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| Hex holes |
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| Trebor:
I'd seen them but £200.00, if it didn't pass the test what would I use it for again and I'm stuck to that size so the hex bar would always have to be spot on. At least if I went and machined the first couple I could still use the tools again. What would be the least tooling I would need just to make a couple. |
| Jasonb:
A drill and a file |
| Trebor:
:thumbup: |
| Lew_Merrick_PE:
Back in the Dark Ages when I served my apprenticeship, one of the standard tests was to make male and female hex by hand. I was given a piece of 1 inch HRS round bar X 3 inches long that I was allowed to file into a (male) .750 (+.000/-.002) inch hex. It had to pass through a (female) hex Herr Meister Muller had (I believe he made it himself) in all 6 orientations without binding. It took me four tries to meet that standard. I was then given a piece of 1/2 inch CRS bar through which I had to cut and file a (female) .750 (+.002/-.000) inch hex. I drilled (ø1/16, as I recall) holes with an "eggbeater" drill just inside the corners of the hex and cut out between them using a fretsaw. I ground down (3, as I recall) mill files to .375 inch wide which were used to file the first side of the hex square to the face of the bar. (I spent 4 hours/day for a week getting that face to me Herr Meister Muller's approval.) I then made (4 or 5 as I recall) a set of files that were .375 wide with a 120° safe edge on one side and a 90° safe edge on the other. I used these to file out the other 5 sides of the hex. A master .750 hex gage pin had to pass through my (female) hex in all 6 directions without binding or tipping (.005 inch maximum side motion at .500 inch from the surface of the bar). I completed that the first time -- though I spent the better part of a month doing so... There is always that approach... |
| Trebor:
I'm not sure what to say to that, well done, sod that, I'm sure I would cock that up although I'm not bad with a file !! I remember casting an alloy block at school to make a rotating cake stand (top marks for that) we used to cut half crown sized disks for the cig machines. :palm: |
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