Group Project: Rotary Broach-- Building complete, all shipped out!

GunsOfNavarone said:
I bet I know the step on the one backing plate...it was the 1st one I drilled and my setup was questionable for the survival of my vice. The bit broke through, but not by a lot. I chamfered the edge, but I bet it left a bit of a wall. The other 3 I learned and changed my setup.
And going back to the original thread "This Madness needs to Stop", this is one of the interesting parts. When all these parts, made by different people, with varying skills on different equipment, comes together. Is it just me? I mean, I know I take it for granted if I order a intake manifold and bolt it to my block....it fits. It's much different when it was a shapeless piece of stock in your hands. I dunno....goose pimple material.
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Ah, that might be it :)

Yeah, I'm REALLY amazed at how easily everything went together! I really thought I was going to have to put SOME part on the lathe in the 4 jaw and cut more to make the bearing fit, but it was a slip fit on the OD, and easily enough to get to fit on the ID!

The lengths/sizes/bolt holes/etc ALL seem to work! I'm really impressed with what you three were able to do! Hopefully in another week or two I'll be ready to start shipping out complete sets! Perhaps not all 3, but at least one :)
 
Nice to see parts fitting together nicely! Particularly from multiple people on who knows what equipment. Great job everyone! :grin:
 
Eric-Sounds like you have your grinding technique down! The broaches look great. I may try to enlist you to make one for my holder!
Robert
 
Only had an hour today but decided to see if the Chinese inserts I found on ebay would survive. First test cut looked promising so I decided to try roughing some of the smaller ones this way.

This was HARD on the cutters, and broke them almost immediately. However, most of the time they broke with a decent cutting edge, so, I sent it :). 3 bits cost me 4 cutting edges (2 per cutter), but hopefully saved me a bunch of time.

I have 2more left to rough out, so I think I'll do it this way! Hopefully I can find a cutting speed that doesn't murder these and can use it on the end profiles.
 

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Hmmm... No progress today! My electric mag chuck seemingly is kicking off my GFCI as soon as I hook it up.

It's strange, it worked fine for a long time, switching out the bridge rectifier didn't change anything, and it only happens when everything is wired up. It also doesn't show any shorts or anything.

Guess I get to spend some time figuring out why this happens :/
 
How do you get in on a group project? Do you just have to notice when one starts?
 
Mheaton92 said:
How do you get in on a group project? Do you just have to notice when one starts?
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Yep pretty much. I think the dividing head has some unclaimed parts, but not sure how many people could make another.

You could always come up with something and organize one! The dividing head shows that complicated ones take a while(if they finish!) and I think the clamps were perhaps not complicated enough to get interest to finish. I think this rotary broach ended up being just a out perfect for both! Only downside is needing one person who can grind the bits.
 
ErichKeane said:
Yep pretty much. I think the dividing head has some unclaimed parts, but not sure how many people could make another.

You could always come up with something and organize one! The dividing head shows that complicated ones take a while(if they finish!) and I think the clamps were perhaps not complicated enough to get interest to finish. I think this rotary broach ended up being just a out perfect for both! Only downside is needing one person who can grind the bits.
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I think I will try to organize one. I am trying to help with the clamps, but I agree 100%. I didn't want to do the clamps, they didnt seem like a lot of fun because of the simple design. That being said, I will still get in on it. This broach looks awesome, I will one day buy a surface grinder and when I do this build will be first on my list!
 
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