Tally Ho Capstan Project: Drilling and Boring Holes in the Capstan Cap on the Horizontal Boring Mill
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- เผยแพร่เมื่อ 23 พ.ค. 2024
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My grandfather was a machinest in the 20's, 30's and 40's in Ohio and I have a favorite picture of him at a milling machine. I had no understanding of what he did until I started watching these videos. I still have some of his measuring tools, which I now cherish. What a wonderful video series.
Back in the day the production and planning of one part of anything would have been epic Complex cast and machined Assemblies In this era were considered as the highest level of production in the day I think that to re produce something from a past age is amazing ! Tally Ho is a time traveller with all that sails in her Nice work Keith your addition to the amazing story of this ship is perfect 😊
Don’t forget that the original company most likely cast many capstans per year but Keith and friends are basically building their first and only one from scratch. That makes such a big difference in effort needed at every step. The original builders could probably do this with their eyes (almost, casting is dangerous) closed…
@@ramdynebix I think that point is often not fully appreciated by people criticising / suggesting 'better' ways for what Keith et al have been doing.
@@ramdynebix Most likely there was lathe for each operation already preset as much as possible.
They may of had some sort of a jig block it would have sat on to drill in correct position, all who have been working on these pieces for this project have been doing an amazing job, thank you to all have posted videos on this project. We appreciate your work and enjoy watching them and learning from them
Great to see get to use the Lucas horizontal boring machine. That thing sure is slick!
I'm holding my breath while watching you drill huge holes in a casting that was so hard to make! Thankfully, it didn't crack. Such beautiful craftsmanship, Keith.
If you don't hamfist it or overheat it (rotational speed, bit, etc. determine this) it ain't gonna crack.
Spoiler alert 😁
@@silasmarner7586 100% untrue. Cast materials can crack even if you're being nice to them, especially when they're thin. Metal shifts. Forces built into it will play when material is removed. Dunno how you got to that information, but it's wrong.
@@asertaWhat? You obviously have no idea what you're talking about. You don't seem to know that the vast majority of machinery on this planet is made from cast. If it was as fragile as you claim it wouldn't be used as engine blocks and as the frames of heavy machinery like bulldozers and loaders. When it's properly made and treated from quality steel by a quality foundry as this piece was, then there is absolutely nothing to worry about it cracking. This explains why Keith and every machinist with any experience wasn't concerned in the slightest.
You can tell from how well the bosses machined that it's quality cast.
Crack? Tell us you don't know anything about cast or machining without telling us. lol.
Seeing this accomplished today certainly makes me appreciate not only your skills but the skills and engineering work of the machinists and designers of 100-plus years ago. We all come from good stock my friends!
Keith, I can't tell you how much pleasure watching you work gives me. To see traditional skills being executed with such competence coupled with the detailed description is just wonderful
As others have observed, a fine compliment to the skill and expertise we have seen in the rebuild of the Tally Ho.
Well done!
Keith, you're doing a great job on the Tally Ho capstan.👍
That horizontal boring machine is a great bit of machinery.
Perfect machine for the job
@@plainnpretty It would be if it had a quartering table (I'm surprised it doesn't)
@@Gottenhimfella I’m not a machinist so I don’t know what a quartering table is .
@@plainnpretty It's a feature where the work table on a horizontal boring mill can easily be indexed around in 90 degree steps very accurately. If you set the job up centrally, it makes it a snap to bore a job from both ends. In other circumstances it often eliminates the need for line boring, which is costly to set up as it requires a long bar of just the right size supported at the far end by a tailstock and machined to accomodate boring tooling.
@@Gottenhimfella I see it would be a good thing to have on your machine.
Thanks again for another interesting installment of the Tally Ho capstan restoration project. Who would have thought such a project would have so many devoted viewers? Watching you expertly mill and machine these parts is a real pleasure. Seeing them come together in the final assembly episode will be a real joy to watch.
Using the Lucas for a real job, something that the machine is ideally suited, must have been intensely satisfying. The effort and time is repaid. Bravo…..
When I first started watching the videos of the Tally Ho capstan's project I was far from anticipating the amazing level of professional work required. From building the wooden pattern, the construction of the mold, the casting of the iron and now the various machining sequences, all these people involvement is just incredible, congratulations to all of you, keep the good work and spirit going folks. Warm regards from Normandy (France).
Keith has such a soothing accent & a wonderfully calm demeanour
Beautiful work, Keith! It is an honor to get to watch “over your shoulder” as you go. Thank you so very much! ❤
Love this Tally-Ho series. Fantastic work. When I was in high-school I looked down on machine-shop and auto-shop classes because I was caught up in academic status hunting. Nowadays I tell young people to take exactly those classes. Manufacturing will rise again in importance in the West. These skills are critical.
Great work, Keith! I have thoroughly enjoyed watching this series on the Tally Ho capstan and have learned so much about traditional machining. Thank you for your assistance to Leo’s project and for putting these videos out there.
I never, in my wildest dreams, thought I would find watching holes being drilled sop entertaining. lol
Amazing work Keith. You've spent a lot of time on this but I'm sure everyone appreciates your attention to detail.
Thanks, Keith. I'm always pleased to find you working on things, and I've followed the Tally Ho project for years now, and it's how I found your channel, as well as Windy Hill. You and Windy Hill got a shout out this week from Essential Craftsman. I'm always pleased when folks in trades throw a bit of love at each other. As always, the work you do is a pleasure to watch.
I really wish you had been my shop teacher back in the day, your clear explanation of every step of this project has been fascinating!
Another good video, Keith. The only thing I was thinking about was why not put brz bushing in where the shafts ride. Salt water is a real bitch. And it won't be used much.
While the hand operated cast gears at top might not be used much. Now the motor drive from the base will be spinning them at speed every time that the capstan is used. Iron is a good bearing material, Especially on a steel shaft provided it is lubricated.
However we do not know what metal those bevel gears were cast in. Most likely at Brighton Foundry.
The different types of engineering machines are amazing. That horizontal drill is certainly a pleasant surprise. Nice work Keith!
It's not a drill, it's a horizontal boring mill and it can employ several attachments including drill bits and boring bars. It can even be used as lathe when machining things like the large wheels of a bandsaw (see Keith's restoration of the Jimmy Diresta vintage bandsaw project).
@@snappingbear And yet it's still a drill as it can drill holes. Don't be pedantic, we all knew what the op meant.
@@bukka6697 No it is not a drill, no more than a nail is a drill but it too can "drill" holes or a wrench is a hammer because people sometimes use them as such when its handy. Vertical mills can also drill holes but we don't call the drills either because they can do so much more.
Once more, the CNC gang (couch naysayers council) is about in the comments. For those who think Tally Ho is perfect to the fraction of a mm, i suggest watching the episode where the tile is set behind the stove. I love those crooked tiles with uneven gaps. Then go watch the episode where the stained glass window door is made, enjoy those imperfections as well. Let it flow through you. Then come back to reality and enjoy machining by a real person, who does his work with better standards than the original, given how crooked that one was. You should see surviving (functional) examples of this capstan, when they turn. The wobble is absolutely delicious. Sheesh.
I have to point out that you are citing two items where decorative elements are not precisely aligned. Who gives a rats a$$ about that! Every functional joint and operational element that I've seen in all of Leo's videos has been of the highest precision fit and tolerance, so many of them so tight and accurate that they had to be hammered together with a mallet and left absolutely no gap or wobble. Tally Ho represents the highest level of craftsmanship and shipbuilding skill possible. To me, your critique is petty and laughable. I would find the wobble of an original capstan charming and quaint but my time building and living on sailboats makes me appreciate tools and systems that fit right and work as the should. In my book, you missed the point and you need to go sit with the CNC gang for half an hour and see if you can get back to reality. I'm pretty sure you can do that if you try. Hey, this was fun! And by the way, I am one of those who think that Tally Ho is perfect to the fraction of a millimeter. Fair winds . . . .
Watching this Tally Ho project has been an absolute joy. Thanks for sharing
Love your manor and professionalism
A big rotary table would have been perfect for a job like this.
Great job Keith. But am I the only one having palpitations watching that capstan head rocking on top of that machine at the end?
I was thinking the exact same thing : )
Haha, not palpitations but a wry smile, thinking about the groans when the foundry hears that their little masterpiece is lying in a score of pieces on Keith's concrete floor.
Good to see the Lucas mill put to good use.
Thank You Keith :) I hope again I will meet you at the Calif. gathering.
Why no bronze bushing on the inner part of gear? Seams like that would rust up. I am always amazed at how much work goes into what seams like a "simple" job.
Hail the algorithm!
#TallyHo and my morning coffee.😊
You could slide your phone under the capstan head to record what is happening, so you could control the alignment.
Just found your channel from Jimmy Diresta. I'm glad to see a local South Georgian on here.
The sight of that capstan cover just wobbling away on that tabletop, after all the work that has been done to make and fit it, fills my mind with dread.
Very talented machinist with a wonderful way of presenting his craft. Thank you Keith, it had been an amazing experience watching you progress through this project
After all the work that has been put into this I would be too scared to ship it to Leo.I'd be driving that sucker up there lol.
This episode is a paean to the "Keep it because you never know when you will need it" philosophy.
There is that certain joy when you can "make do" and solve a problem.
I had to bust out my dictionary to learn that a "paean" is a song of triumph. Talk about obscure vocabulary, but I'll keep that one in the repertoire. Sounds like "peeing'.
Nice to see the Lucas HBM boring its first hole. 😊
... since it was restored. That mill has likely done hundreds if not thousands of holes since it was made so many decades ago.
Wow Keith, your setup and machining skills are top notch. I'm proud to see all the work you are doing for Leo and the Tally Ho.
I have been watching your progress on this for several months and I’m just amazed at your comb matter-of-fact calm attitude about what you need to do and how are you going to do it.
Good morning Keith! Good to see the horizontal mill working. Have a great weekend!
Imagine if the viewers will, dozens of men and women operating lathes and mills all day long producing the machinery necessary for WWII. No CNC just manual measuring and cutting. They went home after a long day thinking in decimal places and fractions, guaranteed. Impressive.
Great work Keith looking forward to see it mounted and working 😊
when you had the casting set up, all it would have taken to make the notches for the bronze pieces is a few passes with an end mill :)
No machinist here, but thought the same thing.
Surprised me as well, best time for doing this has passed but his choice, his shop, his ears and hands on the die grinder!
Thanks for another great video Mr Rucker, superb work, I have serious drill bit envy now!
Hi Keith. I’m NOT a machinist. Just a simple carpenter following Tally Ho build. I own a relatively cheap dewalt laser that mounts to a tripod that shoots a vertical and horizontal line. Super easy to put that line over the top of that drill bit and broadcast that line to the other side of that cap.
Just an FYI maybe for future projects. Really enjoying your work👍
I thought you were going to suggest making the hole with a LASER 😂.
That said there are also spark eroding , and water jet cutting options that could be utilised
True but I’m suggesting a 100dollar item
I wouldn't be surprised if Keith has one. Most people don't know that Keith is also a woodworker who makes furniture. The other half of his shop is filled with woodworking machines and tools.
A perfect job for the horizontal mill.
Ahh, that sound of heavy metal on heavy metal. 🙂
Thanks for all your work on this crucial piece of equipment for Tally Ho!
"rusty crusty" is my new favourite technical jargon 😄
Thanks again Keith
Appreciating the eye-watering cost of producing a one-off gentleman's sailing boat is not difficult.
Without sound, this video is a nerve-wracking thriller that makes my hands sweaty after all the effort that goes into the re-casting... The really hideous thing about everything to do with building sailboats is the unbelievable number of holes that have to go into every single component.
Absolutely!
And they're going to have more huge holes in the deck for this. I wish they had just gone with a much smaller and lighter electric chain wimdlass.
Tally Ho always had this capstan. It feels right that she should continue to have it for another hundred years or so.
Edit to further drive the point home:
The capstan appeared on Albert Strange's original drawings of the boat. It belonged to Tally Ho before a single piece of timber was even cut for her.
If the drawings didn't have the capstan, I'm sure Leo would've considered alternatives. However, it did have the capstan in the drawings, so here we are. Wonderful work being done all around.
@@snaplash Leo likes to call the Tally-Ho project a “restoration” (and sometimes also a re-build) in the sense of restoration, the Capstan would of course be the icing on the cake of the entire project. But I understand your point, on my boat I have a lifting keel and I store the anchor chain midship as far as possible to have a better weight distribution, but Leo will have a plan for the enormously massive anchor chain and the Capstan he will have taken into account in the play of the variable lead modules, and so far I find the Tally-Ho sits extremely well in the water which is an indication of his expertise, unlike the Arabella which hangs in the water like a limp sack. Structurally I don't think the holes required for the Capstan are that significant as only a few deck planks will be affected.
On the other hand, in Leo's penultimate video, he talked about the Capstan and how much he cares about it, which seemed to me as if he was weighing up the sacrifice of the movement space in the bow against all the work that has gone into this project. It would be really interesting to know how he would decide now if it weren't for the enormous commitment of the great people who are restoring this historic curiosity of an anchor winch, which is hanging on this big hulk as an additional weight. I would probably also prefer a modern winch, on the other hand this massive format of the anchor chain is also a profound plus in terms of anchor safety, the technology of the Capstan is being modified somewhat, I didn't pay attention properly, will it be hydraulic?
And if you imagine it in a new color in all its glory sitting on the deck, the capstan on the tally-ho might not only be the i-Tüpfelchen of the whole project, but perhaps even the crowning glory.
@@propylaeen The driver will be an electric motor. All the differences are hidden below decks so the elevation will look the same. Great job on making a more modern mechanism to take care of what used to be such manual labor. Also the electric motor will not interfere with the manual wrenching function, I imagine it will be set to free wheel? Have not heard that but it beats disengaged with all the gear lash being undone or a physical stop/screw point needing setting from time to time. Imagine the sheer forces if it is barely engaged-talk about grinding the gears when you shift!
That was absolutely fascinating to watch - the skill and knowledge needed to operate those machines is incredible!!
You got to Love Old School Machine tools.
It was fun watching you run the horizontal boring mill, in the seventies I ran an AMC vertical boring mill, brought back memories. Have a
great day
Another fantastic video and another fantastic machine ... the amount you can learn just from this series of videos alone is amazing ... thanks for sharing 👍
I bet Clark nearly faints watching this!
I'm a firm believer in, "It's not the size of your drill bit, but how well you use it"!
Thank you Keith!
Great job. Surprised you misses the chance to put a bronse bushing on the inside pinion shaft
I was thinking the same thing and also about installing grease fittings but I doubt very much if the capstain will be used to manually haul the anchor since it has an electric motor so fitting bronze bushings would just be extra streps.
@@Hopalong..75 possibly keep the whole unit from siezing. I'm also concerned about the backlash on the pinion to ring gear since that didn't seam to be any consideration
The pinions will rotate every time the drum turns weather by hand or the electric motor. Bronze bushings would be well worth putting in.
@@ed-beahan918 well, it never was much concerned at the beginning either it seems from the lack of these same items then... All I saw at all was a small hole to drip some oil into on the bronze keepers. These pinions will turn when the capstand is working so any rusting of the two surfaces will work itself out as rust dust, grease does not play well with cast iron so I can see that not happening. A bit of oil in between the CI and the bronze is ok. No need for zerk fittings.
Excellent work as usual Keith. Top job and explanations. Thank you Go well
Way to go Keith. Really coming along!
Surely this is “the project” in which you have put into work more of your items and machines! Awesome work Keith.
I was thinking something similar. How many people have access to all the machines that Keith has access to. It’s all the more impressive because there’s no CnC work being done here.
Great job Keith !
Your work on the Tally Ho capstan has been fantastic. I know that Leo is going to love it.
Awesomeness Extreme. Great Job Keith. You are The Doctor of Machining.
That horizontal boring machine is fantastic!
It's good to see the horizontal boring mill get used. I would be so nervous machining that part knowing what Clark and company went through to get a good one.
Keith, it isn't really a hack, if it was part of you plan! BUT, your wisdom and experience is always appreciated. I have been called a narcissist, because I believe the way I do something is the best, but I counter with it is the best that I know and I am ALWAYS learning and adjusting what I believe to be the best way. Trust and believe that you have contributed to my knowledge base. I also respect your pragmatic approach as well, you cannot let perfection become the enemy of good enough. You don't get lost in chasing the zeros.
Narcissism has to do with self-admiration, not self-improvement. You're either misrepresenting yourself or your accuser is simply an asshat.
A MASTER MACHINIST .... ❤❤❤🎉🎉🎉😊😊😊 .....
I didn't think Id find myself following an engineering guru but here I am. Keep up the good work Keith, your a craftsman that's for sure.
That casting even sounds brittle, much respect for the meticulous care you are taking with it. Another superb video. A+
Thanks Keith
So satisfying to see that beautiful HBM doing its thing so well for the Tally Ho capstan.
Thanks again Keith for helping on the Tally Ho project. She's been launched and, at least to my eye, sits a little bow high. The capstan should get her sitting on her lines.
Much respect my southern brother! Extraordinary working skills. Thank you for the upload, Sir!
Makes you think about how clever the boy’s back then really were especially after watching Clark easterlings attempts to make this capston casting relentless attack but got the job done but the machinists had to take over from then on these guys were also super men of their day what craftsmen we had ,😊 nowadays we have mech lechs whatever they are or brickies who done a full 2 week apprenticeship 😂😂😂
Why not put a brass sleeve on your bearing surfaces?
Probably because there wasn't anything on the original casting. It's lasted over 100 years without so why fix what isn't broken.
Nice job Keith!
The amount of old equipment you just happen to have laying around is astonishng 🙂
It should be a cautionary tale for others 😁Buy the First then decide you need a Second and along the way buy the Tooling and Support Gear and then realize you need a Third to support the first and second .......
@@seabreezecoffeeroasters7994 Yeah. It's like going from a cane pole and a few worms for fishing and winding up with a bass boat, truck, trailer, tackle, rods/reels, depth finder etc. In all things, the closer one looks, the more one finds.
Great stuff Keith, getting to use all the toys on this project. I was surprised that a gigantic rotary table didn't emerge for this bit though, might have made the set up easier perhaps?
Thanks for continuing to share.
Another step has been completed. Amazed at the equipment in one shop.
Love to see these mechanical machines running as they should.
Keith, I have been watching you for years. I dont comment often but I figred it is about time. First, You are looking well my friend, Second I really enjoy watching all the challegning milling and lathe operations you work on that require one off super special unique setups before you can begin your operation. Nicely done as always and I hope you are well. Thanks for all your great content. I have learned a lot over the years.
You make it look easy.
Keith, You should have done a machined jig that would help to locate the cental bore a keep the reference with the machined surface of the cap. If you had done that, it would have helped you fine your ZERO of the central bore and Z height that is parallel with the boring machine table. And a jig would have helped a lot to align that bore from one side to the other side.
I am concerned about the height of the bore for proper engagement of gear. I guess the center hub can be machined down if too much slack, and shimmed up if not enough clearance. I'm sure Keith has it planned out, but I'm interested to see how assembly goes!
Enjoying every minute!
After thought, it's the shaft taper that locates this part to other parts, I can't imagine how to adjust.
@@dfye55I think you have a valid point. For I was considering the same thing.
As a British pattern maker. One of my possessions is a book by a Forman patternaker on making patterns for cast gearing. This was quite common over a century ago. Almost never done in contemporary times ?
For slow hand oporation a lot of backlash in cast gears to account for inaccuracies can be tolerated?
However the speed of the motor drive from the bottom spinning these bevel gears every time that the capstan is used could become problematic?
Keith,
A thought for making it easier to align large pieces for boring. Using a commercial laser pointer as your alignment tool, machine a sleeve that will fit into the tail stock on the horizontal mill. The laser pointer would fit into the sleeve. There should be a means to adjust the laser to make sure it is centered.
Once it is mounted and adjusted to the center of the headstock, it can be used to provide a rough check for alignment.
It is impressive that the capstan, designed and built over 100 years ago stood up to years of use and inactivity is still functional. It is also impressive that it could be modified for powered use.
Bob
Lining things by eyesight, has worked well for thousands of years..
Thanks for my Friday evening entertainment Keith!
Waiting for it to roll off the table and break a chuck out of the side!
And what a great place for that to happen, right, brazing is another of Keith's crafts.
Puts me in mind of when I was a candidate to be an apprentice back in the early days and the bull wheel of a shaper got cracked due to some other student's problems. The instructor was an old-timer from the rail industry who used to do Train Wheel Turning as a specialty. He was in his late sixties and a very knowledgeable CI weldbraiser as well. He took three students with Rosebud torches as well as welding torches positioned to either side of the crack line and one set below the crack. The small holes to keep the cracks from propagating had already been drilled and cleaned, Cast Iron Welding flux and welding rod had been placed in the holes during the preheat and when the cast iron was hot enough to weld, not braised, he proceeded to weld that crack with the appropriate cast iron welding rod and flux - it was amazing to watch and participate in this. Lucky me, I was the one who took over for the bottom rosebud and welding torch holder and was able to see the welding rod incorporate itself into the ground groove on the bottom. When he did the bottom weld, upside down mind you, and filled the small groove all I saw for minutes after was the white hot point of moving heat. We only had welding goggles not hoods so we suffered a bit of eye blaze. Since this was not electric welding we did not get a sunburn on our faces.
All of this was not brazing, it was CI welding, old school, like was done in the foundry to minor flaws in castings. White hot and fluxed continually with high red to yellow heat dwelling for hours after. Then a wrap in welding cloth and the preheat table covered as well. Next day we took the heat off the wheel, still wrapped of course, and after several more days we uncovered the now 400°F wheel and all you could see was a puddle of cast iron, top and bottom where the fusing had taken place. I did a lot of brass brazing since then, not the same at all. Takes a lot more heat and continued heat for hours after followed with lower heat in a similar fashion to what was described above. Major problem was we had no soak pit or oven for the preheat and post heat.that was what we three student and a heating table did, for hours before and after. Too a lot of tanks/bottles of oxi/acetylene including replacements for the over drawn acetylene bottles needing down time. We got these bottles from the weld school next door, boy were they pissed! But theschool approved all the expenditure and time for the teaching moment. Fun times!
Edited for the bottom weld.
Watching this skilled engineer working is a joy, unlike the rest of the capstan project which was a comedy of errors!
That something is old doesn't mean it can't do an excellent job!
Thank You Keith for this series. You get to do some amazing machining and it is all because of a love for the machine. I think that the love of machine is some of what built the Yankee ingenuity. That boring bar chuck and your abilities are great.
I think you are a real asset for dragging this out for so long
Another tosser
Thank you for another great video. Cheers
Merveilleuse et Splendide MACHINE aussi bien TOUR que FRAISEUSE, merci Monsieur le PROFESSEUR pour le partage de votre SAVOIR.
( my english is not very fluent in that matter, i am sorry)😊👍👍👍👋👋👋👋
Bon Courage and stay safe.
I would never imagine that it will be so much work. That's impressive ! Great work !
I'm gradually getting to understand the Rucker Scale of precision which runs from "Dead Nuts" to "Kinda Like Such". I shall adopt this for all future projects.
All I can say is, this capstan project has been one of the most difficult, complex and labor intensive jobs outside of making frames with rolling bevels. In another 100 years, someone is going to be amazed at the modernization of a 200 year old capstan and hopefully appreciate all the effort that went into it.
Still blows my mind how they would have made this 110 years ago. Luckily, I'm guessing they will be using the electric motor drive. Those bevel gears look shot to hell but absolutely, such an important piece for the historical value.
Great work Keith! Outstanding.
So, broach machine for those keyway slots? or vert mill?
That is a lovely lump of machinery. Fun!
Love the bronze pieces, Keith. They'll add a nice touch of class.