Monarch 612 Lathe Restoration: Machining a New Lever Handle Bushing with a Square Broached Hole

Monarch 612 Lathe Restoration: Machining a New Lever Handle Bushing with a Square Broached Hole
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[@donwilliams3626]

It is always amusing to watch someone that really can fit a square peg in a round hole!

[@amateurshooter6054]

Thanks Keith

[@scottvolage1752]

Ginger the shop supervisor. There for all aspects of inspections and advice.

[@hectorpascal]

Ginger is the ultimate cute photobombing pet!

[@brand-x7049]

Wonder where Marion is...

[@crazor01]

Can't believe it's been seven years! Also after rewatching the first video in the series, I can't believe how good this machine looks. As do you, Keith!

[@joeanon1415]

I hope your weight loss is intentional and not the result of poor health. I noticed because the way you sound when you speak and breathe has noticeably improved. Congratulations and well done.

[@cmonster6]

I’m amazed there were no pesky burrs on that square shaft when you pulled the handle off 😊

[@PhilG999]

Lathe work has always been my favorite! Many years ago, I started a new Engineering job, and the "Model Shop" was right next to the Engineering department. The MS was "off limits" according to the sign. One day I had a little "personal" lathe project to do and went in and the lathe was barely bigger than a tabletop machine. 6' travel, about an 8" swing (if that). Thing was COVERED with chips and swarf! Before I did MY project, I cleaned that whole thing. The Chief Engineer came in just as I finished and looked at it and said: "Ok, you are now allowed in here."

[@paulputnam2305]

I’m a machinist,working in a machine shop, watching another machinist machining on his machine. Machiners Rock! That was fun! Thanks!

[@permutatechguy]

Seeing that square busing just slide on is so satisfying

[@lobster8009]

I recon the "gasket lookin thing" was a wiper/oiler and it plays a fairly important role. Might get tight if chips get in there.

[@polakis1975]

Cat has same concerns about the lathe😊

[@levitated-pit]

Dear internet mate Keith, From a fellow machinist/engineer type. Please give a brief summary about Ginger the cat, I am constantly puzzled/concerned about the fact that he`s still alive! In a workshop full of comfortable warm motors, drives etc how has he maintained a full length "question mark" tail? and why has he been denied steel toecap boots?

[@prillewitz]

The small things that irritate every day and make life so much more pleasant when resolved.

[@djfaber]

Hey Keith, just wanted to say, you're looking great these days!

[@petegraham1458]

Nice fix , like you I don’t like equipment not to be functioning as designed, sooner or later lack of service and preventative maintenance and replacement of wearing parts causes a significant problem, better to attend to it . Thanks for the video!

[@walterplummer3808]

Good morning Keith. Thanks for the videos. Have a great weekend!

[@diggerddawg]

I work with machinists every now and then and hear them talk about how hard it is to find a good apprentice. Dang. I would've been all over a machinist apprentice job when I was a young man. When I graduated high school, I thought I wanted to be a mechanic but my Dad (God rest his soul) told me that the life of a mechanic was too hard on a fellow so he offered to send me to college. Several years later, I got a mechanical engineering degree, right in the middle of a recession, and entry level engineering jobs were hard to come by. So....I ended up working the last 40 years in.... (drum roll)......insurance. Wah, wah! LOL. I should've been a machinist!!!!! Maybe next go 'round I'll be a machinist with a wire EDM in my shop!

[@johncloar1692]

Thanks for the video Keith. It good to see shop jobs. Have a great week!!

[@dannyl2598]

Thanks Keith. It's nice to see your machine getting better and better. It will be as good as new without the new price.

[@scottbishop7899]

Maybe should take a wire brush on a grinder to clean thar square rod and maybe dressed it up with a fine file while you were in there, then give it a good light lube to help prevent it rusting a bit (maybe could still do it as there's plenty room to get to it anyway lol). Every little helps 👍 👌

[@danielbutler578]

It's a lot easier to run a file over a small part than to mess around with that square rod and possibly cause other issues.

[@scottbishop7899]

@@danielbutler578 I could see that if it was load bearing, intricate or if it was used for several operations but its just to turn it on or off/start or stop, I know you guys are all about 'patina" function over form sometimes? 😆 🤣 😂

[@robandsharonseddon-smith5216]

Thanks. I enjoy the commentary even if I'm not paying full attention every time.

[@commaux]

Hi Keith. Great content as usual. I was just a little bit concerned about the noise your green lathe is making. It sounds kind of rough. Chatter ? Weird since you seem like you were pushing it that hard.

[@MrChevelle83]

ol green lathe has sounded that way forever and i stood beside him running it. the machine is rock solid.

[@edsmachine93]

Nice work Keith. The Monarch is really turning into a Gem with all of these fixes and repairs you are doing.👍 Thanks for sharing the process. Have a great day.

[@davidc6510]

Another great video fixing up the Monarch Lathe. Thanks for sharing,

[@jackheritage2222]

Really nice repair. I always enjoy your explaining what you're doing. Thanks. ( and I like your cat)

[@melshea2519]

Happy Friday Keith! 😊

[@RRINTHESHOP]

I to have done this job a few times, well done.

[@robertbamford8266]

Interesting. If I ever have a question, you answer it, usually within the next 30 seconds of video. This time I was (idly) wondering why you didn’t show test fitting the unmounted, broached bushing by slipping it over the square shaft. This time the answer showed up in your adjustment toward the end. Thanks for the video.

[@mervynprice7009]

Very enjoyable watching the use of a square broach. I got the feeling that we may be seeing a forthcoming video about adjusting the bearings on the lathe you were using.

[@peterhobson3262]

I remember the first time I saw a square broach being used and thinking: "So that's how you make a round hole into a square one."

[@hectorpascal]

Whoever invented the broach idea should have gotten a Gold Medal!

[@brettbuck7362]

Yes, that looked rather alarming!

[@MikeBaxterABC]

Great Job Kieth!! .. I've had occasion to make square holes by slowly and carefully filing each corner, (after drilling) with one of my big square files, I'd probably choose brass for this job just to save filling time :)

[@robertmcauliffe6989]

25 of my 37 years in the aerospace industry have been in the machine shop environment. One thing that I have learned is the importance of “Clean As You Go”. I understand that you’re not building anything untra-precision, but… it’s just good practice. I think that you will find that you will not need a hammer so often 😊.

[@jensschroder8214]

Fits and doesn't wobble!

[@waynephillips2777]

Thanks for sharing!

[@geraldharkness8830]

excellent job well done keith.

[@Stefan_Boerjesson]

As always, well done a nicely presented. Not having such a broach, jungle methods a la Tubalcain had to be used.... Time 17:35. No testing that it fits the 4 sided rod? Guees it was done and was positive. Time 20.47. We have the same hair style.... It's like a lighthouse when landing the drone.... Bright heads..... Time 25:16. What about the left handle? It's good or uninteresting?....

[@DRNewcomb]

Just happen to have a 3/4" square broach. 😅

[@kensherwin4544]

When you spend a lifetime collecting tooling, occasionally you oughta be able to "just happen to have" the tool you need. Not often enough that your wife can start spending the tooling budget, of course.

[@craigtreleaven7560]

And a press with sufficient height to push it all the way through!

[@ZigZagMarquis]

Keith, Ginger, like us, sure seems interested in this lathe restoration! She mush have some machine work in mind for you to do on her litter box once this project is done!??! 🤪

[@elsdp-4560]

Thank you for sharing. Nice repair.👍

[@SciPunk215]

Great little project! The audio sounds great.

[@TheAyrCaveShop]

Nice repair Keith !

[@ianbrooks6816]

Nice work Keith.

[@daleburrell6273]

14:12...PARTING IS SUCH SWEET SORROW-(?) (snucker-snucker-snucker!!!)

[@jacquespoirier9071]

to perform such a job, you need to have on hand more than 1 machine very good job very good video

[@frankerceg4349]

Thank you Keith!

[@WillyBemis]

Thank you Keith! This was an interesting repair.

[@bulletproofpepper2]

Absolutely fixed. Thanks for sharing.

[@stevenclaeys6252]

Thank you for another great video. Cheers

[@brettbuck7362]

I think the fiber/leather washer is intended to be a wiper, to wipe crud off the square rod before it goes into the bushing, to keep it from wearing out so fast . It needs to be a tight fit or it packs it onto the rod.

[@steveschwartz6138]

Broaching always made me nervous. I had a couple splinter on me. Wouldn't putting a set screw through the handle to the bushing be easier than drilling and tapping a key directly into the bushing?

[@danielmccann4055]

Great Work.

[@TomokosEnterprize]

Always a nice visit with you Keith. Little things like this really make a big difference.Having full sized broaches on hand is a real blessing. You nailed another one Kieth. I sure enjoy these visits. In all of the North of BC Canada. Kamloops to Fort Nelsonthere is not just one set of any kind of broaches to be had. There are few shapers as well. It is hard to imagine but that is just the way things are up here. Down south they are in every metal shop. Schools and profesional type outlets. Great to see this done and done right.

[@billdoodson4232]

Love the fact the shop cat comes to see what's going on.

[@Scodiddly]

I wonder if Keith films those bits just before feeding the cat. :)

[@prillewitz]

You always have to check on your human so that they do nothing stupid.

[@Hoaxer51]

@@prillewitz, That’s a full time job for some of them! Lol

[@billdoodson4232]

@@Scodiddly 🤣😅🤣🤣

[@user3141592635]

I like nice animals as well. I like cats, dogs and birds. However, among the dogs, I prefer the educactionally suited ones with great intelligence, and with a moderated agressivness, so as not to attack people for no accepted reason. For this reason, I prefer female German Sheperds, whom are generally nice and easy to train. Not that they are weak in the defence, but more easy to control. The bite in the arm is hard and painful in the play with sticks, should the dog miss and take a bite in the arm when you fint them. One mistake, a friends young girl made, was to draw the stick to her belly in the strife, so the dog catched her belly-skin in the bite of the stick. Just a nasty blue-mark and some whining. She witnessed though, the dog did not bite her on purpose, just a mistake. This female German Sheperd's greatest fun, was to stride and meter who was the strongest, fighting sticks back and forth, dragging. Sometimes I let her win. Her tail straight up in the air, head raised, trotting with great pride.

[@timziegler9358]

Well done! I enjoy your videos. Best wishes.

[@viniciusvbf22]

New subscriber here. What a wonderful machine.

[@timf6916]

Good Job

[@crsnowman]

Keith, give ginger a nice pet when she is trying to help out.

[@danielelse3914]

Very nice job, Keith.

[@wesleymonske8103]

Will you replace the other handle bushing at the lever at the motor end?

[@CornishMiner]

A satisfying fix.

[@jeffreysmith5018]

Ginger approved 😀

[@iDuckman]

Aw. I was looking forward to learn how to borach a hole.

[@richardsurber8226]

you have good video skills

[@rjw8316]

Thanks once again Keith for an informative video. Looks like your lead hammer could use a little love or recasting. Also, how do you keep Ginger from jumping up on your machines while using them and keep her paws out of chips? Just curious. Thanks again.

[@dwaynekoblitz6032]

We've got a brand new $65,000 large here at work and we can't use it "until testing is complete." Testing??? It's BRAND NEW??!! Ridiculous. Broaches are always satisfying to use. Well done.

[@brucet9799]

(Seeing it in action with the lathe on would have been nice)

[@MikeBaxterABC]

21:20 Great Fit, that will break in, in a week or so, no problem!

[@robertlevine2152]

Keith, Would it help if you put an oversized hole in the bushing and then lined it with a UHMW, Turcite, or a reinforced PTFE material? This would help reduce friction and wear. Bob

[@justinl.3587]

The retention screw used to keep the bushing in place is called a “Dutchman” not a key.

[@marcellucassen8033]

When I see someone pushing a broach trough a hole it always makes me nervous it will break, when I heard how expensive they are it only makes it worse.

[@JohnfromEngland]

Yes Kieth it is know as a Dutch key

[@peterward2875]

I'm curious why you didn't make it out of bronze/brass again? Going with steel will wear out the square rod too, won't it? (The much more expensive to replace part.)

[@ruben_balea]

The old one was also steel, at a first glance it looked yellow but I think it was a layer of oil

[@benjamindusseau4912]

was the original bushing bronze? easier to replace the bushing then the square shaft?

[@wyrdlg]

Hmmm, new microphone?

[@steubens7]

wonder if it had been replaced twice already because they just tweaked the bushing but kept the same wiper plate

[@masteruniverse3506]

Is the sister lever on the left not in need of repair? I see it move up and down with the movement of the repaired lever?

[@bigun447]

Channel's new name? The Keith and Ginger Show.

[@user3141592635]

Nice work as usual. I suppose such a broatch cost a great deal of money.

[@tomswindler64]

Nice 😎😎😎👍👍👍

[@georgegreen-b3i]

Ginger kitty!!!

[@wilsonlaidlaw]

My guess is that that may be the original bushing but it has been turned twice to present a sharper square corner to the square clutch rod.

[@mikeschaefer9516]

Keith - may want to check the top left (if facing machine) of your press, the bolt and plate holding the table seemed to have a bit of play in relation to the throat the table is mounted on. 16:22 thru the end of the broaching process.

[@danielbutler578]

Any arbor press is going to have a slight amount of play in it. If it is too tight you will be dealing with too much friction. That's why you let the pressure off the broach frequently to prevent binding or breakage. Noticed that he was doing that and if you watch closely, you can see the broach move slightly when he released the pressure.

[@mikeschaefer9516]

I noticed that too, Daniel, but it appears that the bolt has not pulled the table/plate up against the back of the throat. Was just mentioning it as something to check.

[@garybrenner6236]

Is the Stoker Engine ever coming up?

[@azlandpilotcar4450]

The thumbnail shows the hole is "borached" , if true, it wouldn't be square! Good video, despite problems with my youtube.

[@danielbutler578]

If you have a good square broach it will be square. He's not using a broach for cutting a keyway.

[@MrChevelle83]

tell us what "borached" is ?

[@jasonhull5712]

Think I would have painted up my handle and cleaned up that shaft while in there. Makes that apron slide that much easier. On that old girl it’s a bit of a task moving that sucker from end to end. Get ya a good workout anyways ! Keith is going to be buff and strong by the end of summer ! 😊

[@jameshatfield7634]

Keith:It's not a leaver It's a lever.

[@alemurillo03]

You know you are doing something good when the part you are turning says "right there"...!!!? 13:48

[@johnnosawyer6423]

Sorry Keith, that hand wheel on the tail stock still looks wired that way round.

[@crystaldragon141]

It might not hurt to run your precision stones on the square bar and take of any high spots or buts.

[@Airtight215]

I see Ginger almost every video but haven’t seen Mary Anne in a while. Is he ok?

[@phlodel]

I hope she's become a house cat, but 'm afraid something happened to her, I've asked a couple times.

[@Throughthebulkhead]

Sounds like you have a worn bearing in the Monarch??😮

[@nfa10]

Can I ask a stupid question to the community? I've seen some videos here, and I haven't seen the use of liquid coolant during various processing, unlike other channels, what's the reason for that?

[@MrChevelle83]

coolant is generally used to cool the part kieth done usually machine large heavy heat soaked parts and he uses insert tooling coolant is super messy and as someone that is fimilar with machining. his work dont really require coolant at the speed and feed hes working with.

[@A.Hidell]

Final proof you can put a square peg in a round hole !

[@bobmurphy6229]

That Monarch appears to have two feed shafts - why is that- one for longitudinal and one for cross slide feed?? Someone explain please. Bob (Edinburgh, Scotland).

[@jasonhull5712]

Bob it has two “rotating shafts” one is for the power feeds of the apron, and the other is only for threading or “the half nuts” the third rod you are seeing is only for the headstock control switch which is what Keith is fixing here. It’s on a shaft that runs back up to the headstock so you can control the headstock from the apron or the headstock itself. On longer machines you Don’t want to have to walk up to the headstock to power up the machine and then walk back to the apron if turning on a long workpiece. Hope that clarifies your observation Sir. Have a great day.

[@MrChevelle83]

i run a lathe 40 feet long and you explained it well.

[@tpobrienjr]

Passed the CAT scan.

[@daleburrell6273]

1:24..."SQUARED AWAY"-(?) (snucker-snucker-snucker!!!)

[@cornoadmin]

Isn’t a 13/16" drill too big for a 3/4" square hole?

[@ruben_balea]

Yes, but the broach is made that way, I guess a broach made to start from a round hole would be really hard to press and therefore very easy to break, considering that a 3/4" broach costs about $600 it's better to have it made in the strongest way possible even if it lefts behind part of the round hole. Many commercial products that use square shafts have the holes made the same way.

[@brettbuck7362]

A 3/4 square rod is 1.06 inches across the diagonals, so the broach cut well at the corners in a 13/16 hole. The rod id driven by the corners, the fact that there is a small cutout on the flats is of no consequence.

[@colinellicott9737]

Puzzled as to why mystery metal was used when it seems that brass would have been best?

[@Vickwick58]

We see a lot of Ginger, but where's Mary Ann?

[@chrisjarvis4449]

it will wear in before it wears out

[@vizibug]

4th bushing in total?.