Spare Parts #4 - Making, Hardening And Tempering A Form Tool For The Lathe

Machining, Hardening And Tempering A Form Tool For The Lathe, by Clickspring
There's something really classy about the old style rope knurls that you often see on tools made around the turn of the 19th century. Making them is quite an involved process, and one of the steps involves making a form tool to prepare the work surface for the impending knurl.
This is the first video in a series of at least 3, that will relate to the subject of these beautiful ornamental knurl patterns
The main project video that this video is related to is "Machining A Set Of 'Vintage Style' Rope Knurls ": • Home Machine Shop Tool...
Free plans for the double angled cutter, and form tool:
www.clickspring...
www.clickspring...
If you would like to help support the creation of these videos, then head on over to the Clickspring Patreon page: / clickspring
You can also help me make these videos by purchasing via the following Amazon Affiliate links:
Cameras used in this video:
Panasonic GH5 - amzn.to/2rEzhh2
Panasonic X920 - amzn.to/2wzxxdT
Tools & Shop Products:
"Solidworks 2013 Bible": amzn.to/2FObS1D
"Lathework: A Complete Course (Workshop Practice Series)" - amzn.to/2yBv4Rb
"Milling: A Complete Course (Workshop Practice Series)" - amzn.to/2K2QZ97
"Hardening, Tempering and Heat Treatment (Workshop Practice Series)" - amzn.to/2KbZo6l
Dykem 80300 Steel Blue Layout Fluid, Brush-in-Cap (4oz): amzn.to/2HGPaJJ
Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: amzn.to/2DR5fdb
Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: amzn.to/2ITfeTa
YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: amzn.to/2G7ylv6
Kaowool 24" X 12" X 1" 2400 F Ceramic Fiber Insulation: amzn.to/2pfsM3d
Saint Gobain (Norton) - 4 Arkansas Stones + case: amzn.to/2HCOAMX
Abbreviated Transcript:
00:05 I'm about to make some brass thumbwheels, with a vintage style rope knurl. But before I can form the knurl pattern, I need to shape the brass perimeter, so that the knurling tool will work correctly, and I'm going to do it using a form tool like this.
00:20 The profile of the cutter is reasonably straight forward, but the relief angles require a bit of planning. I've chosen 10 degrees as the relief angle, and I should be able to take care of these front faces on the mill.
00:29 Ideally I'd cut the central section with a tapered end mill, but I don't have one. So instead I'll drill it out and then finish it off by hand using a file. So starting with some 1/4" O1 tool steel, I cut off a section, and then squared it up on the mill.
00:54 Using this angle block, I set the work on a 10 degree angle in the vise, and then milled a datum face. I'm going to use the digital readout and this sharpened carbide rod to mark out some key points and lines. I milled a small flat for the drill point, and then drilled out the central section of the cutter profile.
01:49 Ok so next I need to mill the work down to this reference line, as well as across to this corner, while at the same time generating the relief angles. I can take care of the main relief angle in a similar way as before, by using the angle block to tilt the work in the vise.
02:05 And the second angle can be generated by using the swivel base of the vise.
02:33 This section here needs to be profiled into a curve, while at the same time generating the 10 degree relief. I think the easiest way to tackle this is to use the belt sander, so I've tilted the table to 10 degrees, to match the other face angles, and then using a 400 grit belt, I formed the curve.
03:05 The curved section terminates at the point I marked out with the dro, and I've sanded as far into the corner as I dared, without risking the profile.
03:58 The last step is to quench harden the steel, and temper the cutting edge to a light straw. A quick polish on this oilstone, and its ready to be put to work.
04:28 A form tool like is a great way to get a repeatable profile onto a short run of parts. There's a few drawbacks in using them though, that are worth mentioning.
04:37 Firstly, there's a lot of cutter surface in contact with the work, particularly when it gets to the full depth, so it really is quite hard work for a small lathe like this. This cutter is about 15mm wide, and I'd say that its at the upper limit of what my lathe can cope with before it simply stalls.
04:50 Secondly chatter on a tool like this is pretty much unavoidable. But I've found that using a low rpm and keeping everything as rigid as possible makes it quite manageable.
References:
Frank Ford (Luthier/Machinist)
www.frets.com/H...
Machining, Hardening And Tempering A Form Tool For The Lathe, by Clickspring

[@basedjorts]

I work for an injection molding company and this video helped me out at work, the other day. We were making a new mold and had to precisely cut a rather complex shape into a cylindrical core. The machinists didn't know what to do, since its not something we come across very often, so I made a form tool on our wire EDM. It worked perfectly.

[@Clickspring]

Awesome to hear that Brett, thanks very much for letting me know :)

[@jojojorisjhjosef]

I gotta say it again, these are the most perfectly crafted video's I've ever seen. This is what makes me proud to be a KZbinr. Seriously, the content, the editing, it's all perfect. If there was ever was a 10/10 channel, it's this one.

[@Clickspring]

+jojojorisjhjosef Thank you for the kind words, I appreciate your support :)

[@southronjr1570]

I have made many form tools to machine molds and have found that when the tool is called to do some extensive stock removal, using a carbide cutter to remove the bulk of the material and only use the form tool to get to the final dimensions, to allow my form tools to last considerably longer than using them to do bulk removal. Another thing I have come to do is to make differing parts of form tools and you can create several different shapes with just a few form tools when using them together like a cutter just for the outer radius, another for the knurled hump, and another for the rear section.

[@CthulhusDream]

I can watch this all day man, it's like poetry.

[@trollmcclure1884]

'It was a sluggish morning. A slight hangover too. I should get rid of the bottles lying on the garage floor. Yeasterday's jamming was not bad. Maybe we really could be a band one day. What was the name he said? Antikythera. It sounds like a guitar... Oh wait, what's this? Someone left a CD here - Chopin. I dont know these guys. Let's play it... Three years later he's making these. :) Maybe he's microdosing cacti. I love the clean art vibe too

[@BickDE]

I can echo what others have said -"just beautiful work". Opening KZbin to find new videos by Clickspring always means a real treat is coming. Thanks Chris. Bob

[@Clickspring]

+Bick1027 DE Thanks for your support Bob, I appreciate it :)

[@briansheehan3085]

I thought that Project Binky was up there with the best KZbin has to offer, but Clickspring surpasses even it. Great stuff

[@Clickspring]

Very kind words, thank you Brian - I'm a big fan of BOM too

[@61066clocks]

Just fabulous work Chris, whoever is thumbing down these vids, eaither don't know and understand what they are watching are just plain jealous of the quality of videography and presentation of the video,

[@Clickspring]

+TIM WILSON So long as you like 'em Tim, I'm happy :)

[@Mentorcase]

+TIM WILSON I'm going to guess jealous and threatened by this man's great work

[@61066clocks]

+Mentorcase , agreed

[@KennethMelis]

Altough i am a machinist for 6 years. Working with some of the best machines and tools on the market, it's still a joy to watch you make these simple, yet effective tools. Keep up the good stuff!

[@Clickspring]

Terrific to have you watching Melis, will do!

[@confirm1022]

Great job . Bought a 10'' Logan mini lathe trying to get as much knowledge using this equipment as possible , and by me watching your videos it has brought the earlier years of my schooling making tooling and hard/temping the steel . I will surely make some awesome stuff with my lathe and some awesome tooling thanks to your videos. :)

[@Clickspring]

Awesome to hear that Louis!

[@miqbal8058]

I didnt pay attention on the products you made but the way you presenting the process. These 're even better than a company profile video. Great...job

[@ZLUNION]

Stunning; a combination of precision engineering and flawless presentation. 10/10

[@edmayhew4261]

When I first started watching these videos I was simply awed by the beauty of it all, however now when I watch them I cant help but chuckle at the time AvE was machining something skookum and said 'whoops, we're getting into Clickspring territory here'

[@michaeldean4362]

Great videos you're making. There's no other channels quite like this on KZbin. Keep up the good work and KEEP POSTING

[@Clickspring]

+Michael Dean Will do Michael, thanks very much for the encouragement :)

[@tylerkrug7719]

There's plenty of videos like these, the difrence between them is Chris Is a fucking master! Lol

[@aarondcmedia9585]

So late to the game here but I was telling my housemate about this brilliant newbie turning idea I had to make a template from tool steel to cut a simple shape. And here's a tutorial from 2.5 years ago to show me just how. Good on ya cobber.

[@ToBeeOrNotToBeHoney]

Darn it, I followed a thread from another set of videos I was watching, and now I have to watch all of yours now too. Excellent set of videos.

[@kevinhoffman8214]

I have said before , it is a joy to watch a master at his craft

[@karlkomec1427]

If I might suggest: Google ‘Wallace Gusler’. He makes flintlock rifles as was done 200 years ago. Talk about a master, as is this video master! Enjoy!

[@donfoster1832]

I just can't decide whether I appreciate your meticulous machine work or professional video editing more! Thanks for both. Very interesting videos.

[@Clickspring]

+Don Foster Thanks very much for watching Don.

[@erik61801]

woohoo clickspring binge!

[@michaeldean4362]

My thoughts exactly

[@someengineer5146]

the only reason i stay up past 2 am lol

[@jeffcanyafixiy]

Wish I could fully express how impressive your work & videos are. Just top notch!! 👍👍

[@FirstIrishKing]

Dear Mr. Clickspring, this is a great video, thank you.

[@Clickspring]

+King of Ireland Great to have you watching!

[@AHMW5541]

You are providing me with inspiration for building tooling to use on my bagpipe making projects. Thank you for posting!

[@TitusLivy777]

Your videos are always interesting and informative. And our "production values" are top notch. Totally professional. Thanks!

[@apistosig4173]

Hi - I have been devouring your fabulous presentations finding myself both enamoured and enthralled equally by your amazing craftsmanship .It's quite humbling. Please accept my gratitude.

[@jaredsaline564]

These videos are amazing and probably some of the best quality on KZbin. Every thing is well explained and easy to replicate. Please continue to make these videos. They are an inspiration to machinists everywhere. Thank You.

[@Clickspring]

+Jared Saline Cheers Jared, thanks for taking the time to watch :)

[@doronron7323]

All these videos are brilliant. Just love how he takes you through each process clearly and methodically. What a teacher.

[@vanguardcycle]

brilliant idea using the mill to assist with layout. never thought of that!

[@jojojorisjhjosef]

The video quality and craftsmanship quality are so perfect, Immediately subbed.

[@Clickspring]

+jojojorisjhjosef Terrific! Thanks for your sub, I appreciate it :)

[@eksund1900]

This is the best! Inspirational, educational an really fun to watch. And the quality of your filming is nothing but excellent! Thank You! (I wonder how anybody can give You negative likes on Your videos?)

[@ScottTurnerformeindustrious]

I'm binge watching - Awesome again.

[@finn127]

This has really been a great day! Three videos!

[@Clickspring]

+FanteFinn Cheers mate, thanks for watching :)

[@ryebis]

Hey Chris, I'm rediscovering a lot of your old gems and have learned a lot. I can see you use mostly HSS on your lathe, it'd be mighty helpful for newcomers like me to show your grinding and honing process, what stones you use etc. Thanks again for these videos ❤

[@kentuckytrapper780]

You never seace to amaze me! Great job.

[@mpetersen6]

I've made cutters out of O series steels before. The first one I made were a set of c/sinks. One of the old timers was telling me "that will never work". And they worked just fine. After that I made a number of form tools for special jobs. They didn't work all that great on tool steels but on brass, bronze alloys and engineering plastics they worked great.

[@magnusnielsen2648]

youre absolutely up there and beyond. thanx for all the good stuff!

[@Clickspring]

+Magnus Nielsen Cheers Magnus, great to have you watching :)

[@ApukEldar]

Like always...AWESOME! Thank you very much for great video and good lesson. Thumbs up!

[@Clickspring]

+Apuk Eldar Cheers Apuk, great to know you're watching :)

[@4lp4z3ro]

thank you for the beautiful videos and wonderful explanations !!!

[@express375]

You could have a channel on how to make beautiful looking YT videos as well:)

[@brandysigmon9066]

+express375 Yeah, I was thinking the same thing. He does a great job on his videos. So do you Shaun.

[@gearboxobs419]

Shaun Hughes Hand Engraving.Any compliment from you is a true compliment.Your work is incredible if you two met and made something together an engraved Antikythera machine .1B views just from me.

[@glenralph5123]

I'm so glad i read the replies because I've now found Shauns channel thanks to you. Cheers!

[@453421abcdefg12345]

That worked very well! Good idea using the centre when you gave it the first test run, once you get a "judder" mark it is difficult to get under it.

[@mechamouse2001]

a fanatastic series of videos , great stuff

[@deemstyle]

Similar to Pete Brown's question about your shop equipment- I would love to see a shop tour. You're whole working environment seems SO clean and pristine. I'd really enjoy a tour of your shop. Absolutely loving your videos!

[@Clickspring]

+deemstyle Will definitely do a shop tour in the future, but in the meantime there's a little bit of shop info here: www.clickspringprojects.com/blog/from-little-things Thanks for watching.

[@tylerkrug7719]

Everything single video you have is very impressive! You really know your shit. Awesome videos man!

[@chwanpang4750]

Its a joy to watch Youre video's

[@Clickspring]

Thanks very much for taking the time to check them out :)

[@chwanpang4750]

ive now watched every single video

[@tsstsstsstsstsstss]

Great set of videos today. Thanks Chris!

[@JoggingWithForks]

Beautiful video as always.

[@topallielton]

Great video again.

[@DieselRamcharger]

Dude, you do some impressive stuff. Really inspiring to see what you do and how you do it.

[@Clickspring]

+Diesel Ramcharger Cheers mate, thanks very much for watching :)

[@patrickbear6727]

These videos are just so enjoyable! The content is interesting and the camera work and production is just amazing for a series of How To videos. Remarkable job--please continue!

[@Clickspring]

+patrick bear Thanks very much for the encouragement Patrick, will do :)

[@A5566z2]

Sir I just love watching your videos

[@KowboyUSA]

That's an excellent way to turn out small near perfectly identical rope knurls.

[@Clickspring]

+John Ratko Yes it really takes the hard work out of making the profiles consistent. Cheers John :)

[@phooesnax]

Great stuff and wonderful job with the editing.

[@michelrichert9052]

Beautiful work ! And what a nice, crisp picture ! You guy know how to film DIY stuff !😉

[@offroadjeepin]

+clickspring recently came across your channel and instantly became hooked. your delivery is awesome! Keep up the good work. I will be a frequent viewer.

[@Clickspring]

+offroadjeepin Cheers mate, I appreciate you taking the time to watch.

[@pjhalchemy]

Thanks Chris! Really liked the idea of using the DRO to do your layout...never thought of that b4. Great video as always! ~PJ

[@Clickspring]

+pjsalchemy Cheers PJ, love your support mate :)

[@Dentistmann]

This should be rated M for mature because that is some serious machine porn you put on youtube

[@MrJwallone]

well done Chris.

[@GregsGarage]

Great vids today. I enjoy the narration and thoughts behind the work. Hoping one day I will have a few machine shop tools and can put your techniques to work. Thanks.

[@Clickspring]

+Greg's Garage Cheers Greg, thanks very much for your support mate, I appreciate it :)

[@GregsGarage]

I passed your channel onto a couple machinists today. I was chatting with them in a "mumble" call... They were blown away by the rope knurling. I believe they subbed up.

[@glennfelpel9785]

Awesome..Your work is very inspirting, indeed. Than you for sharing.

[@daveys]

Great video as always Chris

[@2testtest2]

Really love your videos. Coming from a woodworking perspective though, I wonder: Would it not be preferable to remove the bulk of material on the right side at least with a different tool before you use this form tool? It is at least common to do it this way when woodworking. The reason for this is that the profiled cutters are much more difficult to sharpen, and for your case in particular the part on the right is doing way more work, so it will dull long before the rest. Just my 2 pence.

[@ccfmfg]

Clickspring,Thank You I learned something and enjoyed the video. I would suggest to you that if your lathe is borderline under powered for some jobs and you don't want to spend the money on a bigger motor (many home craftsman lathes and electric powered machines are under powered from the factory but will handle more power) that if you can find a motor of the same rpm and voltage but only in the range of 1/2 to 2 hp you could add a additional drive pulley to your lathe or lathe motor and slave the additional motor on with a extra belt as a auxiliary motor. With or with out a manual or electric clutch or just let it be dragged along when using the main motor but when you power it on with it's separate electrical switch it's additional hp would be added to the primary motor's. You'd be surprised how much life this put's in to a under powered machine. This technic will work on many machines. Sanders,shapers,bandsaws,drill presses etc. It is especially good if you already have a extra motor lying around the shop that is not powerful enough to replace the main motor but is of the same rpm rating.

[@ThePistolero35]

Awesome work !!!

[@kevinbenedict4040]

Fantastic videos. I've been hooked since I discovered your channel. I don't know who I like more you or Diresta!

[@Clickspring]

+Kevin benedict Cheers Kevin, appreciate your support mate :)

[@MichelKiflen]

That was very nice, thanks for sharing.

[@glossblack2045]

You make some great content! I especially like to pay attention to how you heat treat and form O1 tool steel as I'm preparing to make a set of dovetail chisels out of the same stock

[@Veveliben]

It is fantastic!!

[@itanc1]

lovely work and lovely film. cheers

[@jeremytenorio3099]

Great job Chris! What prompted you to make the knurls yourself, I never would have thought to do that! Just wonderful, I can't say enough good things about your videos! Thank you, keep it up!

[@Clickspring]

+Jeremy Tenorio Cheers Jeremy! Rope knurls are very difficult to find these days, so a good reason to make a home brew version :)

[@burninpwder76]

Ran across you channel looking at the bluing tray video. Most of my equipment I restored but I've assembled a decent machine shop. Working my way through all of your videos. my next project will probably be a large belt sander. Keep up the good work

[@Clickspring]

+burninpwder76 Terrific mate, look forward to seeing some pics of the belt sander when you're done :)

[@l0ckcr4ck3r]

Brilliant job!

[@russtuff]

Stunning.

[@gizish]

Perfect as always! But we need a shop tour.

[@Clickspring]

+Gizachew Mebratu Shop tour in the future, but in the meantime: www.clickspringprojects.com/blog/from-little-things Thanks for watching.

[@teenmoon5]

Love your videos. Really useful

[@willierants5880]

Amazing stuff, off to the next one.

[@ngauge22]

You are my new "GO TO" channel for information, ideas, tips and tricks. Joe Pieczynski recommended you.

[@SwitchAndLever]

Chris, wow, very very impressed with these last three videos! You're killing it here on KZbin! Good to see! One question, I really enjoy the quality of your narration, what is your recording setup?

[@Clickspring]

+Switch & Lever Hey Daniel, I use a Blue Yeti mic straight into the PC. It's very sensitive, picks up every little sound in the area. I have a flock of cockatoos that go over my house every afternoon, no more recording once they arrive! Thanks for the encouragement mate I appreciate it :)

[@SwitchAndLever]

+Clickspring Hmm, I have access to a Blue Snowball at work, maybe i should try it. Problem I'm having is that my computer is so loud that invariably ends up in the recording as well, so I've been recording using portable recorders away from as much background noise as I can.

[@Mrhollerr]

Quality videos as usual, I've just sat and watched all three videos with a beer. It's better than Satellite TV. As others have said... NEVER STOP POSTING! Few questions if you've got the time 1) How do you gauge the temperature when your quench hardening? IR Thermometer? 2) Are you considering buying/making a dedicated forge for your quench hardening? 3) When is the next clock video coming? I'm like a kid waiting for Christmas to see this clock build continue haha.

[@Clickspring]

+Mrhollerr I gauge temp by color, it's surprisingly effective. Yes I really should get around to that, my little sheet of ceramic wool is getting a bit messy! A future project maybe. About 3 weeks for the next clock vid, just getting started on that this week. Thanks for watching :)

[@Keith_Ward]

Arg! Multiple part slippages starting @1:37, glad it didn't matter though. Nice job on the machining, and congratulations on manual machine work vs CNC everything these days. CNC does have its place though.

[@Clickspring]

+Keith Ward Cheers Keith, thanks for watching.

[@ranjdall]

Love your videos.

[@Clickspring]

+Randall Natomagan Cheers Randall, thanks for watching.

[@pyro1324]

Beautiful work as always! When should we expect the next video in the skeleton clock series?

[@Ricardo6784]

Looking forward for more. This is my drug :)

[@ChrisB257]

Nice result Chris. I have tried to find some good soft iron wire but so far nothing. Seems a great way to make a 'basket' for heat treating.

[@Clickspring]

+ChrisB257 I pick up my soft wire from the garden section of my hardware store, its sold as a tying wire for plants.

[@ChrisB257]

+Clickspring There's a thought - thanks Chris - will check that out, and hoping it's not that plastic covered stuff!.

[@PeterWMeek]

+ChrisB257 Look for [ stovepipe wire ] but be sure to get the non-galvanized version - sometimes called "dark annealed". I found a listing for it on eBay.

[@ChrisB257]

+Peter W. Meek Peter - thanks a lot - found it. Appreciate that and have order a 5lb spool. :)

[@MrCrispinEnterprises]

Nice work

[@jeffreymiller4624]

hi chris, nice set of videos, keep up the good work. jeff

[@Clickspring]

+Jeffrey Miller Cheers Jeff!

[@asiriomi]

Hey, I'm a new subscriber and I love all your videos, especially the ones of the clock. I was just thinking though, another cool project that I would absolutely love to see is making a steam engine. Keep up the good work!

[@treysawyer]

You should check out JohnnyQ90 for some neat hand-built engine fun if you haven't already!

[@adambertilolof]

I love your channel, Chris! Very good editing and explanations all round. in addition, you seem like the nicest guy. Buying a Sieg C4B in a few days and I will surely have use for a lot of your tips. Keep up the good work! /Emil

[@Clickspring]

+adambertilolof Great to have you watching Emil, have fun with the new lathe :)

[@mikelemon5109]

So complicated such expert much wow.

[@commando340]

very nice work

[@elidouek5438]

Love the videos! Could you do a shop tour?

[@samp-w7439]

5 years later, I would still love a shop tour!!

[@SLOSKY]

Thanks for all, respect.

[@dickda1]

Brilliant!

[@ANproCUBE]

Very nice videos! Good videoquality and awesome projects :)

[@Clickspring]

+ANproCUBE Thanks for taking the time to watch :)

[@Jaio21]

I love your video greetings specifically the manufacturing of tools for lathes and milling machines. I you could detail which chemicals are used to harden metals? please....

[@Clickspring]

+Jaio21 Recommend this book: www.amazon.com/Hardening-Tempering-Treatment-Workshop-Practice/dp/0852428375 thanks for watching

[@9traktor]

Perfect !

[@whyohwhy357]

I enjoy your videos. Who makes a decent, medium size lathe? I thought about a mini lathe but they all seem super cheap. It would just be for a hobby not to make a living.

[@chrisstephens6673]

If you don't have an angled end mill, have you got any taper pin reamers which should give enough clearance. Or, knowing your love of making things to make things, make a D bit reamer.

[@guillermominardi1211]

muy bueno el video! quisiera saber que clase de acero usa para la herramienta? Saludos desde Argentina.

[@lisag2771]

Thank you!

[@oficinamaolivre]

Você sabe como tirar o máximo proveito de suas ferramentas, obrigado por me ensinar !!!

[@Clickspring]

+celso mascarenhas obrigado por assistir :)

[@big0wandy]

Hi Chris thanks for all the great videos I can't get enough! Where do buy all you stock from?

[@bilbo_gamers6417]

i like how all these videos talk about making cutters from O1 or carbon steel instead of HSS. have you considered doing a video on making and using single point tool steel cutters? ive always wondered how that sort of machining was done before HSS existed, particularly if you're machining a steel part with a steel tool...