Producing Extremely Thin Wall Parts ---Made Easy

This video will show you a technique for producing parts with extremely thin cross sections. By thin, I mean less than .015 with extreme accuracy. When conventional machining won't get the job done, this technique will. Take a Look.

[@ThePsiclone]

Watched this yesterday with no idea I'd ever need it. Then today happens and it saved me a lot of hassle. Had to make two screw on aluminium spacers M12x1 on the inside M14x1 on the outside leaving bugger all in between. Worked a treat. Thanks Joe!

[@joepie221]

Outstanding.

[@mertonsilliker4858]

Joe, if I did not see this myself, I would not believe it.

[@tim9lives]

You’re the best Joe. Really appreciate you passing these tips on to us. Thanks again.

[@gertnel4766]

Gert SOUTH AFRICA I LIKE YOU WORK WITH PVC AND COULD NOT GET A THIN WALL LIKE THAT NOW I CAN TRY IT AND SEE IF I CAN ACHIEVE IT ENJOY YOU VIDEO'S

[@SpencerSkelly]

Fantastic technique. Your videos are great, thank you.

[@dand6144]

Thanks Joe ... that's crazy stuff. Didn't even think that this is possible. Just for the show and for when you run out of ideas in view of new videos: can you show us this very same stunt on steel or aluminum PLEASE :-) As far as I am concerned, I will try in the next days on delrin. Curious to see if my lil lathe is up to the task. Probably, the biggest problem will be the machinist, as usual, in my workshop!

[@joepie221]

Start with this one. kzbin.info/www/bejne/jl63nKiHebyXmKM

[@dand6144]

@@joepie221 Have seen this one already (couple of minutes ago) - you've already recommended it in the comments (which I read sometimes!). No, no: I was talking about this kind of thin-wall-tube :-). Seriously: I believe you that it works exactly the same way as on plastic. It's just such a pleasure to watch this kind of "magic". And it's even sexier on metal, c'mon! Cheers Dan

[@richardmills5450]

Wow..Defo learnt something there..cheers

[@joepie221]

Glad to hear it!

[@arienugteren3797]

Excellent video!

[@xlcrider]

Did I miss something? How did you know, you had the correct ID?

[@joepie221]

I preset the boring tool before I shot the intro. My pilot diameter was already a small counterbore. I just touched it and finished the bore. Good question.

[@tomgranberg5651]

Love it, thank you!

[@jamicat]

I make this stuff all the time, always bore first, and big cuts on OD. :)

[@jamicat]

2.5W x 5.5L x.060 wall....with a flat bottom end and no through hole...fun stuff.

[@joepie221]

Sounds like a thick beer can. drink then cut the top off. problem solved.

[@davecross5317]

Damn Joe! I LEARN more watching your stuff than any other source. Please keep it up and keep explaining the why’s and not just the results! Btw, you should sincerely consider doing a machining 101 kind of dvd set. I’d get in line in the cold and rain to buy it.

[@cameronmccreary4758]

I used to encounter parts similar to this one and I would machine the inside first then fill with Cerrosafe a Bismuth alloy which expands to the bore and then I would machine the outside diameter to size. Finally, I melted the Bismuth alloy from the bore and then I had a very accurate and thin walled part with no chatter or other anomalies.

[@oddjobbobb]

How in the world can there be 24 people who gave this YT a thumbs down? I mean, for crying out loud, what could they have found offensive, irksome, or a waste of time? This operation was more, pure magic. Thank you again, Joe.

[@tabaks]

Kids these days...

[@rustypanels1917]

There are losers out there, thumb down to everything. It's them, not the video.

[@kentuckytrapper780]

Damn man with a little more practice you could make condoms. LoL. Great job, blowed my mind '

[@Critical_Path]

This was a super informative video. I have had issues with parts of this nature in the past, and this technique would have totally worked, I bet. Thanks for sharing! Really love the Joe Pie academy here. Crazy heaps of clever, simple solutions to common issues. Spectacular, thanks for being willing to share this knowledge!

[@joepie221]

Glad to pass it on. Thanks for watching.

[@adsomelk5130]

Damn, man! I passed off a job about two weeks ago, to another guy, after getting down to my last pass and it slung out of the chuck. It was almost the exact same set up, same material and everything. I got so mad when I scrapped it I gave it to another guy. Man I wish to god I had seen this before they gave me that thing! Was one of the most frustrating days of my career. BUT, anyhoo, awesome video as usual, too bad I was late on watching it.

[@ChrisB257]

That Joe was impressive! I rather hope I don't need to make quite that thin a wall! Keep the great vids coming .:) Thank you.

[@tweachison]

Yet still, he wears no cape.

[@harryhopkins7798]

Thanks Joe, I know this is an older video but just want to say I am a hobbyist that enjoys making stationary engines. Your channel has taught me many helpful things. Love all the tips on how to make small pieces! I am only KZbin trained but your video's make me feel like I am in a classroom!

[@joepie221]

Thanks. I'll take that as a compliment.

[@T720too]

Thank you so much for what you do and the time you put out to help all of us.

[@screens1979]

Fresh out of the Marines in 1969, I worked for a Czechoslovakian owned job shop in Boulder, Colorado. They had a job come in, super thin wall and they figured it out. I remember them talking about it, “You can’t sneak up on it, you just have to go for it !!” I think the customer was Coors Porcelain and the material was brass.

[@MrRatkilr]

Been machining a while and learned something new. thank you.

[@joewest1972]

Hello I thoroughly enjoy your videos I look forward to watching them as a senior and a newbie just trying to learn about lathes and Milling machines at about 6 minutes and 40 seconds into the video there's a close up of the boring bar all of this is new to me so forgive my ignorance but as I look at the boring bar the side nearest me would appear The Logical side to cut since it's sticking out of the way of the main bar but much to my surprise the boring took place with the end on the left side of the bar I know it sounds stupid but could you please explain a little bit of this

[@brianlewis6208]

Amazing, I have been watching your videos for a while now,you are a good teacher,keep them coming. Brian Lewis.

[@pairdocs]

That was fantastic. I've been looking for a way to make a thin custom bushing. Kudos! from another seventy-something.

[@FrugalFlyRodder]

Awesome, I'm new to metal lathe turning, and I've been looking for someone doing this exact technique. THANK YOU!!!

[@joepie221]

Glad it was helpful!

[@Rich1ab]

Great lesson! Joe thank you for passing on your experience. Clearly, logically organized explanations. To the point and on time like any excellent machinist exp

[@AmateurRedneckWorkshop]

Well done. Lots of scrap from that operation.

[@frankhoose]

Another great video, Joe. Thanks.

[@ttargetss]

When cutting plastic, a shop vac is awesome to catch and pull away the swarf

[@Freetheworldnow]

I wish I could see the same demo, but this time using hot rolled steel!! Great video and great lesson.

[@tnt421]

So basically.....bore hole to size then cut OD to size with one Huge pass?

[@joepie221]

Yep.

[@rickwhittle227]

@@joepie221 yep and make sure the tool's ground acute so you don't rub on the thin bit. Brilliant, thanks. Dad taught me this but I missed the criticality of the tool shape . . . that it was 18/8 stainless helped back then - replacement rivets for a thirty year old chef's knife that was complaining about being in the dishwasher. This time it was brass for thin open rivets for a steampunk light fitting rebuild of a '50s mill work lamp. Nylon's cheating!

[@hadcat1]

Nice job! Another way if this does not work is to finish ID and fit a slip fit solid plug inside....Then turn the OD...The plug method is the only way when working with Nylon or Teflon. The behavior is certainly different on thin stuff.

[@kieronrautenbach4676]

Hi Joe, this wasn't a piece of cake. Actually this was a piece of pie

[@joepie221]

Yes it was. Good call.

[@benkeller3]

AS usual I learned something... Thanks for your Videos Joe...

[@MichaelLloyd]

I'm just a beginning hobbiest but videos like this one are extremely helpful for letting me know what is possible. The lathe you were using, or at least the lathe that was shown at the very end, was different than what I've seen you use.I'm looking for the "turning small parts" video. I've been very successful with screwing that up :o)

[@donzmilky5961]

Just like there's bill nye the science guy, we have Joe pi, the lathe guy. Your lathe videos are great. I miss the eat shit comment on the whiteboard though haha

[@MrKidkiller159]

crafty guy you are joe !!! awesome! !

[@shakdidagalimal]

high rez and I didn't see any wobble when that 11 thou wall was emerging...

[@angrydragonslayer]

Brings me back to when i was doing medical stuff Some jackass wanted a flexible (as in, our CMM moved the middle of the plate .8 mm when measuring) plastic plate with raised edges and standoffs for screws (no inserts despite my objection) that had to be 0.15mm thick across a 800x600mm plate

[@robguyatt9602]

Hi Joe, I do a lot of machining Acetal. Great to see many of my techniques are shared by an expert and even greater to learn new techniques. I make go/nogo gauges for measuring production parts due to the difficulty of micing thin-walled parts. I use HSS mostly but I recently busted another small HSS boring tool. So I thought why not try grinding an old 3/16 solid carbide endmill. OMG, it's great. I take heavier cuts than ever and I can't imagine ever busting this little bugga. Yeah ok, I ain't holding my breath LOL.

[@TheBsavage]

Wow, that was beautiful. Like watching an artist produce a masterpiece. How in the heck did you discover/learn that was the way to do that particular work?

[@joepie221]

Trial and error. It just made sense once the failures were analyzed.

[@bro7269]

Boy, I envy you guys that have rigid, accurate machines and sharp tools.

[@joepie221]

Things we take for granted for sure.

[@cylosgarage]

That was amazing! Great tip joe 👍

[@Idontwanttosignupist]

Awesome. I had to make a 5mm to 1/4 collet sleeve yesterday and remembered this technique. 27 thou thick - easy.

[@joepie221]

Glad it helped.

[@tonycstech]

Me: Think walls on aluminum or steel ? Interesting. Joe: PLASTIC HAHAHAHAHA !

[@adhawk5632]

Wow, that technique worked perfectly 👍👌🇦🇺

[@joepie221]

It really does.

[@c0ulter]

Joe, your not only awesome at machining, but your a great teacher as well. Out of all the other channels I watch, you take the cake in both departments. Thanks for putting your knowledge out there!

[@keithscott9774]

Now that's a great technique, and so simple (when you know how). Thanks very much.

[@joepie221]

Glad you like it!

[@cmguitar50]

Just did this to make a 6mm ID /.250" OD bushing in brass for an encoder pulley. The ID was a tad small, but after I split the tube, it fit great :) THANKS FOR THIS GREAT VIDEO!

[@merlinsunde2094]

never saw THAT before. thanks.

[@grayskwerl4973]

Amazing technique to watch - but it makes great sense, and evidently works very good. + Thanks +

[@jmriph2354]

Just used the technique to make some 1.5 mm cross section x 30 mm thick tubular features in ABS to size in one shot, Thank you Joe!

[@joepie221]

Way to go.

[@hodgepodgeenginerd1258]

Love your vids Joe. How much of this stuff did you learn the hard way?

[@joepie221]

Its all hard if you don't know how.

[@kashibaengineers97]

I want make delrine tube of 0.157 inch od 0.11 id and 5.9 inch length plase help me how can I machining .

[@giuliobuccini208]

Better technique: 1. prepare a long alu-pin having the diameter equal to the desired ID 2. make a long hole of the same length in your part 3. fit the pin in your part 4. tight them together in the jaw 5. do your stuff to get the desired OD A more precise piece of cake.

[@Soulatheunholy]

Depends on if the part is too thin. Or it will distort regardless of the pin.

[@pierdolio]

You have no equal on the web.

[@joepie221]

Thank you.

[@peteramor9810]

Yet again the master demonstrates in way that can be understood by everyone Really look forward to your videos Joe Even thought i was a fitter turner for over 50 years you manage to teach me something every time It's the simple things that can make life so much easier You take care Joe and looking forward to the next one Pete from the UK

[@joepie221]

Thanks for watching Pete.

[@johntenhave1]

holy dooley! When you put the dimensions up, I thought this is simply not possible. Had I not seen it for myself, I would still think it was an impossibility. Pucker factor and education 10/10! Great video from Pie university. Thanks again Joe.

[@joepie221]

Glad you liked it. Have you watched the 'Extended small diameter turning' video?

[@johntenhave1]

I did, Joe. I could not believe what I was seeing there either. But I believe it now!

[@PixieDixie-r5v]

Engeneering Master Class!

[@Harrzack]

As always - a great learning experience watching a machinist’s machinist at work! I just wonder how you get the time to keep that large shop running AND have time to get these very helpful videos done. ⚙️🛠

[@toddsorensen6504]

What a great teacher you are, Joe. Thanks for your willingness to share your knowledge and experience. I don't suppose you'd like a seventy-something year-old apprentice, would you?...

[@joepie221]

Only if shes 5'10, blonde and well preserved.

[@toddsorensen6504]

Well, I guess we'll both have to keep looking. Wrong gender, what hair's left isn't blonde, not so sure about the preservation. OK on the height, though...

[@gilbertodiaz-castro626]

As always a great video. I know you have a full schedule with your company but perhaps you should become a machine shop instructor at the local community college, many would appreciate it. You don't only possess the knowledge for it, you have the wisdom of how to explain things to make them Lieutenant-Proof... Even an old gizzard like me can learn with you as instructor. (Lieutenant-Proof is a term that comes from when Gen. McArthur was having trouble getting the lowest man on the list to understand his exact original orders so he went and found the dumbest guy he could find in the field, made him a Lieutenant so he could be the "General's Aid" when this guy was able to explain to him exactly what he wanted his orders to convey those were the words used to send the orders down the pipeline.)

[@patricksullivan9951]

Now that was impressive!! Thanks for the tip!

[@dougalan5614]

What an awesome demonstration! I need to make just such a part, and this will help immensely! Thanks again, Joe.

[@joepie221]

Nice. Good luck.

[@wallacesaan]

A really great technique, clearly explained and demonstrated (as always!). Thanks very much.

[@red32303]

If there isn’t enough meat on the OD, put a pin in the bore. A narrow or even angled front edge cut off tool will keep you from tearing the part.

[@AlisRIOSteff]

I just blew this exact type of part in my hobby shop, this is just the video I needed thanks for all your knowledge!

[@imysteryman]

Watched this again but problem is I can't click the liked button twice

[@joepie221]

Thank you

[@clemwyo]

Thanks for a great technique. I had a part similar to the one you made that gave me fits. Now I know how to do it. Sure appreciate all the great tips you share. Craig

[@AgentWest]

Hey Joe. I just watched an episode of "Supreme Skill" (a Japanese TV show) and immediately thought of this video of yours. It would be interesting to see you make that part using the technique you show here. The part is 20mm OD tube with a 60 degree flare to 50mm OD on each end. The whole thing is roughly 60mm long and is made of one piece of material. Wall thickness is 0.3mm. You chose the material, no need to go all out with titanium like they did :) Don't think youtube allows links in comments any more, but if you search for "Supreme Skills! Turning vs. Spinning" it would be right at the top.

[@cmguitar50]

Love it! I wouldn't have thought of doing this until I saw the video.

[@teslacoolguy]

I used this technique to make a part with a .020" wall thickness and it worked excellent. As always thanks for the great informative video.

[@martyscncgarage5275]

That was awesome Joe! Thanks for the great tip.

[@bunnythekid]

I managed to make some very thin plastic bushes using this technique but every time I tried to part off it just tore up. I’ll have to remember to part it off like you did next time. If I remember correctly I ended up using the tool as a rest and cutting off with a Stanley knife. Do you think this would work with copper, too? I’ve little experience working with it and I don’t like the idea of spending my time and money turning copper bar into lots of smaller pieces for the scrap man.

[@SirFlibbertyJibbit]

Good techniques. When turning and boring thin walled PTFE the best way I've found is to have a high depth of cut on both ID and OD. I use a vacuum with the pipe mounted on the cross side to suck up the swarf.

[@joepie221]

Thats slippery stuff to hold securely. I like cutting it.

[@sebastianhamann9846]

I always do the id first,deeper than the finished part ,then use a gage pin on the id to support the material,then finish the od.

[@graemebrumfitt6668]

Awesome Joe, TFS that is one great bit of a technique, Bogs Dollocks Dude :-)

[@rickveren5502]

Great to have your videos to educate those that are hobbiest like myself but love the trade. I used your guidance to machine a brass sleeve for the tailstock on my jewelers lathe. Almost the same wall thickness of .010”. It worked great! The draw in bar was about .010” smaller than the tail stock casting and I was considering boring it out for a meatier bushing. The problem was it’s hard for me to justify modifying such an iconic old lathe. So I figured I’d give this a try and see if it last. It will allow me to use the tailstock with a small precision as a drill chuck and keep center as I feed it in. Btw, I tried to sneak up on the final size and it didn’t work to your point. So awesome that your share your skills and knowledge. Truly grateful 🙏 Have a blessed new year Joe!

[@joepie221]

Glad to hear all ended well. Happy New Year to you as well.

[@brianevans1946]

I was just wondering as I was taught to bore the inside first and you just confirmed it..

[@williamreymond2669]

I like it. So... its a little like gundrilling - sort of - the material itself supports and guides the work? At what length/diameter ratio does the turning speed destabilize the process? This was actually a pretty fat part in term of its own stiffness.

[@whatif8700]

Fantastic video as always Joe. Most of us recognize that in this instance, pullng the chip away with your fingers while the spindle is running is not a serious hazard. However, when cutting metal it can result in serious injury. Given that many viewers of your videos are new to machining, perhaps an edit to include a warning would be in order.

[@joepie221]

Good call.

[@bertr5650]

Nice one Joe. Thanks for all of your time on the videos and all the best for you and family over the Xmas period. Cheers Bert

[@joepie221]

Thank you. Same to you and your's.

[@dws8364]

Awesome! Thanks for sharing!

[@ianpendlebury3704]

Excellent, informative content as usual. Was there a special grind on the boring tool - it looked unusual, but maybe it was just the camera angle?

[@richardphatthenguyen195]

Same, I was wondering what kind of boring bar it is from.

[@joepie221]

3/4" HSS drill blank ground down to a 3/* shank. The head is a double angle 45 for internal chamfers and undercut work. I made it.

[@MrJmBecker]

Many thanks for this very informative video. What I'm wondering about is how you would do this in SS ,because a straight one outside cut , like you did in the Delrin, would not be possible , at least not on my lathe.

[@joepie221]

A more rigid machine could pull it off. Starting with a smaller OD would help.

[@Gottenhimfella]

One thing I wondered about stainless, if it "rang" like a bell on the final cut, would be to first tip it up and pour in some low melting point metal so it became effectively solid round stock (bismuth alloy, which melts at less than 100deg C). This would dampen the vibration, and melt out simply by immersing in hot water. I seem to recall shrinkage is minimal with this stuff, presumably partly because it doesn't need to cool hardly at all. You'd need to make sure your sharpness, speeds and feeds were up to snuff or the stuff might melt during the cut and get incorporated in the swarf in the tray!

[@toddk.5873]

Thanks Joe. I watched this video for fun the other day & by coincidence I needed to make a couple of 0.015" walled x 7/16" aluminium bushings the next day to tighten up some slop on a motorcycle clutch lever housing. It worked like a charm. I just wanted to say thanks again.

[@davestambaugh7282]

I had a lot of experience machining delrin and never noticed how stinky it was until I had to hog out some rings from six inch diameter, and the fumes from the formaldihide made my eyes water.

[@cmguitar50]

Get the fan!

[@davestambaugh7282]

@@cmguitar50 I did, and I opened the double doors also.

[@sharkbaitsurfer]

You're a true Guru and you just won a new fan! Subscribed

[@joepie221]

Thanks and welcome to the channel.

[@patdenney7046]

You're a real Machinist wow first time I watch the channel

[@dfpolitowski2]

Good Job! Never knew this technique.

[@jostouw4366]

Material don't matter? Try titanium 3/4 i/d 2 thou wall thickness 2 inch long on a part after two hours of other machining and its down a 5 inch long bore so three inch deep 2 inch hole then thin section and square bottom face, That was fun!

[@dziggy3004]

"Shucks, boss! There goes another one! Got any more blanks?"

[@oddjobbobb]

I know your intention here is for educational purposes, so, did you specify the ID so exactly because you wanted to emphasis that this, apparently difficult operation, can be done to a very exacting specification?

[@glenj.taylor2938]

I would imagine that's exactly what his intention was.

[@rtkville]

Excellent!!! Very good.... thank you!

[@HolzMichel]

say Joe, my first inclination would be to either make the part in a sleeve or on a mandrel. is there anything that would speak against that other than the time factor?

[@joepie221]

A mandrel would influence a part like this. Zero contact is the only way to go.

[@marcellemay7721]

My take on the keys to getting this to work. Use a very sharp tool, HSS is great for this. Bore the inside first. Take the outside cut all at once. This works well because the material that you haven't cut yet , in front of the cutter supports the thin part at the cutter. This is the reason why you cant take a second pass, as there is no support material left.Did I miss something? Great tip!

[@joepie221]

No, your observations are Spot on!

[@TinaKelley000]

Wow

[@richardcox3485]

Wish I would have seen this about six years ago, had to install new steering bushings in my lawn tractor, I tried to make them but did exactly what you said not to do (sneak up on it) oh well only 46 cents a piece at the time but of course 6.50 for shipping lol. Joe you always explain things so well. Thanks.

[@Jointroller89]

Don’t touch the chips. Plastic will cut you too

[@daveknowshow]

I needed this video two years ago. I successfully made the part but there were many failures to get one part successfully. log this in my bag of tricks thanks for another great video!