CUSTOM CALIPERS PART 2

[@oxtoolco]

Hey Robin, You got me hooked. Great work and a great series. Can't wait for number three. All the best, Tom

[@littleworkshopofhorrors2395]

What what, Tom has come down from the screen and joined us mortals in the cheap seats! Must be worth viewing, as if there was a doubt.

[@465maltbie]

You know this is a couple of years old but in 10min I have found 3 things I want to copy....thanks for sharing.

[@anidiotinaracingcar4874]

That was mesmerizing

[@doubledown9333]

A real eye opener as to the precision and workmanship involved in this job,i am amazed,you are a true master.

[@erikisberg3886]

That method for putting precise radiuses on pins is ingenious, definitely a keeper! Great when its not fitting into the dbit grinder, and lapping the surface finish in the same setup...

[@brettzahler7403]

It is a joy to watch a master at work! thanks for taking the time to video your work outstanding!

[@ROBRENZ]

Thanks for the kind words.

[@yawpaw9796]

23:35 epic fingering action, always consider fingerprint thickness when installing chuck on the spindle nose, here an hour worth of wisdom about fingerprint blueing. Love your vids!

[@KD0CAC]

Hay Rob , dang you made miss my friends home shop , I started working with him some yrs. ago with benchrest gunsmithing , and other goodies including split bambo fly rods . He retired from retirement and sold his home shop . Sure with I could bought him out . Watching you channel reminds me how much I miss making stuff , doggie dew ;) Thanks again John

[@BorisSpark]

Such clever man!!! So much to learning to do, literally sitting here and just realising how little I know. Oh how much I want to meet you and learn from you!!

[@paulbluffbearcampbell6035]

Awesome. Anytime you have to make or mod a tool, in order to make or modify, the tool you are using, to make and modify your project, is a winning video for me!! Saweet channel and I can't wait for more videos. Paul

[@ROBRENZ]

Thanks Paul, many more to come.

[@StraightThread]

Very interesting detail work. Really a pleasure to watch over your shoulder.

[@ROBRENZ]

Thanks Richard and thanks for watching!

[@nder12345]

You have blown me away with your skill. I am 20 and your videos are.really interesting I am keen on Part 3 Thanks for sharing and hello from Australia

[@ROBRENZ]

Thanks Andre, part 3 is up and many more to come.

[@thomasutley]

Another excellent presentation Robin. I love the chuck jaw depth stops.

[@ROBRENZ]

Thanks Thomas, I plan on a video on the stops describing the thought process of the design and a some of my other chuck stop techniques.

[@marcellemay7721]

Amazing work! This is true tool maker work. Great stuff.

[@ROBRENZ]

Thanks again Marcel!

[@bcbloc02]

So cool to see this technical stuff done, thanks for sharing.

[@ROBRENZ]

Thanks for watching!

[@deanschober5183]

You have an outstanding skill set! Attention to detail in both design and build is fantastic.

[@ROBRENZ]

Thanks for the kind words.

[@EliteHydronics.]

Absolutely stunning Rob ! looking forward to the next segment 👍🏻 Regards Dave

[@ROBRENZ]

Thanks, part 3 should b up late afternoon.

[@indoorherbivore]

Expert work, excellent presentation. I'm hooked too.

[@ROBRENZ]

Thanks, glad you enjoy the content.

[@droboepk26]

Can't wait for part 3! Excellent work as always.

[@ROBRENZ]

Thanks, part 3 is up!

[@rengecko]

Hey Robin, enjoying the vids since OxTom pointed me this way. It's great to see these types of projects and the techniques needed to execute them. Call it a complement to Abom sized work...fun to watch at a very different scale. Best, Tom

[@ROBRENZ]

Thanks Tom, glad you are enjoying them!

[@1musicsearcher]

I really like how you dub the video with that terrific camera work.

[@PhilsProjects]

like a deer looking into headlights, I'm hooked. great work, great video, I'm schooled Thanks for sharing

[@ROBRENZ]

Thanks Phil, I have just started watching a few of Pierre's videos and have seen you in action but I just subscribed to your channel. Thanks for watching.

[@PhilsProjects]

Hi Robin, Thanks for taking the time and Subscribing.

[@stevenclark541]

I am blown away by your precision. I Have to know, have you ever spent such time on such a tiny part and just dropped it and lost it? I Hope that i can ever closely emulate the precision you have displayed but im Terrified of losing something that ive devoted so much time and effort to. I lost an adjustable micrometer tip on my first day as a machinist and the old_timers gave me hell for it till my last day 4 years later.

[@christurley391]

You do some very nice work. Thanks

[@ROBRENZ]

Thanks again again Chris!

[@RRINTHESHOP]

Great work, watch every minute.

[@ROBRENZ]

Thanks Randy, that is why editing takes so long since I try to remove every second of fluff and speed up every clip I can.

[@886014]

Some interesting techniques here, thanks for sharing. I liked the chuck stops. I have a couple of chuck spiders I made up for this type of job, but I like those stops for more precise work.

[@ROBRENZ]

Thanks Pete.

[@shotgunreloader4964]

You hit on a novel niche for the videos, Like how you explain the the things that might go wrong and love the how to finish items with professional touches because to me for example machining marks on a part is only half completed.

[@ROBRENZ]

Thanks Guy and thanks for watching

[@africanelectron751]

Love your channel learning so much.

[@cnc-ua]

26:00 an everything about stops are amazing. Thanks

[@ROBRENZ]

Thanks cncua and thanks for watching and commenting!

[@Kettletrigger]

"And here I'm power tapping the 0-80 thread." Jesus. Great vid!

[@ROBRENZ]

Thanks!

[@sp1nrx]

Personally, I find #6-32 or 1/4-20 more likely to break than #0-80. There's not that much being removed proportionally to the diameter as the two examples above.

[@ROBRENZ]

I agree completely and if the part was aluminum I would be using a 0-80 thread forming tap in that driver.

[@sp1nrx]

I have replaced most of the small hole tapping with form taps using machines. I rarely have problems with chips and tap breakage. However, most of the work I do requires cut taps since the holes are so close to the edges of the work (.030 from hole to edge with #4-40 in Aluminum). There's a requirement of no edge distortion and form taps aren't consistant within that dimension PLUS I must have fully formed threads into a smaller intersecting hole. We do 10s of Ks of those a year. It's a proven system.

[@duobob]

6-32 is a very easy tap size to break. I must admit to no experience with 0-80, but I am pretty sure I could break them taking them out of the packaging... 8^)

[@turningpoint6643]

You've come up with some really clever and specialized tooling by the looks of it Robin. Just an idea for some future videos. Maybe a shop tour showing what you've built to help hold and machine parts like this might be worth it if your not too concerned about giving your ideas away would be more than interesting. Just holding very small parts can make the job far tougher than dealing with the more average sized in my limited experience. Really liked that extended indicator post on the top of your quick change as well. Again very well thought out.

[@ROBRENZ]

Thanks, I promise you will eventually see all my existing goodies and see me making any new ones.

[@Kettletrigger]

Would love to see more of that HLV-H when you do the shop tour...the dream machine.

[@ROBRENZ]

Kettletrigger They are dream machines. And I have run quit a few but this one amazes me every day.

[@wktodd]

Marvellous stuff Robin. I see you've replaced the awful cross-slide lock-bolt for the taper attachment with a count sink head screw - I've been meaning to do that for years ! How about a video of all the other HLV-H mods you've done ?

[@ROBRENZ]

Thanks Bill, I will be showing all the mods eventually and thanks for watching.

[@AtelierDBurgoyne]

I am completely hooked on this series. I love the precision work and am learning tricks. Your jigs and own-made tools are quite different than other youtubers. Are these your own ideas and designs? Wow! Two six-jaw chucks, one mounted with internal and one with external jaws!!! Time saver. I use laps of iron, brass and hard wood with different grits in clockmaking and toolmaking. You used iron, aluminium and then paper (which I will try!). Do you use wood and brass anytime? If not why not? Thanks. Daniel

[@ROBRENZ]

Thanks Daniel, yes these are my own ideas/designs. Two six jaw chucks, soft jaw chuck, mag chuck Northfield air chuck, etc. I am making a living in this shop so time is money. There are a lot of time saving tricks that I will be sharing in the future. Yes to all of the lap materials. As you well know each has its own strong points and weak points.

[@jasonburns1407]

Nice fine work well done

[@ROBRENZ]

Thanks for watching!

[@ronpeck3226]

I am in! Great analogy with the shot glass and Christmas bulb. I assume there is a radii on the inside of the hole. Looking forward for 3rd phase.

[@ROBRENZ]

Thanks, The lap self forms a matching concave radius where it is in contact. Part 3 should be up tomorrow evening.

[@tesladrummer]

"Shop Notes"* • Overview of steps in this video. • Radiusing the pins • Lapping the spherical ends in the lathe with a die grinder adapted to quick-change toolpost. Hollow cylindrical lap at an angle. • Flex-shaft rotary grinder 22K RPM*: Not a Dremel, not a Foredom, not a DuMore(money), It's an inexpensive import from a company you've never heard of: SE. American Science & Surplus (all around cool company, different handpiece): www.sciplus.com/p/VARIABLE-SPEED-FLEX-SHAFT-GRINDER_43486 Amazon (different handpiece): www.amazon.com/SE-979FSG-Flexible-Grinder-Switch/dp/B000NW4YRK/ Amazon (Foredom handpiece): www.amazon.com/Handpiece-No-28-Tapered-32in-Collets/dp/B000WTM200/ *Note that the similar looking tool sold by Harbor Freight only goes to 15K, which is ~68% of the SE. • Review of the drawings for the jaws • Machining the jaws. • Rob shows his sets of thin parallels including a set of wavy ones. • Loctite 380 (BlackMax): KBC Tool: www.kbctools.com/products/FLUIDS/ADHESIVES/ADHESIVES%20@@26%20EPOXY/4098.aspx McMasterCarr: www.mcmaster.com/#loctite-380/=19rh7aq Amazon (tube 0.1 oz): www.amazon.com/Adhesive-Instant-Black-Loctite-Corporation/dp/B000132VKI/ (bottle 1.0 oz): www.amazon.com/Loctite-135423-Toughened-Instant-Adhesive/dp/B000132VEE/ Loctite website: na.henkel-adhesives.com/product-search-1554.htm?nodeid=8797890609153&msdsLanguage=EN_US&selectedTab=technical • Drilling and tapping the jaws. • Cool-Tool 2 + Tetrahedral Boron Nitride Unfortunately, Cool Tool 2 can't be sold in California. McMasterCarr: www.mcmaster.com/#cool-tool-ii-cutting-fluids/=19perdz Rob's link to Boron Nitride (Amazon): www.amazon.com/Boron-Nitride-BN-Powder-Purity/dp/B015ENSWHA/ • Grinding down a woodruff cutter to make a slitting saw. Using a cut-off disc to slot the flexure in the jaws. • Making support flanges for a cut-off wheel mounted in a surface grinder. • We get a peak at the chuck backstop system that has since become very popular. • Good tip about creating a dish when edge-holding in the chuck. • Norton Cut-off wheels: MSC might have the right one: www.mscdirect.com/product/details/01833508 Obviously you need to size appropriately for your machine. *Not affiliated with any manufacturer or distributor. Updated 10/12/2017 per Robrenz notes.

[@ROBRENZ]

Thanks brs_workshop! I have added the link to the tetrahedral boron nitride powder in the video notes. I got that flexible shaft (new) from our local flea market. I have no reason to think your source isn't the same unit. I corrected the just handpiece link as it is a Foredom handpiece. You may want to cut and paste the corrections in the video notes into your comment. Thanks again for your awesome work!

[@plnmech]

Since this all very small work, it is hard to get an idea of what equipment you are using to perform the work. Would you please make a video showing what equipment you are using?

[@ROBRENZ]

Hi John, Hardinge HLVH toolroom lathe, Bridgeport mill, Harig 6 x 12 surface grinder, Roll in saw www.google.com/search?q=roll+in+saw&biw=1280&bih=566&source=lnms&tbm=isch&sa=X&sqi=2&ved=0ahUKEwiJ_p7krfDNAhXDdSYKHeF2CeoQ_AUICCgD#imgrc=X9_tURbVPzCaaM%3A

[@sapago4166]

My favorite part in the last video was when he said the 1/4" length of the pin wasn't critical and then cut the pins to 0.2500" in his jig.

[@sblack48]

When you are milling and you have to pick up the top surface of the work to mill to an accurate depth how do you do that? And what kind of bandsaw cuts that straight??? Amazing work.

[@ROBRENZ]

I have a 3 axis digital readout on the mill and I just touch the cutter to the top of the work with the spindle off and set Z zero and then move the depth that I am after. The saw is a Roll in saw www.google.com/search?q=roll+in+saw&biw=1280&bih=566&source=lnms&tbm=isch&sa=X&sqi=2&ved=0ahUKEwixuZfQ7PLNAhWNZiYKHUnwDrkQ_AUICCgD#imgrc=X9_tURbVPzCaaM%3A Thanks for watching!

[@RambozoClown]

What is the formula for calculating the radius produced by the hollow lap angle? These are fascinating videos. The kind of fun specialty projects I rarely got to do at a production shop.

[@ROBRENZ]

I usually just lay it out in Solidworks

[@timewarp0077]

Hi, Can you please do some more video on your roll in saw, and any tips that let you use it more effectively? Is it the only saw in the shop? Thanks

[@ROBRENZ]

It is the only saw in the shop because it is the only one you will need and it take s up very little space. I have a full Roll in saw video on the list.

[@parkermusselman9824]

Why is the product of the rotary lapping spherical and not conical? Is the face of the lap getting cut along with the workpiece giving you a sphere? Thanks for the video! Very informative.

[@ROBRENZ]

Think of a shot glass rim resting on a round Christmas ball. Now make the contact line of the shot glass rim intersect the axis of rotation of the Christmas ball. Now turn the diameter of Christmas ball down until only half of the shot glass rim is touching. It is still generating a sphere.

[@parkermusselman9824]

Thanks for getting back Robin, I appreciate it!

[@1jtolvey]

GREAT VIDEO !!! KEEP IT UP !

[@ROBRENZ]

Thanks, wiil do!

[@dizzolve]

2:25 what model flexible shaft do you use there. Thanks in advance

[@dip20000]

Professional skill,and nice videos.What is your full time job?

[@ROBRENZ]

Thanks, you are watching me make a living in my own shop. Tom Lipton just made me realize I should be sharing it with the community.

[@TheMetalButcher]

I love seeing someone with all of their tools set up just how they want, so they can jump from jig to jig as they need. Those chuck stops are cool. I'd didn't notice how the chuck holds onto the lathe. How is the taper tightened? Hold up. Are you bench vise jaws scraped?

[@ROBRENZ]

At 23:36 you can see the pin in the chuck backing plate when I am wiping it out. Then you can barely see the slot on the top of the spindle nose that that pin engages in. You can tighten it either CW or CCW depending on how you will be cutting. Yes that front jaw is scraped. I could not resist when I was scraping Toms level.

[@TheMetalButcher]

I see it, but I don't really see how it works, so I'll just assume it's magic until I google it someday. But it does seem like a tremendously better setup than my threaded chucks. Your crazy lol.

[@anothermoth]

The pin keys into a slot that's nearly T shaped, except the arms of the T are angled slightly towards a Y shape. With the pin engaged with the slot, rotating in either direction away from the centre pulls the chuck onto the taper.

[@TheMetalButcher]

Ah. Thank you. That is smart.

[@ROBRENZ]

That is a most excellent description!

[@floodo1]

How does the lathe + rotary tool setup make the end of the pin spherical? seems like it would put the equivalent of a chamfer (sorta like the end of a pencil) ... what am I missing?

[@ROBRENZ]

The lap has a hole in it. Picture a shot glass rim sitting on a Christmas ball. The edge of the lap hole must always intersect the centerline/axis of the pin. If the rotary tool axis was parallel to the lathe axis it would lap a flat surface which could be considered an infinitely large radius. As you tilt the rotary tool axis the radius generated gets smaller and smaller until it approaches the radius of the hole in the lap. Watch this ball lapping from one of my other videos here kzbin.info/www/bejne/goi4eZ-vnpJrg8Um49s and it should make sense.

[@floodo1]

Isn't the spherical lapping in the Camera Mount video different because the two axis (Lap/Lath and drill) change in relation to one another and because the part is in a different position in relation to the lap? That said, the camera mount video got me thinking about how the lap hole is effectively a 2d circle for a cutting edge and then what the profile of a circle looks like if you approach it from an angle. Really cool geometry and now I get how the offset and angle combine to determine the shape of the end of the pin. For me it's easier to understand the spherical grinding like the Camera mount where you have 3 axis of rotation but this use of 2 axis of rotation (just lathe and lap) is really cool (-8

[@ROBRENZ]

They are the same. The camera mount lap is almost the same size as the ball. Therefore the lap can ride the ball without guidance. The drill gyrations are not necessary if I held it at the correct angle. On the 0.4" radius pins (0.8" dia.) the lap ID is 8.5 times smaller and cannot ride the small spherical surface without external guidance.

[@floodo1]

Thanks for the info. The fact that the drill gyrations are not necessary is the cool part that I didn't understand. All the spherical lapping videos I've seen use 3 axis (3rd one being the drill gyrations) and similar ratio of lap to part as the christmas balls. In that setup the drill gyrations appear to be the sort of 'magic' as to what makes the sphere but thinking about this 2 axis of rotation and wildy different lap to radius size really highlights what's going on with the 3 axis setup. Powerful stuff!

[@hedroncollider]

In a career as a tool maker, when do guys have time to make those time saving devices like the stops used on the 6 jaw chuck? After hours, or is making time saving tooling supported to a certain extent by management so it can happen on the clock?

[@ROBRENZ]

It is definitely supported by the management which is me! I make a living in my shop working with my son.

[@hedroncollider]

I guess I was assuming some of the tools you have made might have come from a period as an employee at some previous job(s)! Anyway, your videos are truly excellent, thanks for sharing your experience and technique! Keep up the good work!

[@ROBRENZ]

I bought the Bridgeport you saw in the video when I was 17 so I have always had access to equipment outside of work.

[@dannymaciejewski]

27:20 "Notice I have no compound on the tool rest... thats intentional" haha!!

[@alexkern9134]

Hey Robin, very cool technique to generate the spherical radius on the pins. Great idea. I assume that it only works "in theory" with a dead sharp corner on the face/ID of the lap, correct? Thanks for the great videos, Alex Kern

[@ROBRENZ]

Correct, the lap starts to wear forming a matching radius that will eventually cover the entire wall thickness of the lap

[@ROBRENZ]

Actually not correct, the sharp edge is just to define the geometry and starts to wear to a matching radius immediately and does not cause an issue.

[@alexkern9134]

+ROBRENZ Gotcha, I was pondering it a little bit after your first reply, wondering if in fact the sharp edge didn't matter. Thanks for the clarification.

[@johncrea9395]

Robin Love the mention of a 'home-brew' mix of • Cool-Tool 2 + Tetrahedral Boron Nitride. Exactly how do you mix it for use in tapping?? John

[@ROBRENZ]

I just eyeball about a teaspoon of powder in a quarter cup of cool-tool and stir it up. It does settle out so you have to give it a stir every day. I am not sure how much it helps but it helps psychologically.

[@travisshrewsbury7169]

Henceforth from this day let Robin be known as the professor,class dismissed.

[@JPGuay]

Awesome !

[@ROBRENZ]

Thanks for coming back!

[@KD0CAC]

So much for proof reading ;)

[@ROBRENZ]

What did I miss John?

[@greasysteve5671]

Saw, joint, saw, joint. Rinse and repeat

[@premierd8988]

Did you miss your weekly manicure Robin ... lol

[@adam19890911]

23:22 I cringe less at the dentist. That is some machinist horror scene.

[@ROBRENZ]

LOL

[@aronnootebos805]

5:00

[@JustinAlexanderBell]

11:32 I thought I turned my multimeter off...

[@ROBRENZ]

At least you remember what it is called : )

[@joshua43214]

/sigh, I always wanted to be a tool maker. Any tools makers out there that want to be a mathematical biologist? Ill trade you careers...

[@ROBRENZ]

Thanks for watching Joshua, I don't think you will find any takers/.