch a half- hour video of gear changes.

[@johnl4540]

Great instructional. Wondering why you opted for hammer forming opposed to spin forming. Thanks for the videos!

[@thething4763]

Same reason to not hit it with a metal hammer. It would stretch the material.

[@chucksmalfus9623]

+The Thing: any time metal is formed either hammered, pressed, rolled, or spun it is stretched

[@dicksargent3582]

Unless you use a hammer to shrink the metal :)

[@oxtoolco]

Hi Chuck, You can add shape to sheetmetal by shrinking which is the direct opposite of stretching. In general most forming operations are stretching but some actually thicken and shrink metal. Thanks for the comment. Cheers, Tom

[@oxtoolco]

Hi Yupper, Because that's what I wanted to show. Not all hammerforms are round or even symmetric. Hammer forming works for not revolved shapes. You are correct that spinning would have worked for this particular shape. Thanks for the comment. Cheers, Tom

[@shanek6582]

That's a badass hole punch.

[@howder1951]

They used to buy these by the gross in the bearing shop, this is way more interesting! As always Tom another elegant means to an end, I like the design to finish project approach to your videos. What to go starting the new year, Cheers!

[@erlingweiseth2774]

Great video! I'll be using this knowledge on a project for my exhausts for my Kawasaki tomorrow! Thanks for sharing!

[@jasongladen82]

Your sketching was awesome. That was fun to watch.

[@PeterWMeek]

After the dialog, "Sure, why not?" (~10:00) with the bird's-nest following, I expected a caption, "That's why not." I made a set of dies to form flat-head screw pockets for 1/4" stove bolts in sheet metal. (Cutting the pockets reduces the holding thickness of sheet metal.) The main thing I learned was how much the metal moves sideways. I had to start with a 1/16" hole to end up with a 1/4 inch hole after forming. (I also had to partially countersink the material I was fastening to since the cone of the head was deeper than the thickness of the sheet metal. Then I had to countersink it deeper yet to accommodate the cone of sheet metal.)

[@shawnmrfixitlee6478]

I agree SWEET ! Nobody knows there hammers like you Tom.. Thumbs up man..

[@esoomreltna]

Tom, Marvelous! You REALLY know how to do everything!! Thanks for the great video. Eric

[@ardisd01]

Great video like the way you used the mini pallet clamps on the lathe

[@pauldevey8628]

Just got your second book. It is nice. Thank you for passing on the knowledge.

[@oxtoolco]

Hi Paul, Thanks for the comment. Cheers, Tom

[@skeeter50001]

Very nice job Tom. This is the first time I have seen this done. Thanks much for the video. Happy New Year to you and family.

[@stephenwagar2663]

fantastic ... I love the sheet metal work ! Your BEST Video Yet !!! Best Regards

[@jr3628]

at 12:57 : would a chip breaker ground into the tool help at all with the birds nests and if so how would you do yours? im just learning about tool grinding and the hows and whys.

[@oxtoolco]

Hi Jesus, That tool will break chips if you increase the feedrate. I was too lazy to change the feedrate for a short cut like that. Thanks for the comment. Cheers, Tom

[@elmarqo_3448]

nice work Tom. you made it look easy

[@oh8wingman]

I've always liked the Marvel line of vertical sliding bandsaws be cause of their accuracy and their simplicity in their design. On the older units they used to use a cork clutch that was counterweighted by a lever mechanism to drive the saw into the material. The further you slid the weight away from the clutch the harder the drive pushed on the material. I was working in a shop that had an old Marvel that was in really nice shape but I noticed that the fellows using the saw were hand feeding the blade. I asked why they didn't use the clutch drive and they said it didn't work properly. I asked if they would show me what it was doing and when they did and I knew immediately that the clutch cork had worn to its limits and couldn't drive the mechanism properly. It bothered me for the rest of the day and part of the evening that no one cared enough to fix that machine. The next morning I was the first worker in the door and I had a plan of attack. Right next to the time clock was a large cork bulletin board. A few seconds with my trusty Buck knife and I had a new clutch. It took about 10 minutes to tear it apart and cut the cork to fit the drum. I got it put back together just before we were to start the day shift. When the fellows who ran the saws came out to start up I asked if I could see the drive work again an they gave me a strange look but agreed. They threw it into engagement and low and behold it worked perfectly. They asked what I had done and I told them I just adjusted it a little better. Later that day we had a safety meeting and one of the first topics was destruction of company property and they wanted to know who had vandalised the bulletin board beside the time clock. No one ever owned up..............

[@charrontheboatman]

Tom, Thanks for demonstrating yet again an old school technique, that is soon to be a dead breed, everyone nowadays wants faster less effort instead of hands on time crafted techniques.wonderful New Year to you and Your Mrs. tom.

[@Gottenhimfella]

In the aerospace industry, when one-off sheetmetal items are needed, they are often machined from solid. For complex shapes this requires CNC, but for this it's simple turning. For something shallow like this, it seems to me it would be less work and require much less material. The second side op could be done by pressure turning (using a tailstock centre forcing a support disk against the work, friction grip helped by abrasive dust or superglue)

[@eleventeenmachine5991]

I just caught this and I've always wanted to accomplish something like it. But I didn't know how to do it. I do now. Thanks Tom!

[@johneslaughter]

Very nice work. Thanks for sharing your knowledge.

[@UFOGEORGE]

ALL THE BEST FOR A HAPPY AND HEALTHY NEW YEAR TOM ! ALL THE BEST FROM CRETE !

[@MatthewRulla]

Tom, I would love to have seen you make a two-stage forming press tool where the first stage creates the inner flange and the second stage slips down around the outside to create the outer rolled edge.

[@JohnBare747]

An O ring under the new flange would keep even more crap out but would be overkill with the new sealed bearings, Happy New Year.

[@TheUpperGlasscom]

Wow that's a tight fit that could work really good for some other applications

[@siggyincr7447]

It turned out nice. Though I wonder if an apron, a short tube shaped piece, press fit over the hub of the wheel that extended out over and slightly past the original washer shaped protector wouldn't have been a better solution. It would have made it nearly impossible for dirt to make it to the bearing. Though it's probably a moot point if your using fully sealed bearings.

[@oxtoolco]

Hi Siegfried, The shield is fixed in relation to the rotating gear. Thanks for the comment. Cheers, Tom

[@siggyincr7447]

Hi Tom, I understand that the shield you made will be clamped to the fixed axle, as was the original flat one. What I was suggesting is a fixed flat washer, similar to the original, with an OD slightly smaller than the ID of a rotating apron fixed to the wheel's hub that extends out past the fixed part of the shield. I just wanted to clarify, not trying to be a smart ass.

[@chuckkline9428]

Siegfried Gust

[@FredMiller]

Nicely done Tom. I saw a new project for me here. Loved the faceplate with "mini pallet" type holes. Gonna have to make me one! And thanks for the tin knocker tutorial. Happy New Year... Fred

[@scottwillis5434]

Great video, thank you! Wondering whether the best angle for the outer rim of the shield is 90 degrees? Seems a bit like the equivalent of a flat roof; won't shed chips and dirt as well as a slope. Also with 90 degrees there's some concern about wrapping it around the die and having, er, fun removing it. Another idea is to add a 'roof' piece of sheet metal, attached to the bearing support, that reaches over the bearing to shed chips. Might want a plastic or rubber edge in case it rubs, though.

[@AmateurRedneckWorkshop]

Always something very interesting to see here.That was a really nice build. I think you may need more meat loaf if your going to be forming sheet metal with that arbor press. Thanks for the video.

[@rlsimpso]

Great video. I see I'm not the only one that buys those laser cut round remnants.

[@MegaHellslayer]

nice project, you could make the last band on the lathe. you can roll it with a bearing on you mold. thet is how we make ouwer exhaust for very old motorcycles.

[@oxtoolco]

Yep that would have worked also. Thanks for the comment. Cheers, Tom

[@AF6LJSue]

Cool Never seen hammer forming like that before

[@tates11]

If the recess in the die and the punch were left with square edges instead of 45 degrees, would the part follow the natural angle between the two edges to create the taper in the recess.

[@Bigwingrider1800]

Im suprized you didn't make a set tools male &female for the sheet metal part . Done a truck load of hammer forming in my day. Memories

[@axnbjsbdudbydvydubu9355]

nice work Ox. in your videos could you please mention each metal type used in the video before working on it ? just for knowledge. thank you.

[@TheMetalRaymond]

I do not understand your language but the images are worth more than the words. I like your channel and I follow it frequently.Animo.Saludos.

[@oxtoolco]

Hi Raymond, Thanks for the comment. Cheers, Tom

[@TheMetalRaymond]

Very good videos.👍👍👍

[@oxtoolco]

Hi Raymond, Thanks for the comment. Cheers, Tom

[@ghostwalker100]

Instead of the clamp a large nut and bolt and bolt it down instead? Saves moving the clamp. Also could you run a bead of something like silicon round the edge of the shield once all mounted up and remove the small gap that way?

[@manoharsagunthalla9215]

Thank you very much for best demo idea!

[@simoncrabb]

I'm intrigued by the hammer material choice. Steel would stretch it, but plastic shrinks it? I'm trying to figure out what's happening with each hammer blow now!

[@dougbourdo2589]

Nice tools & piece Tom. Would it be worth while to insert a thing circle of felt or other filler to keep 'stuff' from working its way in & under the plate?

[@elmarqo_3448]

Doug Bourdo the felt would be a nice addition

[@rc166honda]

beautiful work

[@RALLIR]

The punch at 22:58 what is it called ? Looks fantastic

[@P40BTomahawk]

You are a master. Can you place a felt seal on the ID and OD of the cap?

[@SlowEarl1]

Nice work Tom!

[@mattcurry29]

Really cool video Tom. Happy New Year to you and your family.

[@mfsolutions]

Nice job ... You could use the lath and a piece of wood to spin the complete shape. I did this in Grade 8 on a wood lathe with a wooden form (you would need to use brass and not steel

[@3347861]

Beautiful work. I learn something new every video... Thinking out loud....... Any chance of finding a freeze plug, etc and just fitting it to the app?

[@geoffmorgan6059]

Thanks, Tom I have enjoyed watching your videos for a year or so. As always, good work. Just one constructive comment - and you are not alone in this, most all of the sheet metal bashers on youtube with English wheels, dollies, etc. - what is the gauge or thickness of the sheet metal. My experienced gained through some unfortunate outcomes is that there is a big difference between 22 gauge and 18 gauge and so on. Thanks again!

[@lesfoster4364]

Hi Tom, Nice job as always. Cheers, Les

[@gwheyduke]

Could you machine a slightly tapered female die to bend the OD lip, then press both shapes at the same time?

[@joehackenberg30]

nice plat tom love your show I think I would have clamped it in the lath pressing it together with that tale stock and spin rolled the edge with a makeshift barring tool but your probably only making one so it don't matter just my two cents happy new year

[@AverageJoe2020]

Nice work Tom, I used to enjoy making up odd press tools to make trim parts for classic cars, an example of which is in my profile pic. Whoever can guess the car the reflectors were for wins the internet!. Best wishes for 2017, J.

[@bernie7958]

Another very cool video, thank you for sharing. BTW, my son, (13) looked over my shoulder and said "he looks like a cross between Jamie and Adam, but he sounds a lot smarter"

[@cirebeaclaudiu2867]

Nilos rings are similar as functionality with the presented cap but they have better protection. However, what we will enjoy watching if you choose that option? Thank you for your effort in creating this good content channel.

[@pcka12]

is there a picture or video showing this interesting bandsaw anywhere? I think that i have only been able to find more modern versions so far. Thanks for the video

[@july8xx]

If you can, use some silicone sealant between the gear and the protector to help the outside seal.

[@jerrylong381]

july8xx The cover doesn't rotate.

[@georgedennison3338]

Would love to see a short bit on that interesting turret hole puncher thingy... unless you have one in the archives, you can point me to. Thanks... GeoD

[@shawnhuk]

The lack of chatter on your Yam lathe is beautiful.

[@skippy1460]

Hi Mr. Tom, you could use silicon calk to seal the fang.

[@oxtoolco]

Shield does not rotate. Silicone would not help in this situation. Thanks for the comment. Cheers, Tom

[@skippy1460]

ah, that does change things :)

[@jacksat2252]

A sting of leather glued on the inside of the lip will seal it completly ,and when glue is dry soak the leather in oil,now dirt is going treu .And the leatherstrip can take some friction.

[@Georges-MILLION]

Excellent Tom !!! Bonne Année !!! Georges ( France ) Excellent Tom !!! Happy New Year !!! Georges (France)

[@jmwarden1]

Tom, I just had another thought, how about a large diameter o-ring to seal up the small gap between the wheel and the seal that you just made.

[@StefanGotteswinter]

That came out great, looks perfect :)

[@oxtoolco]

Hi Stefan, Thanks for stopping by. Handy for making things look like a big factory made them. Best, Tom

[@billdlv]

Nice job Tom. Happy New Year

[@lesbender236]

Since the sheet metal seal goes behind the spacer,does it really need to have an offset?

[@oxtoolco]

Hi Les, It actually goes in front of the spacer. I got that one wrong on my sketch. Good eyes! Thanks for the comment. Cheers, Tom

[@Stephen1455]

Wow! Where did you get that hole punch! Your scrap yards must be primo all the old military bases in CA?

[@kurtisjohnson4562]

Nice job, was surprised you did not build the outside edge into the forming die though.

[@KC9UDX]

Kurtis Johnson My thoughts exactly. By the time he did all that hammering, he could have replaced his dowel with a screw, and made a die for the outside. But it's easy to say for this Monday morning quarterback.

[@oxtoolco]

Hi Kurtis and KC, A forming die that would push the flange over is much more complicated. In its simplest form it would not take in for the springback. The hammering was only a few minutes. Much less time than it would have taken to make a all in one die. Net savings in work. The fastest would be to roll the edge over with a bearing while the blank turned in the lathe. I wanted to show hammer forming and how simple it is. Thanks for the comment and Monday quarterbacking. Cheers, Tom

[@kurtisjohnson4562]

Thanks Tom, I figured you had a reason or two for doing it the way you did.

[@inspctrgadget1970]

what about a oiled felt washer ? along the lines that motors use.

[@eformance]

Tom, how come you didn't use the lathe and roll the shoulder of the shield to form it??

[@royreynolds108]

I was wondering the same thing when I saw your comment.

[@oxtoolco]

Hi Perry, I wanted to show hammerforming. You are right that this could have been spun easily. Hammerforming is more versatile and will makes shapes that are not revolutions of a section. Thanks for the comment. Cheers, Tom

[@ji0050]

Another great video.

[@shanek6582]

This technique will come in handy if the hearing protection act passes, everyone can make their own suppressor baffles.

[@travisshrewsbury7169]

right on as usual, Happy new year

[@steamerpowered]

cool process. I think I'm going to make myself a thin parts chuck like yours ;)

[@19672701]

One hell of a hammer form for a one time use!

[@RRINTHESHOP]

Nicely done Tom, thanks for sharing. Happy New Year.

[@francescolaporta2706]

Randy Richard In The cartoni animati

[@ofujuncky]

That was way cool ! Great info Thanks!

[@АлександрЧернышов-ю8я]

Шикарное видео. Ждём продолжения.

[@paulmurphy612]

Good job. I enjoyed that.

[@richardcentesette1057]

I like your hole punch press - who makes it?

[@oxtoolco]

Hi Richard, The punch is made by a company called Rotex. Thanks for the comment. Cheers, Tom