Nice job! I looked into this book series about 25 years ago, but could never justify all the time put into building them, to the quality of cast aluminum machines at the end. I'm glad someone did it though. I'm sure Mr Gingery is smiling somewhere, and it does look like a fun project. I am now considering finding a plan for a bench top mill to build. Thanks for the video...
I am so sorry that youtube dont give people like you enough so that you can keep making video's. I loved your channel and I do hope that what ever you do you are having a good time with good health and everything good that comes with it :) GOOD LUCK
Hi, I'm from Austria and I'm an engine builder since 40 years. I build lathe's and al kind of grinding machines. Congratulations for your real great work. It's interesting to look the way from alloy aluminum to the complete shaper. I think your videos ar'e good stuff for every young people to learn what is possible. Thank you for your videos!!!
Holy freaking crap! Sometimes I think to myself, "Why am I trying to make this thing? I could have saved so much time if I just bought it." Which is totally wrongheaded thinking, but that's besides the point. The real point being, your dedication on this project blows me out of the water! Kudos, and thanks for your work!
I’m impressed to say the lest, you have done a excellent job of making the shaper, it goes to show that if you put your mind to it you can have massive achievements and you have proved that right here, thank you for sharing this mate
Isn't it just the cutest little shaper, personally i would not make it out of cast Aluminium, but out of steel The shapers i have worked with, also had an adjustment on top of the ram, to move the ram forward or backward.which is great. A Shaper is a very handy machine, it can do a lot of things that a mill also could do I once made a set of brake Calipers with just a drillpress and a shaper.
I would love to see someone follow the Gingery build series with cast iron instead of aluminum. The increased weight would really help to make the machines more capable. I especially imagine that it would help with the chatter you’re getting if the clapper box wasn’t so light. Very nice build!
Dude! You're my new sensei. My wife just bought the hardcover "Build Your Own Metal Working Shop From Scrap" by David J. Gingery. Such an awesome Father's day gift. I will be starting on page 1 and completing every project. I'm so glad you made these videos. Thanks!
Hello, well done for completing, As a pro shaper machinist, I often use my shaper to make historically accurate parts that can't be done on a mill as the machining marks are all different, to improve finish on Aluminium you need a tool with 10degree s neg lead, 15 degrees front and side clearance, & this'll sound nuts but 30degrees back and side rake with a small nose radius about 1mm/0.040". Also polish the tool facets with 1500grit stone or wet n dry, & wd40 as lube to prevent stickup. Also, the chatter is from over long unsupported tool use a HSS lathe tool holder with inbuilt rake to help. Also, your tool tip is too far in front of the clapper box pivot, it's a "Gingery" thing, either move the pivot forward or raise it higher to improve the clapper movement angle. Sorry if I've laid too much on you. All the best
Fun setup and with the right planning you can turn it into a gear maker also by replacing the table with a assembly that rotates a disk of metal at the right speed for the tooth to take a strip off.
been waiting a lllooonnngg time to see how to make one of these. cannot express with words how much i personally appreciate your work and information on this project. watched your lathe build in its entirety, stoked everytime i saw that there was another one chronologically posted. at the end of that build i thought to myself, "man, all i need to know now is how to build a mill and a shaper", and sure as anything, here it is. good job brother, and thank you very much for showing the world..
hi my name is Kevin from Aus it is good to see you make little shaper in out famley engineering business we have tool room shaper yes you can do just about any thing on it I notest you had a weight on the set screw holding the tool in ,you might think of making a tool lifter so wen the ram goes backward it lifts the tool off the work piece you don't get makes on your work piece our machine has power feed on every thing it mite be a good idea putting dowels pins in some parts wen you line thing up your shaper looks very nice I like it I am a retired engineer
I have been a Machinist for 42yrs and I find this Very impressive its one thing to have the materials flat stock round stock etc on hand and machine them but to cast and machine them is a challenge in itself Excellent job I also have all of the Dave Gingery books bought them from Lindsay Publishing about 10 yrs back sorry they went out of business I liked all their books
if you use extruded polystyrene ( AKA pink or blue foam) instead of expanded, you will get a much better surface finish on your castings , its much nicer to work with , you can even turn it on the lathe to cast pulleys etc.
The machine is cool, I was wondering how a shaper would work as a project in the longterm. However It won't meet the needs of what I may require it for as a keyway inside of a shaft on about a 45 degree tapper. Super cool to understand a bit on how it works.
I had no idea you could use Styrofoam that way in aluminum casting! That opens up a lot of possibilities for making useful parts, I will have to keep that in mind for the future!
One thought on final shaper placement - I would suggest that you bolt it to the cement table so that the vertical slide projects just a touch over the edge of the table. That way, you add more vertical travel to the machine should you ever need to plane something taller than the current work envelope of the shaper. Also, I think it would be cool to see the the shaper and the lathe sharing a common power source. It might end up looking like a mini line shaft set up but since I don't think you'd use both tools at once, I think it might work.
I was going to share a power source until I realized that the shafts would be rotating the wrong way. Both shafts need to rotate with the top coming toward the operator. If I mount the shaper on the back side of the lathe cart I will need a way to reverse the rotation. I don't think v-belts would do well with a half twist.
Very cool, I have not used a shaper since I was in tech school in 1984. Great job, it brings back great memories. It was a scary machine, especially when you made a heavy cut.
well its been a long time coming! Looking at the video I did notice that the table should only be traversing during the back stroke of the cutting tool. if you traverse the table while cutting you will add more wear and inconsistent cutting load on the machine. just a heads up.
I have been tracking the timing more consistently as I have used the machine since it does make a difference in cut quality. @ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
In various shots you are running the machine backwards. That would help explain at least some of the issues you're listing. The ram is only supposed to advance during the top half of the rotation of the bull wheel. This is so that the ram is driving on the most powerful part of the the rotation. You never just reverse the drive. If you're doing this with the idea of cutting in both directions of travel of the cross slide, just stop. When cutting, the table feed is in one direction only. You're supposed to just stop the machine and manually return the cross slide to your starting position. Also,if you're trying to use inserted carbide inserts, don't waste your time. Carbide needs an extremely ridgid setup, which, due to the clapper box needed on this machine you'll never have. Also,if there is any side to side and/or twisting play in the box you'll get crappy results. That's what I was just able to figure out from your video. Settle down. You're jumping around to much. Speaking as a thirty year+ veteran of the machine trade's, I can tell you that if you don't sit down and actually analyse and understand the process and how it's supposed to work, you'll just keep chasing your tail. Break out Dave's series and actually get in depth in the setup and operation sections of the book. He has a basic but very solid how to set of instructions in it. Also, when in doubt about something follow his instructions as closely as possible, especially the correct check and setting up of all the axis slides. This machine,as most machines, needs to be be as ridgid as possible. That means that most, if not all, of your plastic parts are most likely adding to any other issues you've got, making trouble shooting all but impossible. Sorry, but that's the truth. Plastic parts don't have any application in the driveline of a machine like this. Not solid enough.
I noticed that quite a few of the components interfacing with the plastic are maybe 22ga steel. Those are worth upgrading to at least a 3/16 plate to increase rigidity.
Well written post from somebody who obviously knows what they are talking about... 😎👍 The carbide tools thing is definitely a no-no... a nice sharp HSS cutter with generous rake and clearance angles will DRASTICALLY reduce the input power requirements & general loading on the machine. I own an ELLIOTT 12" stroke shaper & love using it, the finish , with the right tool-grind, is easily better than a milled surface. 🤗
Peter Fitzpatrick Just an FYI, the tooling he’s using is HSS. It’s a design that looks like carbide because it’s an insert, but he showed the packaging which stated it’s HSS insert tooling.
Nice job on the shaper. When You get it sorted out the cut will amaze you. I'm just a hobbyist, but stick to hss on a light machine as carbide likes fast cutting speeds and heavy cuts two things your machine does not do. I don't no if gingery talks about what way the feed mechanism should turn but there is a specific direction. Tubalcain has a great video on the subject, with a teaching aid he built. Look for shop tips #172 Whitworth quick reverse mechanism. He also has a couple videos on a very small home made shaper that is incredible.
@@Makercise No way we need to stay with tradition, and be real men and not use a computer to run it. :) We just have to be careful when we turn it on and off.
I advise you watch some abom79 videos. He does some nice shaper work. For high surface finishes, he uses what looks like a lathe grooving or parting tool. He hones it by hand on the machine to ensure the cutting edge is parallel to the table travel and seems to have good results that way. One other thing he said was important was to tilt the Clapper box so the step over doesn't rub the tool on the return stroke. I was going to mention the step over should happen on the return and not the cut but saw someone already did and you replied. That being said, nice work building it. Looks like it will be a lot of fun once you get the hang out of playing with it.
I used to get the book catalogs, loved reading those. I have everything to build a furnace, & the book to build the lathe, just never started. I have to admit my ignorance though. Please, someone, what does the shaper do? Probably best I haven't tried building the lathe, not understanding what the shaper does.
metrology .. in a one inch square after scraping the spot count matters the less there is/spots/ the flatter the part the surface plates can get pricey and used ones can be found but they regularly get abused which affects their accuracy so you can apply some elbow grease to marble or steel blocks by using them to get them flat all it takes is your willingness and some diamond paste and three of the same blocks to alternate them out as you go. applying even pressure as you rub them together fine grain diamond sharpening plates would help you get the roughness out until you get to where you could have it rated for flatness or learn to do the rating your self but there again that gets pricey as well it takes specialized equipment to do that it really comes down to just how close your tolerances have to be you could get away with eyeballing it until it just has to be tighter
To achieve a better surface finish use a bull nose cutter and increase the feed rate, try 1/16". You lose some power with the Al ram being so light. Cast Al is porous making it difficult to obtain a good finish. I hope this helps.
It has been a long time since I used a shaper back in early eighties.Haven't used one since or seen anyone use them.Looks pretty cool though you must have the patience to build one.
Minor addition to running the shaper, ensure that the table is advancing during the backstroke for the best surface finish, that way it's not trying to take an unevenly loaded cut
I have been doing this consistently as I have used the machine more. @ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
Are you planning to make the Gingery milling machine next? How about adding things to the lathe, like screw cutting gears, back gears, dividing head etc.?
I liked this project build very much. Of all the Gingery projects, this is the one I most want to build. I never seem to be able to get the time to get started on a project like this though...so many others going on. Also, somehow, it looks like around 16:50 you have the cross feed set up to move during the cut, so that mechanism is not in phase properly at that point. I'd be interested to hear how you did that.
@ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
I loved your lathe and shaper projects ! how about you make a new lathe ? one double or triple the original dimensions so you would have a lathe that is capable of much larger work ? I would love to see that ! the original to me, is just too small to bother with ... ....Bob......
Have you looked at gear involute gear cutting on the shaper? It's a very interesting process just using a v bit and rotating the workpiece to produce the gear tooth.
I love these videos! With regard to the tool needing a counter weight (otherwise known as a wrench) to stop it chattering, Couldn't you use some kind of sprung attachment to ensure it returns firmly? Just a thought from someone who didn't even know what a shaper was until I saw this series... in fact, I initially thought the lathe and the shaper was called the 'Gingery' because... er... well... because you're ginger. Okay... I'll show myself out.
This is the first time I have run across your channel and I gave you the TH-cam Trifecta! Only recently have I let the Bell be rung as I don't like the scroll as I am watching TH-cam videos on something else! I used to get the old orange cheap paper catalogs from some guy in Illinois someplace, maybe Chicago? I just wasn't at a place where I could afford to do even what you are doing. I have done some lost wax silver jewelry casting in the area of Annapolis, MD with the Patuxant Lapidary Guild after seeing a TV show about classes in Sedona, New Mexico for over a grand! I got to thinking when I was going to have that much money to blow, especially if I was in N.M.? So I looked for something closer to Baltimore. It was so much fun when I let the broken-arm casting machine loose I let out a Rebel Yell and I scared the woman who was the only other person taking the class. She thought that I was trying to intimidate her! I have seen all of the Chinesium microtools and so much applaud you for the effort not to just drop money on the issue! All of the the upgrades to those tools are not even close to a well used & mostly used up refugee of every kind of jobshop for so many decades from nowhere near when it was brand new or even workable grade can be brought back easier than to put the stretch on junk! How much is it to be a cadre level supporter? Very nice work! Carry on!
LOTS more heat required, much more safety-related measures involved, different molding characteristics (not sure about lost foam with iron, but green sand characteristics are less forgiving), different crucible requirements, etc. Check out luckygen1001, for some real quality hobby work in cast iron and great info.
You should have an introduction video showing the shaper . I wasn't familiar with the shaper and had to jump to the end to see what it was. It's good to have an idea of what you're working to. You could also do the same for the lathe. If you do iron casting, it's a much higher temp, and I believe its harder to work with. I believe that's why Dave Gingery did most of his work in aluminum. What video do you describe the differences between green mold sand casting, and lost plastic foam casting ? Are the castings more porous ??? Also, I saw a similiar lathe project where instead of bronze bushings, they just went out and purchased bearings from Northern Tool for $9. Thanks.
Could perhaps the whole advancement mechanism be replaced with a hall sensor, a stepper motor, an arduino and a stepper driver? With such you could dial in the amount of advancement to microsteps.
@@Makercise Well, you certainly wouldn't need a full cnc setup with a dedicated PC and all. There are just so many cheap off the shelf components that solving the problem electronically seems more "beer and bait money". Perhaps it could be done with a small encoder , a hall effect sensor, and an H-bridge, skipping stepper drivers/stepper motors altogether.
@@Altcapball I think it's actually likely less work to use a stepper because you don't have to implement a control algorithm for ensuring perfect positioning. And drivers are dead cheap, just buy the cheapest and shittiest 3d printer control board you can find (usually these have safety hazards with their heated bed controls but it doesn't matter since you aren't using that part), and an equally cheap stepper motor. You can program it all like an Arduino.
Why am I doing exactly the same thing you're doing, with the same materials even, but I'm 5 failed attempts into lost foam casting the bases for the gingery mill? It's extremely frustrating and incredibly disappointing. I'm going to keep going, but it's getting hard to continue failing. Is the quarter inch foam just too thin? I've made several castings that where thicker for other projects, so these would be the thinnest. I'm going to try to make a set of base patterns for the mill that are half an inch and see if that helps, but if not then I'm abandoning lost foam.
Dedicated and rewarding work ! I actually have a serious question and forgive my ignorance, but why Scrape the right-angle plate instead of just laying some wet/dry sandpaper on your Granite flat plate and cleaning it up that way...it's Aluminum !
7:50 first I clarify that i don't want disrespect you, I'm asking for curiosity. Is the worktable showing lack of rigidity ??? it will be a big problem i think. in any case amazing job
![BOWKYLION - วิงวอน (ex-change) [Official MV]](http://i.ytimg.com/vi/cLdnZWDaO-w/mqdefault.jpg)
Nice job! I looked into this book series about 25 years ago, but could never justify all the time put into building them, to the quality of cast aluminum machines at the end. I'm glad someone did it though. I'm sure Mr Gingery is smiling somewhere, and it does look like a fun project.
I am now considering finding a plan for a bench top mill to build. Thanks for the video...
I am so sorry that youtube dont give people like you enough so that you can keep making video's. I loved your channel and I do hope that what ever you do you are having a good time with good health and everything good that comes with it :) GOOD LUCK
Hi, I'm from Austria and I'm an engine builder since 40 years. I build lathe's and al kind of grinding
machines. Congratulations for your real great work. It's interesting to look the way from alloy aluminum to the complete shaper. I think your videos ar'e good stuff for every young people to learn what is possible. Thank you for your videos!!!
😇 my pleasure. 🙏 thanks for the kind words.
This takes me back. I used to work a planning machine with a two metre stroke. Proper engineering. Well done.
Holy freaking crap! Sometimes I think to myself, "Why am I trying to make this thing? I could have saved so much time if I just bought it." Which is totally wrongheaded thinking, but that's besides the point. The real point being, your dedication on this project blows me out of the water! Kudos, and thanks for your work!
It is very appreciated to see those who truly work with their hands and mind.... Just a outstanding effort.. roger
Nice work on the casting, I'll have to tuck that in a grey cell.
I’m impressed to say the lest, you have done a excellent job of making the shaper, it goes to show that if you put your mind to it you can have massive achievements and you have proved that right here, thank you for sharing this mate
My pleasure!
Isn't it just the cutest little shaper, personally i would not make it out of cast Aluminium, but out of steel
The shapers i have worked with, also had an adjustment on top of the ram, to move the ram forward or backward.which is great.
A Shaper is a very handy machine, it can do a lot of things that a mill also could do
I once made a set of brake Calipers with just a drillpress and a shaper.
I would love to see someone follow the Gingery build series with cast iron instead of aluminum. The increased weight would really help to make the machines more capable. I especially imagine that it would help with the chatter you’re getting if the clapper box wasn’t so light. Very nice build!
Seeing how much Abom 79 loves shapers I'm sure he'd be thrilled with your project.
Dude! You're my new sensei.
My wife just bought the hardcover "Build Your Own Metal Working Shop From Scrap" by David J. Gingery.
Such an awesome Father's day gift.
I will be starting on page 1 and completing every project.
I'm so glad you made these videos. Thanks!
Hello, well done for completing, As a pro shaper machinist, I often use my shaper to make historically accurate parts that can't be done on a mill as the machining marks are all different, to improve finish on Aluminium you need a tool with 10degree s neg lead, 15 degrees front and side clearance, & this'll sound nuts but 30degrees back and side rake with a small nose radius about 1mm/0.040". Also polish the tool facets with 1500grit stone or wet n dry, & wd40 as lube to prevent stickup.
Also, the chatter is from over long unsupported tool use a HSS lathe tool holder with inbuilt rake to help.
Also, your tool tip is too far in front of the clapper box pivot, it's a "Gingery" thing, either move the pivot forward or raise it higher to improve the clapper movement angle.
Sorry if I've laid too much on you.
All the best
Great info. I'll have to give some of these tips a try. Thanks!
Fun setup and with the right planning you can turn it into a gear maker also by replacing the table with a assembly that rotates a disk of metal at the right speed for the tooth to take a strip off.
I might have to try it.
been waiting a lllooonnngg time to see how to make one of these. cannot express with words how much i personally appreciate your work and information on this project. watched your lathe build in its entirety, stoked everytime i saw that there was another one chronologically posted. at the end of that build i thought to myself, "man, all i need to know now is how to build a mill and a shaper", and sure as anything, here it is. good job brother, and thank you very much for showing the world..
It was fun. More to come!
You certainly get down to the " nitty gritty " BRAVO !!!
"It's going slowly" - you know what they say, you can make anything with a shaper except money.
You can make something with a shaper that can in turn make you money.
Dropping airsoft BBs to block vacuum in unused areas of the vacuum table.
You just changed my life.
What a smart and easy solution for the vacuum table design :)
hi my name is Kevin from Aus it is good to see you make little shaper in out famley engineering business we have tool room shaper yes you can do just about any thing on it I notest you had a weight on the set screw holding the tool in ,you might think of making a tool lifter so wen the ram goes backward it lifts the tool off the work piece you don't get makes on your work piece our machine has power feed on every thing it mite be a good idea putting dowels pins in some parts wen you line thing up your shaper looks very nice I like it I am a retired engineer
I have been a Machinist for 42yrs and I find this Very impressive its one thing to have the materials flat stock round stock etc on hand and machine them but to cast and machine them is a challenge in itself Excellent job I also have all of the Dave Gingery books bought them from Lindsay Publishing about 10 yrs back sorry they went out of business I liked all their books
Thanks a lot!
Congratulations, I really enjoyed the series. You have inspired me to excersize my inner maker. I look forward to your future projects.
if you use extruded polystyrene ( AKA pink or blue foam) instead of expanded, you will get a much better surface finish on your castings , its much nicer to work with , you can even turn it on the lathe to cast pulleys etc.
I just recently switched over. I do like it a lot! Surface finish is great!
The machine is cool, I was wondering how a shaper would work as a project in the longterm. However It won't meet the needs of what I may require it for as a keyway inside of a shaft on about a 45 degree tapper.
Super cool to understand a bit on how it works.
Nice to see the shaper finishing itself
Haha. Yes nice indeed.
Hi, Rex sent me and I'm glad he did.
I had no idea you could use Styrofoam that way in aluminum casting! That opens up a lot of possibilities for making useful parts, I will have to keep that in mind for the future!
One thought on final shaper placement - I would suggest that you bolt it to the cement table so that the vertical slide projects just a touch over the edge of the table. That way, you add more vertical travel to the machine should you ever need to plane something taller than the current work envelope of the shaper. Also, I think it would be cool to see the the shaper and the lathe sharing a common power source. It might end up looking like a mini line shaft set up but since I don't think you'd use both tools at once, I think it might work.
I was going to share a power source until I realized that the shafts would be rotating the wrong way. Both shafts need to rotate with the top coming toward the operator. If I mount the shaper on the back side of the lathe cart I will need a way to reverse the rotation. I don't think v-belts would do well with a half twist.
@@Makercise Could you potentially reverse the direction of your induction motor with clever wiring and a direction switch? Great project, btw.
So cool! This is a super creative project, Cressel! Glad that X-Carve could be a part of this huge undertaking.
Thanks! Definitely an asset in the shop.
Very cool, I have not used a shaper since I was in tech school in 1984. Great job, it brings back great memories.
It was a scary machine, especially when you made a heavy cut.
Wonderful job, great summary video! I can’t wait to see more shaper videos when you get it “dialed in” and make more with it.
More to come!
Good work Ginger.
I think your casting work is impressive. You probably make it look too easy :)
G’day Cressel, nicely done. Hand scraping is still required to get that machine fit. The Shaper really is shaping up, cheers, Peter
Thanks Peter!
It would be cool if you had an overhead shaft from your lathe motor to power all your machines. Like the old workshops that used steam power !
Wow! Brilliant! Ginger Power!!
well its been a long time coming! Looking at the video I did notice that the table should only be traversing during the back stroke of the cutting tool. if you traverse the table while cutting you will add more wear and inconsistent cutting load on the machine. just a heads up.
I have been tracking the timing more consistently as I have used the machine since it does make a difference in cut quality. @ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
Incredibly fascinating projects, been binging a few videos the last hour. Makes me really tempted to try and make a shaper!
In various shots you are running the machine backwards. That would help explain at least some of the issues you're listing. The ram is only supposed to advance during the top half of the rotation of the bull wheel. This is so that the ram is driving on the most powerful part of the the rotation. You never just reverse the drive. If you're doing this with the idea of cutting in both directions of travel of the cross slide, just stop. When cutting, the table feed is in one direction only. You're supposed to just stop the machine and manually return the cross slide to your starting position. Also,if you're trying to use inserted carbide inserts, don't waste your time. Carbide needs an extremely ridgid setup, which, due to the clapper box needed on this machine you'll never have. Also,if there is any side to side and/or twisting play in the box you'll get crappy results.
That's what I was just able to figure out from your video. Settle down. You're jumping around to much. Speaking as a thirty year+ veteran of the machine trade's, I can tell you that if you don't sit down and actually analyse and understand the process and how it's supposed to work, you'll just keep chasing your tail. Break out Dave's series and actually get in depth in the setup and operation sections of the book. He has a basic but very solid how to set of instructions in it. Also, when in doubt about something follow his instructions as closely as possible, especially the correct check and setting up of all the axis slides. This machine,as most machines, needs to be be as ridgid as possible. That means that most, if not all, of your plastic parts are most likely adding to any other issues you've got, making trouble shooting all but impossible. Sorry, but that's the truth. Plastic parts don't have any application in the driveline of a machine like this. Not solid enough.
I noticed that quite a few of the components interfacing with the plastic are maybe 22ga steel. Those are worth upgrading to at least a 3/16 plate to increase rigidity.
Well written post from somebody who obviously knows what they are talking about... 😎👍
The carbide tools thing is definitely a no-no... a nice sharp HSS cutter with generous rake and clearance angles will DRASTICALLY reduce the input power requirements & general loading on the machine.
I own an ELLIOTT 12" stroke shaper & love using it, the finish , with the right tool-grind, is easily better than a milled surface. 🤗
duro esto que ha escrito (creo) pero es mejor así, yo ni papas entiendo, solo se que así debemos ser si
Peter Fitzpatrick
Just an FYI, the tooling he’s using is HSS. It’s a design that looks like carbide because it’s an insert, but he showed the packaging which stated it’s HSS insert tooling.
Титаническая работа! Моё уважение автору!
great video bro . thats the speed most of them run at if you want nice looking work !
Thanks
Try to keep tool stick out as short as possible it will help with any chatter and improve surface finish. Regards, Matthew
Nice job on the shaper. When You get it sorted out the cut will amaze you. I'm just a hobbyist, but stick to hss on a light machine as carbide likes fast cutting speeds and heavy cuts two things your machine does not do. I don't no if gingery talks about what way the feed mechanism should turn but there is a specific direction. Tubalcain has a great video on the subject, with a teaching aid he built. Look for shop tips #172 Whitworth quick reverse mechanism. He also has a couple videos on a very small home made shaper that is incredible.
The table should advance during the backstroke rather than during the cut. Hope this helps, great work sir.
Let's see you build an RBMK-1000 starting with a flower pot foundry and all the #2 pencils you can get your hands on.
I just added this to my list. Unless we cure aging first, unfortunately I don't think I will get to it in time.
Also probably will go with a different design when I get to it.
@@Makercise No way we need to stay with tradition, and be real men and not use a computer to run it. :) We just have to be careful when we turn it on and off.
It is interesting how were made spindles and other rotary parts of the first machine tools in the world
I advise you watch some abom79 videos. He does some nice shaper work. For high surface finishes, he uses what looks like a lathe grooving or parting tool. He hones it by hand on the machine to ensure the cutting edge is parallel to the table travel and seems to have good results that way. One other thing he said was important was to tilt the Clapper box so the step over doesn't rub the tool on the return stroke. I was going to mention the step over should happen on the return and not the cut but saw someone already did and you replied. That being said, nice work building it. Looks like it will be a lot of fun once you get the hang out of playing with it.
Thanks for the pointer! I have watched Adam’s videos but now that I own a shaper I should revisit.
very cool vaccuum system! another great video!!
Great project, nice job.
I used to get the book catalogs, loved reading those. I have everything to build a furnace, & the book to build the lathe, just never started. I have to admit my ignorance though. Please, someone, what does the shaper do? Probably best I haven't tried building the lathe, not understanding what the shaper does.
This is super cool! Nice job!
metrology .. in a one inch square after scraping the spot count matters the less there is/spots/ the flatter the part
the surface plates can get pricey and used ones can be found but they regularly get abused which affects their accuracy so you can apply some elbow grease to marble or steel blocks by using them to get them flat all it takes is your willingness and some diamond paste and three of the same blocks to alternate them out as you go. applying even pressure as you rub them together
fine grain diamond sharpening plates would help you get the roughness out until you get to where you could have it rated for flatness or learn to do the rating your self but there again that gets pricey as well it takes specialized equipment to do that
it really comes down to just how close your tolerances have to be
you could get away with eyeballing it until it just has to be tighter
Really cool fundamental tool.
To achieve a better surface finish use a bull nose cutter and increase the feed rate, try 1/16". You lose some power with the Al ram being so light. Cast Al is porous making it difficult to obtain a good finish. I hope this helps.
I have started degassing with argon so the castings are getting less porous.
It has been a long time since I used a shaper back in early eighties.Haven't used one since or seen anyone use them.Looks pretty cool though you must have the patience to build one.
congratulations
Minor addition to running the shaper, ensure that the table is advancing during the backstroke for the best surface finish, that way it's not trying to take an unevenly loaded cut
I have been doing this consistently as I have used the machine more. @ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
@@Makercise fantastic, I guess I only really noticed it at one point in the video.
Are you planning to make the Gingery milling machine next? How about adding things to the lathe, like screw cutting gears, back gears, dividing head etc.?
Currently building the mill
Been waiting for this video!!!! I love that shaper so much makes me want to build one
I miss your videos. I hope your doing ok and start posting again soon
I liked this project build very much. Of all the Gingery projects, this is the one I most want to build. I never seem to be able to get the time to get started on a project like this though...so many others going on. Also, somehow, it looks like around 16:50 you have the cross feed set up to move during the cut, so that mechanism is not in phase properly at that point. I'd be interested to hear how you did that.
@ 10:33 I did adjust the timing so it advances on the return stroke. I have to remember to change the timing 180 degrees when I switch feed directions though.
Just checking in on yah. Haven't seen a post in a while. Are things ok?
Best Matt
Things are good. Had some other priorities this summer. Bout to get back on this horse. Answering comments is putting my foot in the stirrup.
Great.. 👌👌👌👌
Awesome!
I would love to see a video of how you made the vacuum bed for your x-carve.
perhaps I'll have to do it then.
@@Makercise Thanks! That x-carve is a great addition to your shop. I am going to try and build a DIY one eventually.
I loved your lathe and shaper projects ! how about you make a new lathe ? one double or triple the original dimensions
so you would have a lathe that is capable of much larger work ? I would love to see that !
the original to me, is just too small to bother with ... ....Bob......
Correct tool grind will make a huge difference.
Muy versátil gracias
Have you looked at gear involute gear cutting on the shaper? It's a very interesting process just using a v bit and rotating the workpiece to produce the gear tooth.
I know it is possible but I will probably just wait until I finish building the horizontal mill.
@@Makercise look it up on Google. It's the one by 'base circle"
I love these videos!
With regard to the tool needing a counter weight (otherwise known as a wrench) to stop it chattering, Couldn't you use some kind of sprung attachment to ensure it returns firmly? Just a thought from someone who didn't even know what a shaper was until I saw this series... in fact, I initially thought the lathe and the shaper was called the 'Gingery' because... er... well... because you're ginger. Okay... I'll show myself out.
HAHA. Probably could be done with a spring setup.
Bravo ! I am really surprise that it can work so well
I am subscribe
and I will order the book
this machine can be a treasure for small steam engine
Very cool man, how are you measuring perpendicularly of the work surface
خدایی دمت گرم زنده باشی
im iranian
Its beautiful
This is the first time I have run across your channel and I gave you the TH-cam Trifecta! Only recently have I let the Bell be rung as I don't like the scroll as I am watching TH-cam videos on something else! I used to get the old orange cheap paper catalogs from some guy in Illinois someplace, maybe Chicago? I just wasn't at a place where I could afford to do even what you are doing. I have done some lost wax silver jewelry casting in the area of Annapolis, MD with the Patuxant Lapidary Guild after seeing a TV show about classes in Sedona, New Mexico for over a grand! I got to thinking when I was going to have that much money to blow, especially if I was in N.M.? So I looked for something closer to Baltimore. It was so much fun when I let the broken-arm casting machine loose I let out a Rebel Yell and I scared the woman who was the only other person taking the class. She thought that I was trying to intimidate her!
I have seen all of the Chinesium microtools and so much applaud you for the effort not to just drop money on the issue! All of the the upgrades to those tools are not even close to a well used & mostly used up refugee of every kind of jobshop for so many decades from nowhere near when it was brand new or even workable grade can be brought back easier than to put the stretch on junk! How much is it to be a cadre level supporter?
Very nice work! Carry on!
Your an engineer !
Have you ever considered making parts in cast iron? How much more difficult would that be compared to aluminum?
LOTS more heat required, much more safety-related measures involved, different molding characteristics (not sure about lost foam with iron, but green sand characteristics are less forgiving), different crucible requirements, etc. Check out luckygen1001, for some real quality hobby work in cast iron and great info.
It is on my goal list. More difficult than aluminum by a lot. I will get there eventually.
PARA MI EL CEPILLO ES GENIAL
You're awesome
Do you get a lot of burning plastic smell when you pour or does the sand absorb that? I have neighbors.
Does Gingery have a surface grinder book too? I feel like a surface grinder would be the least complicated of any of the shop machines
Not that I have ever seen. I want to build one though let me know if you find any examples of home built stuff.
Does the book tell u to scrape the surface cut by the machine and the cross side surface?
Yes.
You should have an introduction video showing the shaper . I wasn't familiar with the shaper and had to jump to the end to see what it was. It's good to have an idea of what you're working to. You could also do the same for the lathe. If you do iron casting, it's a much higher temp, and I believe its harder to work with. I believe that's why Dave Gingery did most of his work in aluminum. What video do you describe the differences between green mold sand casting, and lost plastic foam casting ? Are the castings more porous ??? Also, I saw a similiar lathe project where instead of bronze bushings, they just went out and purchased bearings from Northern Tool for $9. Thanks.
Could perhaps the whole advancement mechanism be replaced with a hall sensor, a stepper motor, an arduino and a stepper driver? With such you could dial in the amount of advancement to microsteps.
Yes this could be done. A cnc shaper would be comically anachronistic, but the thought has crossed my mind as well. ;)
@@Makercise Well, you certainly wouldn't need a full cnc setup with a dedicated PC and all. There are just so many cheap off the shelf components that solving the problem electronically seems more "beer and bait money". Perhaps it could be done with a small encoder , a hall effect sensor, and an H-bridge, skipping stepper drivers/stepper motors altogether.
@@Altcapball I think it's actually likely less work to use a stepper because you don't have to implement a control algorithm for ensuring perfect positioning. And drivers are dead cheap, just buy the cheapest and shittiest 3d printer control board you can find (usually these have safety hazards with their heated bed controls but it doesn't matter since you aren't using that part), and an equally cheap stepper motor.
You can program it all like an Arduino.
Wau how did you made that cast this way is impressive! The material all melted and just gone
look up lost foam casting, it's indeed pretty impressive.
were are the eletrical furnace? these was made by gingery recipe too? ( fire clay and play sand)
Stock Gingery calls for a charcoal foundry. I have a 2300W kiln, but the propane foundry is soooo much faster.
Complimenti bel lavoro...
Great
Brilliant clever man
It's a pity that the channel project was stopped. 😔
Why am I doing exactly the same thing you're doing, with the same materials even, but I'm 5 failed attempts into lost foam casting the bases for the gingery mill? It's extremely frustrating and incredibly disappointing. I'm going to keep going, but it's getting hard to continue failing. Is the quarter inch foam just too thin? I've made several castings that where thicker for other projects, so these would be the thinnest. I'm going to try to make a set of base patterns for the mill that are half an inch and see if that helps, but if not then I'm abandoning lost foam.
Dedicated and rewarding work ! I actually have a serious question and forgive my ignorance, but why Scrape the right-angle plate instead of just laying some wet/dry sandpaper on your Granite flat plate and cleaning it up that way...it's Aluminum !
In keeping with the theme of the project, your first piece has to be a vise for the shaper table
Already done. Nothing deluxe but I used it to hold the mill spindle head.
where do you source most of your aluminum?
Tá ficando muito boa gostei
I am curious as to the type of aluminum that you are using?
7:50 first I clarify that i don't want disrespect you, I'm asking for curiosity. Is the worktable showing lack of rigidity ??? it will be a big problem i think. in any case amazing job
I’m confused is it supposed to be a success? Looks like it has basic properties but can it actually shape metal to any reasonable tolerance?
your scrapping pattern looks weird. but it spreads out correctly.
Bro osm
This is so cool! Can you make a small od grinder?
Possibly!