Making a gingery style shaper

Ebel440

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A few years ago i got a partial set of the gingery books. I finally have some time to build something so i decided to try making the shaper. I made my furnace a few years ago using a home made refractory and some scrap steel and a bathroom vent fan i dont have the gingery book for the furnace but its easy to find info on the internet. I am changing the design to use materials i have on hand and methods that are easier for me to do. I will be using scrapped parts and drop for as much as i can. Though i can make the castings I will be using as few as possible i have two little girls that like to help me and I dont use the furnace while they are home. I will also be changing to a gear drive to use other parts i already have. I am a machinist and could easily cnc the parts and put it together in a few hours but i want to try and build it with just a small lathe and drill press. So far i have worked on it for a few hours and will keep working on it as i get time. iphonep 303.JPGeiphone82814 013.JPGeiphone82814 025.JPGeiphone82814 044.JPG

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I made the sides from 2 pieces of 10x12x.5 bar stock they were drops from my job that i had already used to build a small speaker stand years ago. The pieces were already milled square so im using them as is, they have 2 large countersunk and 3 smaller holes from their past use. I started by clamping the 2 sides together and laying out the hole pattern and step drilling through both sides at once up to .250dia. Next i clamped the sides to the front and base and used a drill bushing in the .250 hole to locate the holes for drilling and tapping. this allowed me to drill all the holes at once without having to change drill sizes and tap each hole one at a time. I used a cut tap on the first side but after trouble with a cheap tap i switched to a roll tap on the second. The row of holes at the top looks staggered because it has one set of holes to hold the ways for the slide which will be made of .5 square 1018 or 12l14 im not sure which it is but i think its 12l14. the other set of holes is for the radiused aluminum parts which i had saved years ago and will help strengthen the top, dress it up a little and give me a place to mount the clamps? for the rams ways. As you can see i have not really followed gingerys plans but it is serving as a guide. today i hope to get the ways for the ram installed and possibly the clamps for it. Due to the changes i have made i need to get the ram in place to figure out where everything else will go.
 
i spent some more time on it yesterday. I made a last minute change to hold the ways for the ram with 5/16-18 bolts instead of 1/4-20 which now has a larger head then the ways so i need to use some screws and grind the diameter down. It looks like i can use some gears i have from an old Honda to make the bull gear.

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Thanks for letting me know it actually takes me time to post the pictures because i have to take them off my phone and use my computer which seems to play the movie Frozen non stop these days. I didn't do much with the shaper today. I drilled out the rivets holding the bull gear to the old clutch assembly. I need to figure out all the gears locations again because I had all the information stored in my phone and one of my kids killed my phone. I also lost some of the pictures which had the sides being laid out. I think the next step will be making the bull gear shaft and the bearing block for it.
 
i had a little time last night so i started on a bushing to fit the bull gear to the shaft. I have a short piece of .750od ground stainless rod i will be using for the bull gear shaft so i need a bushing that will fit the 1.185 gear bore to the shaft. The only lathe i have at my house is an old craftsman 109 which is about as capable as the gingery lathe i think. I started with a short piece of 1.375 6061 drop it was the only material i had that was big enough. I made a few passes taking .04 off the diameter each pass until i was within .01 from there i had to make about 6 more passes as the 109 has no dials and i didnt want to take too much off. Then i faced the end and spot drilled it and then drilled through with a .250 drill. Ill drill it as big as i can then finish it with a boring bar im not sure how i will attach the gear yet.

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I was busy all week with work and family had a little time today to work on the shaper I finished the bushing for the bull gear. I have a new appreciation for things like graduated dials and reverse switches. The largest drill I can use in my 109 is a 3/8 so I drilled .25 then .375. The travel on the tail stock is only about an inch so I had to drill to the limit then move the tail stock and finish drilling. I then had to bring the bore out to .750 which meant I needed a boring bar but I haven't made one yet for the 109 so I searched and found a 1/4 tool which had been ground for boring and was long enough. Of course it had been shortened so much that it would only be held by one screw in my toolpost so I had to drill any tap it for another screw. Then after lots of cranking I got the bore opened up to .750. After that I took it out of the chuck parted it off on my bandsaw and put it back in the lathe and faced the saw cut. I
 
Really cool project!

Just from my own perspective, having 2 girls a bit older than yours, I avoid posting any pics of them not fully dressed on the net. You never know who will find them and where they will end up.
 
I have the Gingery books, and I happen to have a full (I think) set of patterns for the Gingery Shaper. I also had a Gingery shaper on loan from the guy that made the patterns, but could not figure out how to get it to work.
I hope to break in my furnace and casting skills making one, but need someone to show me how to use it! Keep up the great work, I'm watching closely...

Chuck
 
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