Milling Catastrophe while squaring-up Horns - Steam Loco Build #15
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- เผยแพร่เมื่อ 14 ต.ค. 2024
- A build series on a passenger #train hauling, 5" gauge #livesteam #locomotive, built using traditional tools and materials by an amateur #machinist in a home workshop.
Thank heavens for silver linings.
Thank you showing that mistakes happen and your solutions. Well done on the excellent progress. Very enjoyable 👏👏👍😀
Gosh I don't know if it was a solution rather than maddly paddling upstream but I guess this is probably the most interesting part!
Hi William, quick word of caution. Measure your 123 blocks in all aspects before using them like that. I ordered some from Banggood and 2 were slightly out. I have found someone to surface grind them all (I have 3 sets) to the same dims. I was using them all mixed up and expecting them to be the same thickness but they weren't. Loving your vids, mistakes and all. We have make them and it takes courage to share them with us all.
These things happen to us all William, even on big stuff like mine. I’ve always insisted that errors, mistakes, mishaps and accidents are where we learn the most, working out a solution to rectify the situation gives us skills and techniques we didn’t have before. If that accident didn’t happen, would you have checked the thickness of the horns?! Most likely but you never know. Keep them videos coming, most interesting to see how others tackle these situations and how they’re builds are coming along. All the best my TH-cam friend, Matt
Thanks for the encouraging words, Matt - honestly I could have probably just edited the mistake out of the video and nobody would be any the wiser (except for maybe in a close up of the inside face of that particular horn) - but ultimately that's not what this series is about.
Looks like a good result in the end and a few lessons learned. Keep up the good work.
Yeah, and the rest - I'm not too sure how it happened but I suspect it was an inadvertent climb mill when it caught the corner of the hornblock. Certainly taught me to not take my eye off the prize - it was the very last cut!
This was very interesting to watch, thnaks. Shame about the mill incident but these things do happen, we did something similar whaen we made some large clevis forks on our big mill
Interesting - for the snow plough? (I was doubting for a second if that was the correct spelling). I would love to come by one day to see your workshop (re: your cameraman's recent comment) - Norfolk's only about a 3hr drive so doable with an overnight stay somewhere...
Bad luck on that one mate, happens to us all at times, "character building " I think it's called . Anyway you did a great job of sorting it out!!!! Onards and flipping upwards ehhh . Regards Mike
Yeah, certainly - I'm sure they heard my 'F - - - - K' in the big smoke!
Nice recovery William.
As a general observation, I would look for more rigidity when holding your workpiece(s) in the mill.
When I assembled my frames/chassis I spent a good few hours to get the whole lot square: tightening the bolts into each stretcher, loosening them back off applying pressure to the frames before re tightening again, repeated many times. Look long and hard at the buffer beams to make sure they are square to each side of the frame and assume that no part is dead straight - I didn't realise how much my buffer beams had bowed until I couldn't figure out why I couldn't get them square to the frames on both sides 😁 If you can get some bar to sit across the frames in the horns (machined to fit) when assembling that will help too. I put the final cut on my horns with the frames assembled but table travel on the mill may be an issue. My frames had also bowed a lot in the vertical plane too (my chassis was noticeably banana shaped), and once assembled I had to apply a lot of pressure to get them back to being level.
Good luck and keep sharing 👍
Great video, William.
Very well presented and to the point.
Great to see how it is coming along, glad you managed to remedy the mishap.
Mark, thank you - this was the first time trying to mount something so large in the mill and I was caught a bit off guard. After milling the insides of the slots I bought myself a proper clamping kit and no doubt that should help. Do you have any advice on that arrangement? I'll need to set them up again to drill the oiling and spring plate holes...
Thanks matey, it's been a somewhat traumatic learning experience but thankfully nobody's life is at stake: the only thing lost is time, after all. I'm glad you enjoyed the videos, I do vascilate between longer and shorter content but it would appear about 10 minutes is a sweet spot.
@@williamsworkshopuk part 5 of my Jack series shows how I did it William, but I probably went a bit OTT and of course having a large enough mill table is a pre requisite.
I also had a disaster with mine very similar to yours which I allude to at around about 5:45 in that video. Mine was caused by me not securing the milling head on to the column - D'Oh!
Hello Matt,
If you went to the gym and there were no weights you would not get any stronger... if you did not have any challenges in the workshop you would not get any better... Nicely recovered.
Take care.
Paul,,
That's quite true. It's all a learning experience and one benefit of 5" loco size is that though some components can come from expensive materials or take some time, messing up one piece doesn't affect any others!
Well it turned out ok in the end so nothing to worry about. Shame the camera wasn’t compatible with your computer but at least you know now. Keep up the good work as usual.
Yeah that was a right pain in the behind, days worth of filming for a few minutes of video content on YT! Oh well, my iphone is good enough. The only problem is that when I'm filming the missus can't get hold of me without tromping down to the workshop - ah well, a sacrifice I'm prepared to make I guess?
I often tell folks I have mentored in the hobby over the years the scrap box is your friend, if the part is not right and cannot be quickly repaired throw it in the scrapbox as you have indicated you are planning with the with the bogie bolster and the frame stretcher. Just a side note if the misstep on the hornblock had not been able to be rectified by bring the hornblocks to the proper size you could have always told folks the marks were oil groves. I have noticed Matt is back in his shop coat but you have the red flannel jacket on saying the weather isn't warming up over there. It is still cold and wet here in New England.
Dick B. USA
Thanks Dick - it's sometimes a tough call to make especially when time is invested in a part but even if the part is lost the experience stays with you. Easy to say that - hard to do! I think I'm rapidly getting this into working order, so not to worry! Weather here is changeable - bright sun and then rain and snow on the same day. Right now? high winds. Who'd have thought?!
It certainly is coming along! We all have those type of incidents, it is how you recover that makes the difference. You managed to make them look good so no problem :)
Thanks matey - Hopefully they work well too. I feel blessed that I'm able to treat this all as a learning experience and so any time spent is not really wasted; just degrees of being taught various lessons.
Good recovery from the accidental dig in with the milling cutter. I hate when that happens. Looking forward to seeing the axle boxes fitted.
Yeah, it was quite frightening but hopefully we're back on the straight and level.
Not too big a catastrophe, as it turned out you were going to machine that off anyway. Well done.
I didn't know that up front lol - actually that face was bang on 0.625" so I'm about 15 thou under on all horn widths, but not so bad!
@@williamsworkshopuk If it is consistent you can make the axle boxes to fit, so all will be well.
Well, there's a lot to thinking to do in this project.
But if it's too easy, there is no challenge :)
Yes, exactly! I have been doing lots of milling on my mill recently, I am envious of your Deckel. I was offered a clone of that machine, but had just paid for my Centec. Now I think, I should have fought to get my money back and gone with the Deckel-clone!
Hi William
Shame about the dig in!! don't get disheartened, it happens to us all!!! anyone who doesn't make mistakes has never done anything!!!, I don't how, but if you were climb milling at the time, if everything's not super clamped up, the cutter will pull in to the work on these hobby machines.
My other comment is as Aam Cro, said keep a close eye on the wheel centres position, or you will have to adjust the connecting rods. etc!!
Also for every operation that is a little out to the drawing, it will have a knock on effect on everything else as you get to it!!
take care
Kev
Yeah as I said in a reply to Gurnhills Garage I think I somehow had backlash 'available' to the direction of cut, which pulled the workpiece towards the mill, and then that meant I was suddenly climb milling and then it all went a bit pete tong.
With regard to diverging from the drawings, you're not wrong. The two features (slot depth and width) only affect the axleboxes presently, and I hope to keep it that way!
Just a note to make for the future, when axleboxes are in, check the wheel centres. I don’t know if you plan to machine from scratch or buy laser cut blanks but as you have tweaked the openings the centres May no longer be exactly as drawn (may not have been in the first place).
Thanks Adam, I don't think there was any chance in hell whatever was there was even remotely as drawn. I have coupling rod blanks from M.E.L. and my plan was to use the same method as Mark's Home Engineering i.e. large calipers between axles once they're in and square, less one axle diameter. The build notes suggest drilling a small pilot hole first, reamed for a very close 3/16" fit and using 3/16" silver steel rod to check for squareness first - then adjusting as appropriate. Sound OK? ps. Does your Grandad's Maid have a cast bolster or fabricated? Wondering if I should machine the integral cast bolster bogie pin or cut it off...
I’ll go and check this evening when back from work!
Will I feel your pain on the "incident" well recovered once again I did a similar thing when I was doing the same operation on my tender axle boxes. I skipped my (2 1/2" gauge) frames and restarted
That sounds painful. I think for mine, if I had been unable to get a reasonable finish then that would be the next port of all - I already have the laser cut main frames, but (foolishly?) figured that the ones I got in my box were OK. I think it would have been less work to just start from scratch!!
There were always going to be bumps in the road. (Speaking of bumps, I trust that your other half is doing well).
She's doing swimmingly, thank you!