A bit of an old thread, but going on..
I needed to make a new oil catch tank for the Nissan, but wasnt sure the plate bender was up to it with its broken hinge.
The cast hinge part has broken in half, probably when bending something much thicker than 1,5mm. The casting wasnt very good though, showing evidence of a lot of air pockets. The previous owner had tried to weld the broken part with limited success.
Hyllus 1020 x 1,5 plate benderSo i removed the hinged part
Hyllus 1020 x 1,5 plate benderAparently the shafts holding the hinge had been bent too
Hyllus 1020 x 1,5 plate benderIn order to get the bent shaft out of the good hinge part, i had to machine the head of it
Hyllus 1020 x 1,5 plate benderSo a few new parts needed.
Hyllus 1020 x 1,5 plate benderRough cutting to size on the bandsaw, not sure this was the best sequence to do the machining in, but this is how I did it.
Hyllus 1020 x 1,5 plate benderI turned both sides of the part to make it parallel, then put it in the mill and milled the sides of it
Hyllus 1020 x 1,5 plate benderScribed the hole to be bored
Hyllus 1020 x 1,5 plate benderCentered in the mill and drilled to my biggest drill size Ø30mm
Hyllus 1020 x 1,5 plate bender
Hyllus 1020 x 1,5 plate benderNot owning a boring head, I had to put the part in the lathe to bore it to size
Hyllus 1020 x 1,5 plate benderFinally got it to size
Hyllus 1020 x 1,5 plate benderThe eccentric part of the hinge fitted
Hyllus 1020 x 1,5 plate benderThen i started drilling the Ø28 mounting hole. The closest drill was Ø22.
Btw. i have started using a new approach to drilling big holes. I used to use sulfur based oil, but it would smoke a lot making the shop quite unpleasant. So now i have started using the coolant that i use on the band saw. Now the trick is to not bore through until you have drilled with your biggest drill, this way you can have the hole full of coolant and not have to have coolant flowing all over the machine!
Hyllus 1020 x 1,5 plate benderIn the same setup i drilled Ø10,5 for tapping M12. Should have drilled Ø10,2 but I dont have that drill size.. yet
Hyllus 1020 x 1,5 plate benderPart ready to be bored in the lathe, but with this odd shape i needed to mount it on the faceplate
Hyllus 1020 x 1,5 plate benderHaving never used the faceplate before, I washed of the dragon fat it was covered in and put it on the lathe to check it for runout. It had 0,07mm of axial runout
Hyllus 1020 x 1,5 plate benderI figured I could do better, so i ground a HSS tool and started cutting the surface. After 3 passes i got the runout down to 0,02mm.
Hyllus 1020 x 1,5 plate benderMade a setup to mount the part and dialed it in
Hyllus 1020 x 1,5 plate benderThis is when things went south. I got out the longest boring bar i have and started to turn the ID
Hyllus 1020 x 1,5 plate benderOn the finishing cut, something went wrong and the bore became full of steps, going far over the desired Ø28mm
Hyllus 1020 x 1,5 plate benderSo i got out a HSS boring bar instead and bored the hole to Ø32,01
Hyllus 1020 x 1,5 plate benderI removed the faceplate, put in the 3 jaw and turned a bushing
Hyllus 1020 x 1,5 plate benderMade a small lip on the bushing and on the hinge part to locate the bushing.
I made the OD of the bushing to 32,05 (0,04mm press) and the id 27,50 to allow for a finishing cut once in position.
Hyllus 1020 x 1,5 plate benderI used the parted-off part of the bushing as a press tool
Hyllus 1020 x 1,5 plate benderThen I pressed the bushing in, while still keeping the part on the faceplate. I made sure to distribute the load on the faceplate to avoid damaging it. Then i put the faceplate back on the lathe and turned the ID with the HSS boring bar to Ø28,02mm
Hyllus 1020 x 1,5 plate benderHaving never used the rotary table before, I made some mounting clamps
Hyllus 1020 x 1,5 plate benderClamped to the table
Hyllus 1020 x 1,5 plate benderFinished milling
Hyllus 1020 x 1,5 plate benderMachining recess on back side of part
Hyllus 1020 x 1,5 plate benderFinished milling
Hyllus 1020 x 1,5 plate benderDrilling the Ø10,5 hole and counterboring to Ø12,5 to half depth
Hyllus 1020 x 1,5 plate benderI was wondering how to make the split in the part. Cutting it on the saw would be simple, but it could become a bit too narrow and possibly not end up at a perfect 90 degree angle, so I wanted to try using the shaper. So i started making a holder for a parting blade in the shaper.
Hyllus 1020 x 1,5 plate benderOn the shaper i cut a groove in one of the parts to fit the parting blade
Hyllus 1020 x 1,5 plate benderMock up with 3x M6 setscrews
Hyllus 1020 x 1,5 plate benderThen i ground some chamfers on the parts and welded them together. I used a 0,1mm shim to ensure that I would be able to get the blade out later
Hyllus 1020 x 1,5 plate bender
Hyllus 1020 x 1,5 plate benderTo make it look nice, i put it on the shaper and cut both sides of it and added some chamfers.
Hyllus 1020 x 1,5 plate benderReady for use
Hyllus 1020 x 1,5 plate benderI made a test cut on a piece of scrap, but I struggled a lot with the tool digging in and creating a lot of chatter. I tried aligning the tool vertically, tried changing the tool geometry to make it dig in less, but in the end it dug in so deep that the shaper pushed the vice of the table and the blade broke. So parting on the saw it is..
Hyllus 1020 x 1,5 plate benderCutting the split. Note to self, dont saw all the way through with a BAND saw, it could become difficult getting the saw blade out afterwards!
Hyllus 1020 x 1,5 plate benderFinished part
Hyllus 1020 x 1,5 plate benderThen I started turning the mounting shafts, got the OD to Ø27,96
Hyllus 1020 x 1,5 plate benderCutting the threads M16x2,0
Hyllus 1020 x 1,5 plate benderFinished parts
Hyllus 1020 x 1,5 plate benderStarted assembly
Hyllus 1020 x 1,5 plate benderNew shaft in old part
Hyllus 1020 x 1,5 plate benderLeft hand side
Hyllus 1020 x 1,5 plate bender
Hyllus 1020 x 1,5 plate benderFinished and test piece bent.
Hyllus 1020 x 1,5 plate benderNow im ready to start making the cath tank
