Recreating Dan Gelbart's Bending Brake, Part 2

[@dgelbart]

The 3/4" support bar for the fingers is indeed welded on both edges to the top 1/2" plate. After welding the plate is straightened in a press (+/-0.04") and the finger mounting surfaces are cleaned up in a mill. 2. The vertical bar to stiffen the bottom A2 plate is screwed to the plate with 5 M8 or 5/16" Allen cap screws. All the shafts are 3/4" dia 1045 shafting. The rear eccenters should be hardened. No need for so many segments, use a 0.5"-1"-2"-4"-8"-8.5" set. This gives you 48 sizes with just one extra tapped hole between the 1" holes. .

[@edworks7718]

Thanks for stepping in and lending a hand Mr. Gelbart!

[@dougschafer5161]

Hi Dan, your videos are amazing and have inspired me to develop a large range of field machines. If I ever get the chance to meet you please let me know, it would be an incredible honor.

[@JonScottSmith]

Fantastic! Glad this project is not dead. Perhaps Mr. Gelbart will come give some more insight in the comments section.

[@michaelnelson123123]

If there are only 11 of us following this project then I'm proud to be a member of such an exclusive club! Such a cool project!

[@numberkruncherr]

Finally!! I was thinking about this a couple of days ago and had written it off as never finished. Quite understand the hassle of moving a workshop, our hackspace has been largely in limbo for a year. Now if somebody could just replicate Dan's spot welder...

[@JohnDoe-ki6yd]

I’m turning this over in my head right now.

[@numberkruncherr]

@@JohnDoe-ki6yd The Spot welder? Dan's video on the subject is a masterclass, and it would be great to have that sort of functionality in our hackspace. But it really needs a spotwelder as capable as his. It wouldn't need to be an exact clone, but there are three things that I can see in Dan's design that raise it a couple of levels above the DIY designs I've seen on KZbin 1) The foot operated pneumatic closure 2) Fittings for different jobs 3) (possibly least important) It looks like it closes vertically, rather than like a pair of jaws

[@capcloud]

these drawers look sharp!

[@bradywalters2931]

So happy to see part 2 and looking forward to future videos. Thank you.

[@heinrichhemker8123]

Very well done - somebody once wrote: If its good in wood, I'll settle for metal. Very much looking forward to your next video!

[@Rube2017]

Fascinating project. Really enjoying watching the reverse engineering process in action.

[@skivvy3565]

Part 2!!! Finally! I’m so excited to see this, and anything with dan gelbart’s name. Thank you

[@VastCNC]

Super happy to see this moving forward, and glad I thought to look it up a day after you had posted the update. I was subscribed with notifications but didn’t see it drop

[@altonschultheis303]

So glad I subscribed, I was hoping this project was still alive!! I’m very interested in seeing it come together!

[@clauderamsey9904]

Nice work. Truly a labor of love. I do reverse engineering for a living and the fact that you've gotten as far as you have, is very impressive. Kudos.

[@mattym8]

Weld distortion can be minimized by simply not welding a full pass. Stitch welds will do fine. If you share your Photoshop files I’ll model this in CAD and assist with the build. I own a fab shop in Canada.

[@junkyard_kahrs]

That's a good tip on the welding. Photoshop file with layers (and a jpg version) are now linked in description. This is a 5000 X 7000 pixel image, errors and all. I do like the idea of open-sourcing this...

[@mattym8]

@@junkyard_kahrs Let's open source the design when a working example has been built. We should work privately until then. Put a contact method in your profile so I can get in touch. I have a rough model done but YT wont let me post the URL

[@mattym8]

FYI: McMaster sells spherical washers that eliminate machining your own ball/socket. I didn't know either until today.

[@junkyard_kahrs]

@@mattym8try to dm me: stoakmachine on Insta

[@wmc7870]

Thanks for sharing, im sure it is very rewarding seeing it come together after head scratching and doing detective work with clues along the way! I would love to get a better grasp of the lapped back plate 4 jaw self centering chuck set up that Dan has on his lathe. I have tried and failed to figure it out on paper...

[@yirgalemdesta7869]

Nice work I was also impressed with that brake .please finalize it and realeze the video. With regard to the little bit over sized sprocke holes i think you ca use loctite to fill the gap I hear Dan Galbart saying you can apply loctite to fix bearing movements. Thanks

[@SamEEE12]

I think Dan mentioned that he nitride coated the mild steel parts - I might be remembering that wrong though

[@AdityaMehendale]

As one of the eleven guys: Did you try to reach out to Dan Gelbart regarding this project? He is surprisingly approachable, and reads/replies to messages on his YT-channel.

[@junkyard_kahrs]

He provided just the right amount of clues to keep me going in the comments of the first video. Would love to meet him one day… one of the charms of this project is the challenge of figuring it out…

[@dgelbart]

Re questions in the video: all parts are mild steel (cold rolled to minimize machining, but can be machined hot rolled). All parts that touch the sheet metal are case-hardened. The stiffening bars and side plates are welded (after placing alignment dowels or screws). The welding caused little distortion but the case hardening caused some additional distortion. The case hardening was very deep (about a mm) to allow to correct the distortion by grinding with a sanding disc held in a table saw. At the time I had no oven or press, so I could not fix the distortion in a press. If you have an oven you can heat up the parts to case-hardening temperature, quench, straighten or machine off the distortion and then send out to case hardening. The didtortion now will be small as it already went through a "dummy cycle".

[@AdityaMehendale]

@@dgelbart Thanks for your clarification! Also thanks for your 25-part UBC lecture-series on servos, sensors, actuators and system-design (uploaded by "fizzym" on YT). :) Binge-watch-worthy!

[@DavidCAdams]

I might try to see if I could replace one of the links in that roller chain with an offset link to tighten it up.

[@TheBetterRyanKelly]

Is this still an active project for you? I'd be happy to put your drawings in CAD and put together a model if that would be helpful for Clearances/Confidence and what not...