Author Topic: Rounding Over Jig (Read 28090 times)

Bernd · « **on:** March 12, 2009, 11:11:33 AM »

When I started my index head thread I discovered I needed to make a few jigs to make the clamp that will hold the spindle from turning. That piece is made from aluminum. Here's what I ended up with. You'll notice that the corners still need to be rounded.

I did some brain storming as to how I was going to do it.

The easy way would be to use a rotary table but unfortunately I don't have one at the moment. So I needed to come up with something else. I remembered that Marv Klotz had made a small round over jig for doing small links for steam engines and such. Here's his Round Over Jig

This gave me the idea to make something similar but a bit bigger. This is not going to be a how to with dimensions. Just a few pics of how I did it with a short explanation.

Here are all the parts. The table (upside down), the square drawbar holder with the appropriate holes, the draw bar, a 5/16" centering pin, and the bolt and washers to draw the drawbar tight.

The square bar attached to the table with the draw rod in place with the washers.

A quick shot of what it looks like before inserting the locating pin.

Here it is right side up with the locating pin installed and clamped tight.

And a picture of the whole works clamped up in the vise ready for some action. I still need to add some stop blocks. That will come with the first job.

Now here's the dilemma. I ordered a 10" rotary table yesterday after clearing it with the CFO. It should be here next week. So the question is, do I wait for the table to get here or do I try out my jig and possibly ruin the clamp?

Stay tuned and find out.

Bernd

P.S. Ralph, this is how I thought of rounding over the square ends on this part.

Darren · « **Reply #1 on:** March 12, 2009, 11:16:40 AM »

Get the drift here Bernd....

Bernd · « **Reply #2 on:** March 12, 2009, 12:09:29 PM »

My ISP provider for my website is having problems apperantly. I did notice earlier they were loading very slowly for haveing a DSL line. Stay tuned.

Bernd

12:45 PM. Looks like my ISP is back up and running. Enjoy the pics.

Darren · « **Reply #3 on:** March 12, 2009, 12:56:35 PM »

Let you off then

Looks good btw, be interesting to see how well this works

bogstandard · « **Reply #4 on:** March 12, 2009, 01:01:37 PM »

You made it, you gotta use it!!

Bogs

Bourne Bill · « **Reply #5 on:** March 12, 2009, 01:18:35 PM »

looks good to me, but I think I would have threaded the pivot pin, so you could make different size pins for different things that need to be rounded over...... hope that makes sense.........

Bernd · « **Reply #6 on:** March 13, 2009, 01:47:58 PM »

I worked on the round over jig today. I made the plug to fit in the clamp plate, plus I cut 1/4-20 threads on the end of a piece of steel for the pin, plus nut and washers. Here's a pic of all the materials.

Here are all the parts assembled on the round over jig.

While I was working on all the above and unbeknown to me the UPS driver was here and left a package for me.

Low and behold it's my 10" (254mm) dia. rotary table and a free present.

And here it is on the machine.

Now the dilemma. Do I use the round over jig or the rotary. I know Bogs said "you built it, now use it". I will but I decided I wasn't going to use it on a piece that has taken me several days to make. So as soon as it warms up to room temp and I put some oil in the table, plus I need to make some T-nuts to be able to hold the parts.

Stay tuned as the saga continues.

Bernd

Darren · « **Reply #7 on:** March 13, 2009, 01:59:44 PM »

I would love to see you use your own jig Bernd, but I'd probably feel the same way having spent so many hours working on this part.

Sooooo,,,,,,,up to you mate, I know what I would do

Divided he ad · « **Reply #8 on:** March 14, 2009, 04:43:09 AM »

Nice tool you built there Bernd..... As John said " You made it, you gotta use it!!"

Just one thing... Don't you need a recess for the cuttig tool to drop through/into? Else you will not get right to the bottom of the workpiece... Or were you planning on turning it over?

Well that's a very nice looking hat you got there.... and a free rotary table too!! Not a bad deal.... These hats can be quite expensive without the free gift to take the edge off the price!

Well.... Talk about a dilema.... I'd at least make a mock shape to prove your jig works

Then if your still edgy, use the RT..... Well that's my opinion anyhow

Looking forward to seeing the work and result either way

Ralph.

sbwhart · « **Reply #9 on:** March 14, 2009, 05:35:39 AM »

Hi Bernd

Quite a choice you've got there,

I take it each ends got a radius, if it has do a judgment of Solaman do one with each bit of kit they

Cheers

Stew

Bernd · « **Reply #10 on:** March 14, 2009, 09:19:17 AM »

Ralph,

The jig will definatley get used. I'm just a bit afraid that if the part got away from me I wreak the part and end mill. So I'm going to use the rotary to do the radius. I need to make some ipmerial threaded and sized bolts ro bolt it to the table and I need to make some t-bolts to bolt the part to the table first.

I eas going to hold the cutter up from the bottom about 1/8", put on the radius and then turn it over. Just like you suggested.

That hat cost me $232.95 plus $16.60 for tax for a total of $249.55. Sure glad it came with a free rotary table.

Stew,

Your right, quite a choice. Both ends will get radiused.

I will be using both tools and will post on the progress as I go.

Bernd

cedge · « **Reply #11 on:** March 14, 2009, 07:00:52 PM »

Bernd
Nice work on the rounding table. Without trying to hijack your thread, here is the one I made a while back. I took a little different approach and gave it a round table top, which made it an even more useful tool. It was the tool of choice when I built the pivot arms for the Water Pressure Engine. I let me do both, the rounding and the tapered cuts with ease. The whole design is shown, in full break down, in a thread on the HMEM board at http://www.homemodelenginemachinist.com/index.php?topic=2055.0

Steve

Bernd · « **Reply #12 on:** March 15, 2009, 05:49:00 PM »

Oh sure Steve, now you tell me about the round table after I get done with mine. Sheeeeeesh.

I guess I needed a few of these

and maybe a few of these

since I didn't think about it.

So, you know what's going to happen now don't you?

Bernd

Bernd · « **Reply #13 on:** March 25, 2009, 05:03:49 PM »

Well I finally got some T-nuts and bolts made for the RT.

I used a bolt to make the bolts for the RT. I cut the bolt to length. Made it to .500" dia. and threaded a 1/2"-20 thread on the end using a single point tool in the lathe. Why, because I don't have 1/2"-20 thread die. The T-bolts are milled from some mild steel. The four for the RT slots are tapped for 5/16"-24. Why? Becasue I have 5/16"-24 threaded rod on hand. Now all I need to do is make some 5/16"-24 nuts and I'll be ready to start rounding over the clamp I've made for the indexhead.

This could happen this weekend if all goes to plan.

I'm itchen' to get this done so I can start on a pipe/tube bender. It's going to be the same as Ralph made.

See Ralph I told you you'd get it yours done before I did.

Bernd

Darren · « **Reply #14 on:** March 25, 2009, 05:12:16 PM »

Nice, I must spend an eve making some T'nuts...

Divided he ad · « **Reply #15 on:** March 25, 2009, 08:29:55 PM »

Looking good Bernd

I'm waiting to see this rounding procedure.... It'll come in handy I'm sure?!

The tubing bender.... It'll be interesting to see your version....

Darren, I don't know how the others do it but I made my "T" nuts by shaping a long length of steel in the mill then drilling and tapping it before I cut it into the smaller nuts.... Worked well for me, and they're all the same size!!

Ralph.

Bernd · « **Reply #16 on:** March 26, 2009, 08:09:54 AM »

Quote from: Divided he ad on March 25, 2009, 08:29:55 PM

Darren, I don't know how the others do it but I made my "T" nuts by shaping a long length of steel in the mill then drilling and tapping it before I cut it into the smaller nuts.... Worked well for me, and they're all the same size!!

Ralph.

Why didn't I do that.

Next T nuts are going to be made a la Ralph's way.

Bernd

Divided he ad · « **Reply #17 on:** March 26, 2009, 04:08:45 PM »

Quote

Why didn't I do that.

Dunno..... Why not?

Now this is rich coming from a guy sat in front of his computer instead of his cold shop (and it has turned really cold!.... Well colder than last week anyhow!) But....... You ready to round this baby off yet Bernd?

What.... It's not the weekend? .... Do you retired guys know the difference?

I'll wait patiently like I should

Ralph.

Darren · « **Reply #18 on:** March 26, 2009, 04:21:14 PM »

Yes Bernd, just how did you torture yourself making these then

Bernd · « **Reply #19 on:** March 26, 2009, 08:32:55 PM »

Ralph,

I discovered that if I don't keep track of the days I get very confused. But then any day is Sunday to me so it doesn't count when I say weekend.

Yup, I'm ready for rounding. But I'm not telling when now. (could use a "sticking out tougne" )

Darren, I've included a picture or two so I won't have to type 2000 words.

Here's a piece of mild steel all milled up ready for the threaded holes in front of the original four I made.

And here they are, all cut into little pieces about 1" long ready for use. The first four that I made are on the left. It took about 2 hours to make the other six. A lot faster than the individual four I originally made.

So, that's it for this thread. I'll be back working on the indexhead thread as I start the rounding over process on the clamp plate.

Bernd

Bernd · « **Reply #20 on:** April 04, 2009, 11:36:54 AM »

I lied a little about this thread being over.

While I have the RT all lined up I figured I'd make it round. Like what Cedge showed earlier in a picture he posted in this thread. I saw how to make clamps to make stops for the amount that you want the end of a part rounded off. With a square plate like I had made that couldn't be done very well. Sooooo..............

And here it is all finished up.

Now all I need to make are a couple of stops.

So I guess the thread won't be over until I get those done.

Bernd

cedge · « **Reply #21 on:** April 04, 2009, 10:22:36 PM »

Lookin good there, Bernd. The round top definitely adds a bit of function to an already useful design. Mine gets used fairly often. Glad I could share the idea.

Steve

sbwhart · « **Reply #22 on:** April 05, 2009, 01:13:54 AM »

Well done that man

it certainly looks a tidy bit of kit

Stew

DeereGuy · « **Reply #23 on:** April 05, 2009, 10:04:42 AM »

No doubt very nice work. I have some parts that rounding and I am more than disappointed with my by hand method. The Webster I am working on I would like to have a more professional look to it and a jig like this sure would help.

Darren · « **Reply #24 on:** April 05, 2009, 01:44:21 PM »

Good looking piece of toolkit there Bernd, very nicely finished off

Bernd · « **Reply #25 on:** April 05, 2009, 07:18:16 PM »

Thanks guys.

I'll be working on a couple of clamps over the next few days.

Bernd

Divided he ad · « **Reply #26 on:** April 05, 2009, 07:33:54 PM »

Waiting to see it in action now Bernd

Just one thought.... Shouldn't the mounting pin be centred? .... Or am I missing something? (entirely possible at this time of night!!)

Ralph.

Bernd · « **Reply #27 on:** April 05, 2009, 07:48:20 PM »

Boy Ralph your a slave driver.

The pin doesn't need to be centered on the table. You just need to make sure that the pin is on the center line of the mill spindle. Then move the appropriate axis for the radius you want.

Now all we need to do is see if I can follow my own directions.

Bernd

Divided he ad · « **Reply #28 on:** April 06, 2009, 07:22:56 PM »

Well Bernd..... As John said (I think the words are close to correct?)

"You made it now use it"

Follow the destructions indeed....From what I can work out it works on a similar principle to the ball turners

When your ready, no real rush.... Just ribbin' ya!

Ralph.

Bernd · « **Reply #29 on:** April 13, 2009, 03:01:55 PM »

Hey Ralph, been working on my rounding over jig. How's that aeopile (sp?) coming along.

Anyway now that I got to

Ralph.

I drew up a quick sketch on my cad program, sorry John I'm a bit faster with that than the C-o-O. Here's what I cam up with.

So off it was to the table saw to slice a couple of pieces of aluminum to the size I wanted.

That looks about right.

And a bit of milling to get the stop fingers for the top of the table. Now I'll need to add a slot, a couple of holes and a clamp screw.

While all this metal working was going on the first coats of finish were drying on the kitchen cabinets. Do you know how long it takes to dry before you can add the next coat? At least another day.

Oh, the sketch or drawing has 1/4" hash marks along the top and left side for measurements. The solid line through the drawing on the left will be for the clamp screw.

More later this week I hope.

Did I tell you how long it takes the finish to dry...................

Oh ya, I did.

Bernd

Darren · « **Reply #30 on:** April 13, 2009, 06:20:53 PM »

I'm not quite sure where this is going, but I will sit back and wait

BTW, you should write a book, "101 ways to get in the workshop" or "the longest kitchen.......build"

Divided he ad · « **Reply #31 on:** April 13, 2009, 07:50:35 PM »

Quote

Hey Ralph, been working on my rounding over jig. How's that aeopile (sp?) coming along.

Well you see it's like this Bernd.... I've just had a four day weekend and managed to spend the whole damn thing mostly in bed with a humdinger of a cold and a lung slapping bronchial thingyradoo!!

Not the happiest bunny!

I did get out there tonight.... I was determined to do something this weekend, so I finished the pipe bender

Only one little bit to do for the Aeolipile to have it's pipes made and then that will be back on course

You see, it's all there..... Just need a

and the bacteria to sod off!

I see how your clamps will work, nice and neat

Good luck with the kitchen

Ralph.

Bernd · « **Reply #32 on:** April 13, 2009, 09:25:23 PM »

Quote from: Darren on April 13, 2009, 06:20:53 PM

BTW, you should write a book, "101 ways to get in the workshop" or "the longest kitchen.......build"

Na, won't work. It take to long.

Bernd

Bernd · « **Reply #33 on:** April 13, 2009, 09:29:28 PM »

Sorry to hear your under the weather Ralph. It does put a damper on having fun in the shop.

Glad you mentioned the pipe bender. I completly forgot about that.

Can't wait to see a vid of the Aeolipile running.

Here's hoping you feel better soon.

Bernd

Bernd · « **Reply #34 on:** April 14, 2009, 04:56:05 PM »

Well you already know what's going on in the wood shop. "Stuff" is drying

So on with the clamps. First a bit of layout dye then some lines to mark hole location and finally a centre pop to locate the centre drill.

Next into the mill, I'm going to use the Grizzly mini mill for this because I don't have a holder for the smaller 1/4" end mill in the Bridgeport. I'm going to clean out that portion between the holes following the centre line and working out towards the sides to make a nice sliding fit on the table.

This picture will clear up any confusion in my writing above. The 1/8" holes are for corner clearances.

A quick bit of filing and we have a good fit on the rotary table.

Both clamps are almost done. They have had a slot cut down the centre to the 1/4" hole to help make it easier to for clamping.

A closer view from the bottom.

And here's the finished product. All clamped down and ready for some rounding over project. So stay tuned for the video coming on a forum near you………………someday after the kitchen cabinets are done.

Did I ever tell you how long it takes for polyurethane to dry ?

Regards,
Bernd

bogstandard · « **Reply #35 on:** April 14, 2009, 05:08:04 PM »

You've finally got there Bernd, feels good dunnit?

Now to try it out.

I am still a bit undecided whether I want to make one of these. I will have a look at how your bits turn out, then decide.

Nice one.

Bogs

cedge · « **Reply #36 on:** April 14, 2009, 05:24:39 PM »

Way to go Bernd!! Interesting to see Marv's original idea go through a few design modifications.
Nice to see your take on the idea. I like the long arms you used on the clamps.
Steve

Bernd · « **Reply #37 on:** April 14, 2009, 08:19:51 PM »

Quote from: bogstandard on April 14, 2009, 05:08:04 PM

You've finally got there Bernd, feels good dunnit?

Oh ya feels real good.

Quote

Now to try it out.

That's next on the agenda. I'm thinking of just taking a bit of ali or brass and rounding over an end to get the feel, so to speak, of the tool.

Quote

I am still a bit undecided whether I want to make one of these. I will have a look at how your bits turn out, then decide.

Nice one.

Bogs

I see this as nothing but a faster way, or should I say, easier way of rounding a part than using a filing button and a file.

And thanks for the compliment.

Bernd

Bernd · « **Reply #38 on:** April 14, 2009, 08:26:28 PM »

I'll have to give Marv the credit for the idea. what I didn't like about his was that you needed to take the whole table out of the vise to change the center post of you wanted. With mine you just untighten the screw and you can change the center.

I'm a little leary of the holding power of those arms. It doesn't take much pressure to move them. I still need to cut them back a bit. They interfer with the centering post.

Already have a second design in my mind for the next set of arms if these don't work out. First I need to give this a try before I can make a call weather it will work OK or not.

Bernd

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Author Topic: Rounding Over Jig (Read 28090 times)

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