Tally Ho Capstan Project: Turning a Tapered Bore on the Capstan Cap

Tally Ho Capstan Project: Turning a Tapered Bore on the Capstan Cap
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[@InArcadiaSum]

Quite apart from the technical marvels, I am always amazed at Keith's unflappability in the face of unforeseen problems, and his ability to resolve them calmly and inventively. Truly a master.

[@amham48]

Is there a master machinist more knowledgeable and capable than Keith in America today? I don't think so!

[@garybrenner6236]

@@amham48 You have got to be kidding!

[@markschweter6371]

Clarke Easterling at Windy Hill Foundry is almost as unflappable.... keeps going until he gets it done !!!!

[@lothianmcadam1]

...and his ability to draaaaaag out a job to the n'th degree.

[@uncleop22]

Of course there's the comments and reactions left on the editing room floor... It's soothing to watch the rough places become plane. I wonder if the original capstan was a one-off piece or if there was a full-scale production line. It's a lot of work for that part.

[@ewetoo]

One of the gifts of the Tally Ho project is connecting us all with the people with a passion for their craft and the tools of their craft, often in ways you least expect. It's been such an education to me and one of the few things the internet is good for.

[@christianmccollum1028]

Well said. 👍

[@cbhirsch]

Amazing work by the whole team who made this step possible. The number of man hours that have gone into restoring this vintage capstan is amazing. People who see the assembled capstan on Tally Ho won't have a clue about all the people who have touched this machine and that's not even taken into account the men who originally built the capstan 100 years ago. Thanks to all the people who touched this and were kind enough to document the process!

[@yoyopg123]

That's fun to think about. Hidden depths. It's like being a regular at a diner and one day being told by the waitress that the sweet, unassuming old guy that always comes in for coffee at 7:30 is a highly decorated WW2 veteran who fought in every major battle in the European theater and was part of the group that captured the Eagles Nest. Hard to tell the amazing stories behind things just by looking at them.

[@russellcraven251]

I'd be nervous doing what might be a final operation on it.With all the sweat and tears getting to this point Id hate to mess it up.

[@musicbro8225]

It's like a silent witness and with every step completed it's story deepens. One day, relatively soon, it and the rest of the capstan will reunite with Tally Ho and then will return to where it all started in the UK and beyond. That's an amazing thought and to think of all those men and women is humbling to me. That a thing can contain so many spirits kind of makes a mockery of modern 'products' that are lusted after so shallow.

[@EnderGate]

I too respect all the craftsmen and their hours, passion

[@1965cjh]

Not only this part but the man hours of the whole of the Tally Ho project is just mind-blowing. I've followed both with avid interest

[@stevendasilva9256]

I can see Clarke biting his nails watching this after all the fun he had casting this part.

[@matthewhelton1725]

And everyone else who helped: Steve Watkins, et. al... That part was a cast iron.... well I don't have to say the rest, really... to cast.

[@A2Z1Two3]

The foundry cast two , one he had minor reservations on , but he thought it would clean up OK, but cast this one to be sure . If someone drops this one ( God forbid) then all is not lost , which is a nice position to be in . I enjoyed going to patternmakers then foundries and watching our machine shops finish the items many times during may career , and it was a privilege to watch and speak with those craftsmen )

[@snappingbear]

Fortunately, Clark made two of them. The first attempt where he came up a little short on the pour wasn't a fail because Keith said that area would be machined out anyway. I don't know which one Keith used in this video, he didn't say.

[@snappingbear]

​@@A2Z1Two3Unless they drop it from a height on to concrete it will be fine. God help anyone who drops it on their feet or worse, onto that beautiful wood deck Leo's crew made. lol.

[@TomokosEnterprize]

LOL, Me too.

[@mikequinlan9585]

The amount of patience’s required to build this capstan is just amazing. Keith, I take my hat off to you, and the men at Windy Hill Foundry, for sticking with it and getting it done.

[@user-us4dm6qp2i]

people may disagree, but i have always held craftsmen in higher regard than any lawyer and most doctors I've run into.

[@johnmalenchek6597]

These craftsmen display what I call "native intelligence." In their way they are just as intelligent as any "professional". These are the men that built our country. Hats off to them all!

[@CS_247]

I did an apprenticeship as a fitter/turner/millwright back in the 1980s, not a CNC in sight (not many of our machines had a DRO either!). Today, I build race cars, and I have a manual lathe and mill in my shop, and always chuckle at highly educated customers and friends, when they watch me do a complicated job, and how they say "wow, that's incredible, how did you learn to do that?!" and gee, you spin those wheels and flip those levers like you are connected to the machine!" 😂 A lifetime of working these machines, my friend... Never, ever sorry I never went to uni for some useless degree and desk job. Love what I do.

[@lunarweasel]

People talk about working with your hands and being a desk job professional-type like they are mutually exclusive. That's always bothered me a bit. I have a college degree. I have a professional desk job. I have built a wooden boat. Framed a house. Restored two 1960's cars from the ground up with no outside help. I write music. I restore guitars. I build furniture. A person doesnt have to only be a tradesman or an "educated professional". You can be both, either, or neither.

[@banjopete]

Until you get sick.

[@jackpledger8118]

As an 18 year old back in the early 1970"s when I was learning to use the 20 foot long lathe in a textile mill in Georgia that was used to make 18 foot long rollers for manufacturing carpet...everything was very crude. We only had a 4 jaw chuck and no dial indicator. While watching you centering up the casting in the 4 jaw it reminded me of how I was shown to set up the rollers. The "machinist", and I use the term loosely, held a piece of chalk on the tool rest and rotated the roller. The chalk marks would show the hight points, or the points closest to the operator, and the chuck jaws would be adjusted until the chalk left a mark all the way around the part. Very crude and not very accurate, but thousands of rolls of carpet were made with the rollers made on that lathe.

[@paulatkins894]

I got to see the Tally Ho in person last week and have to say "what a boat!' They had it out testing the motor and prop for a couple of days. Can't wait till the sails are up!

[@kenbetthauser4226]

28:53 Keith says “Oh yeah!!” He was a happy man.

[@martinvandenbroek2990]

Having done some of this work I know how badly that could have come out. He was happy for good reason.

[@dfye55]

I've seen complaints of Leo's choice of suppliers for the pattern, casting, and machining for the capstan, but what an awesome pleasure to see it all coming together! Once again, Leo's careful choices have provided amazing content. I thoroughly enjoy Keith's work.

[@tomoakhill8825]

Complaints!?! WTF?!? I have watched Kieth, and subscribed, since BEFORE Tally Ho began. I have watched Windy Hill Foundry, and subscribed, since BEFORE Tally Ho began. I _knew_ this part was too big for Windy Hill. But I was _certain_ they would get it done, and they did. Who ever is complaining, is ignorant of the seniority of these KZbin channels, and the status of their creators as Masters of their crafts.

[@pfsteinbach]

I've been following Leo's Tally Ho rebuild for a long time now, and I've just binge-watched Keith's work on the capstan, from shaft to cap. As a newcomer to Keith's channel and to metal machining, I really appreciate Keith's clear and precise "play-by-play" explanations of his process. About the machines that Keith uses: I'm not familiar with the details of modern CNC machines, but I sure am impressed with the engineering of those vintage lathes and milling machines -- and if Keith *restored* them, too, then he did a heck of a job! I never really thought about how gears are made until I watched Keith make some. Being a detail-oriented guy, I think I'd really enjoy machining work myself. It seems very satisfying. I'd never thought of working in thousandths of an inch -- or ten thousandths! -- until I began watching this channel. So enjoyable. Thank you, Keith! And yes, @JackHawkin5, it's very cool to be catching up on Keith's previous capstan videos and suddenly see that there's a brand new one to watch! I'll be eagerly awaiting his next (and last?) Tally Ho capstan video.

[@jakeeasterwood3204]

As an Athens Georgia resident who has been following the Tally Ho project for a while I’m proud to see a critical part of the restoration being done in our state by skilled craftsmen. I really hope Leo and crew bring Tally Ho to Savannah after it is completed so we can see it in person.

[@CornishMiner]

Good to see the old Lodge and Shipley again.

[@Hopalong..75]

I had no idea the amount of machining that would be required to restore the capstan, great explanation, superior result.

[@JackHawkin5]

Love seeing a Keith Rucker video hot off in the press in my feed. So good to see it all coming together!

[@WmCRobison]

Nice to see you using soft jaws. Several times I found myself yelling at the screen "SOFT JAWS, SOFT JAWS, SOFT JAWS !" My first job was machining an aluminum part very similar to the Capstan cap, just a bit bigger.

[@astronorthwet636]

You’re turning us all into antique capstan experts! Love watching this come together.

[@carldaniel6510]

Keith's collection of speciality micrometers continues to impress!

[@mchristr]

Keith, I have no idea if you've made any money on the Tally Ho capstan. But you've been a part of one of the most noteworthy wooden boat builds in history. Thanks for taking the time.

[@raymondjames9734]

How fitting to use the museum shop lathe that has restored historic locomotives and other historic machines to work on the Tally Ho. Well done!

[@gordonmcmillan4709]

English lathe for an English boat too. 8-)

[@garybrenner6236]

Maybe some day it will be used on the Stoker Engine.

[@martineastburn3679]

Love the Slide Rule on the headstock of the lathe. Looks good for calculations. Have mine, used through grad school. Then I bought a 600 US$ 5 banger (had 1 memory). Wow was that handy. Young people have no idea today what we went through for a Final Exam in Physics 3 classes a semester. It was my Major and having Mathematics, Geology and English as Minors.

[@frederickstibbert7389]

I took 6 semesters of architectural structures - a basic treatment of statics & strength of materials - & always used a slide rule. Except for one month when I had a calculator that had been left behind in a classroom. The only time I attempted to use it for an exam, the on/off switch broke! Stayed strictly old school from then on.

[@tomoakhill8825]

The Empire State Building, the Golden Gate Bridge, the Saturn 5 moon rocket, all built without computers, much less pocket calculators. My third year of college was the first year the Physics Department allowed calculators to be used during the tests.

[@mumblbeebee6546]

Wonderful to see the cap after all the blood, sweat, tears and curses that it cost all of you to make! It’s now being shaped for purposes and that is awesome!

[@mickeyfilmer5551]

These old lathes (and Milling machines) were made to last by craftsmen/engineers for craftsmen/engineers. They were designed to be sturdy and were actually "over engineered" in most cases so that they could take anything you threw at them. I trained on a Ward Haggis Lathe back in the 1970's in Scotland, that was a solid brute of a machine, and extremely versatile and accurate.

[@A.Hidell]

The pinions that rotate in this capstan top need to be meshed correctly with the ring gear bolted to the rotating capstan base. When you disassembled the capstan using heat, there was a pile of lead melting under the ring gear. I believe that lead served two functions. 1/ To seal the underside of the ring gear and stop corrosion.2/ As a form of bedding shim to set the ring gear higher to mesh correctly with the cap pinions.

[@leebropro]

Great work Keith, can't wait to see the finished piece installed!

[@TomokosEnterprize]

Thanks a bunch Keith, One step closer to seeing this done. Leo just included the Capstan waiting so he can start his sea trials. No rush though as he still has a ways to go before leaving the harbor. All kinds of those little things to check off his list.

[@darkhorsegarage9623]

Looking at that cap, I can appreciate the amount of work it took the break the original. That is a serious hunk of metal.

[@user-di4kv9yk3g]

wow setting stuff up in a lathe with irregular shapes, nightmare, but you have to take your hat off to those old boys of yester year, how they made things and things so much larger, got to love old technology and engineering

[@josephmagedanz4070]

I remember that lathe. I'm glad Keith still has access to it and can take advantage of its capabilities for this job. It does seem like there is more stuff stored around it now, but the job still got done. That's what counts! Thanks, Keith.

[@jacquespoirier9071]

that capstan will much better than when it was new, that happens quite frequently when refurbishing such historic mechanisms excellent job very good video

[@johncarter1150]

Mind, muscles, and machines over metal. Practical problem solving and persistence... thanks for sharing this long, challenging project beginning to end!

[@MrRgr004]

Fantastic team work people on this project !

[@christopherhurren629]

I loved the train whistle in the background at the start of the video. Thanks Keith

[@garybrenner6236]

Maybe that's the train looking for the Stoker Engine!

[@johneriksen5504]

Dial indicator on taper was really helpful to “see” the change. Thanks

[@mby_dk]

Nice to see someone working who is aware of slack in their tools. Maybe something that young folks should learn as well.

[@adriannicol8529]

Six attempts at making the mould, four(?) attempts at casting it and just one usable casting exists on the planet. Leo keeps mentioning the capstan is one the the last major jobs to do on Tally Ho. As yet no way to test that the modification to add the electric drive will actually work. And the capstan head just barely fits in the chuck. So - no pressure then? You have to admire the way Keith remains calm and methodical throughout - I think I would have been a gibbering wreck by now!

[@edsmachine93]

Nice work Keith. This phase of the operation had its challenges for sure. Very nice job dialing in this taper. 👍👍 Thanks for sharing the process.

[@passenger6735]

It's always nice when the taper is such a good fit but you were clearly overjoyed at the results. I personally don't enjoy machining castings as at some point you have to take a leap of faith to establish a reference. This was a lovely casting to work with as there was a lot of meat on it. Great job.

[@wouterw.schalkoort1988]

Nice job and entertaining video as always. The methode for adjusting the taper attachment with an indicator requires that the tip of the indicator is exactly at center height of the shaft. I missed that in the explanation and I saw Keith bumping the indicator by accident and readjusting the height without any precision.

[@aserta]

Good to be back at the museum. A return to the old days, in more ways than one. Awesome!

[@alejandrohuerta988]

I'm always amused when I learn about a new tool. This time it was the bore micrometer. Of course there's a tool for that specific purpose 😁

[@CothranMike]

That is called a hub micrometer, the bore mic is a lot different. Hub mics are made to measure lengths rather than diameters. Before hub mics the normal means of setting a hub length was to go to the bench mics and check the guage rod created by a tool maker for that specific hub... The bench mics were made to be used by several groups of jobbers and were heavy enough to stay put in the place they were installed. Find old pictures from the mid 1700s when mics were actually installed on the shop floors near the men using them if you can. Before that in the 1600s all gauging was done in a tool room and the secondary gauge was brought to the machine by the in-place inspectors. Workers had wood measures with fire hardening ends to guess where they were in the process. Maybe wiki has this and more if you wish to dive down that rabbit hole and explore. Remember though, tiny doors means tiny people and the way to achieve that state is one for those pills, which was it again I do not remember...

[@alejandrohuerta988]

@@CothranMike yeah that was a mistake. I meant hub.

[@andrewzanto8591]

Great work Keith! So fun to hear the excitement in your voice when the shaft fit!

[@johncloar1692]

Good to see the old shop. Another step along the way, and as always thanks for the video Keith.

[@johnnyholland8765]

I saw that lathe at a workshop Keith had a few years ago and it is a monster. Adam Booth was there that day and made a part on it. Mind you he had never seen it or ran it before but he dove right in and made a part on a strange machine. Adam is top notch. A lot of stuff for that boat has come from Georgia. When he first started he came to a south Ga hard wood mill and purchased a large quantity of thick oak slabs that went into it and now Keith is contributing a lot of time and labor going into it. When Keith says "I think were good" then it is a done deal...

[@chrissmith513]

😊 Dial Indicators quite the invention for so many things 😊😊😊

[@jaypruss3236]

How the heck did the original manufacturer manage to make these parts without the many special tools Keith has been using. Truly impressive workmanship.

[@CothranMike]

Good point there Jay, the original manufacturer 100+ years ago used heavy machines made much the same way they created this one. Watch some of the Pakistani Machining videos now and you will see what English and American manufacturing was like back then. The sandals are not used in the English or US shops but the back breaking labor was still the same. In fact the footwear for the men working those shops was made in similar conditions back then. That was all anyone had for job. The era of Capitalism at the cost of labour and lives reigned supreme then. On both sides of the pond folks were dying for their jobs and got little in return unless the foreman was related to the poor sod who paid with his life. Even then the widow was not set for life anymore than that is true today. Always one paycheck away from eviction and one meal from starvation. The specialized tools and metrology equipment came out these conditions as did the unions and labour organizations that grew to the groups we see today. I do not plan to start arguments here and I won't entertain any. Bad blood on both sides doesn't make any more than three wrongs make a right.

[@keith0alan]

One of my lathes is over 100 years old. Precision machine tools have been around a long time.

[@jaypruss3236]

I get that but considering they didn’t have computers, CNC machines or any of the specialized tools that are available today. We don’t give the people who were responsible for what we have today the credit they deserve.

[@keith0alan]

@@jaypruss3236 I agree. Some of the apprentice exercises done by hand would challenge us with modern tools. One that comes to mind is: Take a piece of round bar and file it into a cube. Take a piece of flat stock with a round hole and file the hole square. The cube needs to be a nice sliding fit through the hole in all orientations. The hole must be very square and the cube perfect on all sides and angles. again, by hand with files the apprentice made themselves. When you showed you could do basic things you got to the machine tools.

[@keithjones8659]

As someone that works on machinery, but has not skills when it comes to machining, you're engrossing to watch, and I appreciate your narrative.

[@jamesdavis8021]

I have been following this project from the beginning,without comment. I have enjoyed every video.Good job,Keith.

[@bulletproofpepper2]

Thanks for sharing. Love collaboration.

[@jhgmusic]

Marvelous video. So excited to see this coming together. I’ll bet Leo and his team are too! Oh to have access to those wonderful machining tools - and to also know how to use them so well. I enjoy your channel, Keith!

[@milesemery9103]

Keith, real craftsman old school.

[@charleswelch249]

I miss you working for the museum on the trains and other historical machines. You look right at home back working on the old lathe again. Can't wait for the next update Kieth.

[@artothevid]

Do digress Keith! Do digress! 🤓

[@prillewitz]

I will check the old vids to see if the fittings in the rack against the wall have changed place. 😂 Thanks for the video Keith!

[@kentonyoderii3443]

Knowledge is the key and practical experience makes us into a quilified craftsman!! We have lost much of both in the industrial world in america automation and computers have stolen the soul of what made us great. You are a true master craftsman and a blessing thank you for sharing with us. God bless you sir

[@HorsleyLandy88]

Good Job Keith, hope you get a ride on Tally Ho.

[@elitearbor]

Always fun figuring out workholding for the odd shaped jobs! Even though I solve similar puzzles regularly, it's enjoyable to see how you go through the process.

[@user-kp3lt1gy8s]

Nice work Keith. Loved the soft jaw solution.

[@radamus210]

Really awesome to find no voids in that critical taper for the main shaft. It's going to be amazing to see it installed!

[@malreynolds9591]

It was amazing to watch you truing up and machining that part. Nice work.

[@twin40dave]

You don't realise how rough the casting is until you start to spin it and put Dail indicators on , but great job so far, Keith 👍 😊

[@RoyBlumenthal]

Thanks Keith! Absolutely loving your work.

[@danielnorman8595]

Awesome job I think I would've just cleaned the nubbins off that inside rim while I had it on the lathe. That would also give you another reference point

[@CothranMike]

Yup, me as well... those gas vents are not anything that needs saving and the true surface will help in the future. In fact I would have gone further than just knocking them off, I would have rounded both inside and out to keep handling cuts to save my fingers.

[@c.a.mcneil7599]

Nice work explaining your thought process. Thanks

[@markdamm7715]

Another fantastic video, Keith. Thanks

[@WillyBemis]

Great project! Thank you Keith!

[@jamesnielsen347]

Love your work, Keith!

[@paulputnam2305]

What an absolutely awesome job! Way to go!

[@DTBaker-gq4fd]

Lodge & Shipley - you are a lucky man. Your presence is a real treat…your videos are excellent.

[@walterplummer3808]

Good morning Keith! Thanks for the videos.

[@imfrcd]

Amazing work

[@petegraham1458]

Nice work on a wonderful project!

[@daki222000]

great series Keith, thanks for sharing. fun to see the museum workshop lathe again. cheers.

[@andyrbush]

Wonderful to watch your skill and the machine.

[@ApexWoodworks]

Thanks for sharing your high level of experience with us, Keith. It's so nice seeing Tally Ho's capstan getting closer to being finished.

[@davidc6510]

Amazing work Keith. Another great segment of the Tally Ho capstan restoration. Thanks for sharing.

[@stuartnicholls1569]

An absolute joy to see such craftsmanship and engineering brilliance.

[@reginaldgraves1684]

Fascinating video.

[@jeffhreid]

Great work. That’s a challenging shape

[@dtoad48]

I went back 10-11 years and that part at 3:42: in the lower right hasn't MOVED! That shelf hasn't been touched; however, those chips are new.

[@yoyopg123]

great way to start my morning, thank you!

[@thirzapeevey2395]

Yeah, I remember you using that lathe a lot. I've been here a long time. So glad to see you making progress on this. You'll have it licked before you know it.

[@frankerceg4349]

Thank you Keith!

[@johnarrington6292]

Improvise, adapt, overcome. Well done, Keith!

[@bobtherat99]

I certainly do remember the Lodge & Shipley. I've missed its dulcet tones. One of the first videos I remember was doing the head gaskets on the steam engine. I had watched that being done on a 2-8-2s owned by D&RGW back in the day, so the video caught my eye. It is good to see you and it working together again

[@avoirdupois1]

"Nice little machine..." Keith then hastily correcects- "actually a big machine!" I love the commentary!

[@ronburns268]

Keith, you could not have been more pleased when you tested the fitting as we could hear it in your voice.

[@amunderdog]

The amount of patients applied. Amazing

[@stevepritchard7957]

Great job Keith. Getting close to seeing the capstan back on the deck of Tally Ho again. 👏👏

[@rexmyers991]

Great machining demonstration. The capstan project is moving along nicely. EXCELLENT WORK, Sir!

[@steves524]

From a small job to a big job, but handled with expertise…

[@dillydallydollcomachineand8246]

Thanks for stepping back to the old work shop. Boy its been a long time. My best Tighe

[@anthonyelam2257]

Another great video on the work and Expertise of the Tally Ho Capstand .... so much knowledge in working these machines .... I am so impressed .... ❤❤❤🎉🎉🎉🎉😊😊😊 .............

[@randrew89681]

It's awesome to watch you bring this to fruition @Keith Rucker! Incredible to think of the amount of knowledge, craftsmanship, and hard, elbow grease work that goes into something as complex between the mold making, casting and precision machining work you're showing us here. Bravo Sir!

[@TonyHammitt]

Nice Job Keith! And kudos to Dave for making a pattern with all of the parts needing machined made extra large to allow that, and starting from some broken pieces! And the casting looks great, too. Master class work

[@shawnmika9275]

Turning these large parts takes nerves of STEEL! I would be weary to get close with that much metal spinning. Great job as always, can't wait to see this finished.

[@president2]

Love it so much keep it up as always 💘

[@geraldharkness8830]

great work keith!

[@fredfernald8016]

Great video Keith! This is a wonderful opportunity to teach a lesson to viewers. To those young folks in ANY trade (not just machinists) it’s a good example of innovative thinking. There’s not always an off the shelf answer for every problem you’ll ever encounter. Problem solving is crucial to success. Love the videos. Thanks.

[@ddblairco]

thank you Keith