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  • Drawer Bracket

    I know that this is a Welding Forum and it is heresy to talk a customer into machining a part from solid instead of making it a weldment, but that is exactly what I did. The first two pictures are the solid model that my customer gave me of the weldment that he desired. The flange is 4" in diameter and the boss in 2" in diameter and sticks out 1-1/2'. The hole in the middle is 1".

    1. Weldment Back
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    2. Weldment Front
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    A friend gave me some stock that I could use to make the parts. As you can see in the following picture, the stock was already partially turned down, so it would save me some time.

    3. Stock Pieces
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    The following two pictures show facing the bottom and turning OD of the flange of the stock.

    4. Facing Flange
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    5. Turning Flange
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    And here is a picture of the flange at the correct diameter.

    6. Flange complete
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    For this picture I turned the part around and grabbed the flange of the part in the three jaws of the chuck.

    7. Part flipped
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    The following two pictures show the process of parting off the end of the stock piece.

    8. Parting end off
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    9. Parting completed
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    The next operation, which is shown in the following picture, was turning the OD of the 2 inch diameter of the part.

    10. Turning 2 inch diameter
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    When I was done, I used the same tool to clean up the top face of the flange (not shown).
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      At this point I faced the end of the 2 inch diameter the correct distance from the flange.

      11. Facing 2 inch diameter to length
      Click image for larger version  Name:	11. Facing 2 inch diameter to length.jpg Views:	1 Size:	73.0 KB ID:	613440

      The next four pictures show the steps to create the 1” hole in the center of the part.

      12. Center drilling 1 Inch hole
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      13. Quarter inch Drilling of 1 inch hole
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      14. Undersize drilling 1 inch hole
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      15. Boring 1 inch hole
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      The last picture #15 was a mock up, because I forgot to take a picture of the boring operation.
      Last edited by Don52; 02-04-2021, 07:32 PM.
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Colchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        I ran into trouble when I tried to cut the 1/8 inch radius on the corner of the flange. The tool holder interfered with the largest step of the jaw of the chuck. To solve the problem, I used a set of soft jaws, which were previously machined to a 4 inch diameter. This jaw allowed the tool holder to pass over the top of the jaw.

        16. Turning .125 inch radius
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        Once I machined the radius, I could flip the part around and remove the excess material from the bottom of the flange, which I left to allow me to hold the flange. The next picture shows facing the bottom of the flange to remove this excess material.

        17. Facing flange to length
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        The lathe work on the part is now complete.

        18. Lathe turning done
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        I removed the chuck from the lathe and clamped it to the table of the milling machine. Next, I used the coaxial indicator to find the center of the bore of the part.

        19. Coaxial Indicator
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        I used an 1-1/8” cutter to mill off half of the 2 inch diameter using .1” depth per cut.

        20. Milling 2 inch boss
        Click image for larger version  Name:	20. Milling 2 inch boss.jpg Views:	1 Size:	79.1 KB ID:	613450
        Last edited by Don52; 02-04-2021, 08:55 PM.
        Miller Thunderbolt
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Colchester 15" Lathe
        16" DuAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          I used a Center Drill (not shown) and a 1/4” drill to create the four mounting holes.

          21. Drilling .25 inch hole
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          I ran into trouble when I attempted to 90° counter sink the four holes because the drill chuck interfered with the 2 inch diameter.

          22. Albrecht chuck hits 2 inch boss
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          I attempted to use my ER 16 extension shaft to support the counter sink but unfortunately this Chuck also interfered with the 2 inch diameter.

          23. ER16 chuck hits 2 inch boss
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          My drill doctor has marks at 118° and 135° but has travel beyond the settings in both directions, so I attempted to to cut a drill at the most acute angle possible. It turned out it was only 100° instead of the desired 90°.

          24. Nice sharpening - wrong angle
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          I found that the chuck on my drill press would actually clear the 2” diameter and allow me to counter sink the holes. If this didn’t work I would have been forced to machine an extension shaft, which would support the counter sink with set screws.

          25. Chuck on drill press worked for 90° counter sink
          Click image for larger version  Name:	25. Chuck on drill press worked for 90° counter sink .jpg Views:	2 Size:	77.6 KB ID:	613456

          I find that when I run into difficulty and have to try a bunch of different things to solve the problem, it does take a lot of time.
          Last edited by Don52; 02-04-2021, 07:16 PM.
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            I used my Kurt vice to support the part to enable me to drill the 1/4” cross hole in the 2 inch diameter. I used my 3-D indicator to find the center of the shaft.

            26. 3D Indicator
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            The last step was Drilling the 1/4” cross hole.

            27. Drilling .25 inch cross hole
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            And here is the part all done.

            28. All done
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            I actually had to make two of them.

            29. Two parts done
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            -Don
            Last edited by Don52; 02-04-2021, 07:19 PM.
            Miller Thunderbolt
            Smith Oxyacetylene Torch
            Miller Dynasty 200DX
            Lincoln SP-250 MIG Welder
            Lincoln LE 31 MP
            Lincoln 210 MP
            Clausing/Colchester 15" Lathe
            16" DuAll Saw
            15" Drill Press
            7" x 9" Swivel Head Horizontal Band Saw
            20 Ton Arbor Press
            Bridgeport

            Comment


            • #7
              You do nice work, Don---and take great pictures!

              Comment


              • #8
                Originally posted by Aeronca41 View Post
                You do nice work, Don---and take great pictures!
                Thanks,
                -Don
                Miller Thunderbolt
                Smith Oxyacetylene Torch
                Miller Dynasty 200DX
                Lincoln SP-250 MIG Welder
                Lincoln LE 31 MP
                Lincoln 210 MP
                Clausing/Colchester 15" Lathe
                16" DuAll Saw
                15" Drill Press
                7" x 9" Swivel Head Horizontal Band Saw
                20 Ton Arbor Press
                Bridgeport

                Comment


                • #9
                  No kidding Don, good job. Anyone that’s done something on the lathe and mill like that know how long it takes, and then to have the process documented so well on top of it!

                  So, what are those brackets for?

                  Comment


                  • #10
                    Originally posted by ryanjones2150 View Post
                    No kidding Don, good job. Anyone that’s done something on the lathe and mill like that know how long it takes, and then to have the process documented so well on top of it!

                    So, what are those brackets for?
                    The brackets will support a 1” shaft that will hold two bushings that will support a drawer that will be used on a boat. The two cross drilled holes are for screws that will actually retain the 1” shaft to the brackets. The shelf and 1” shaft must be removed to access to the engine compartment through this hatch. To remove the drawer you would just have to remove the two screws that are in the cross drilled holes.

                    There is another access hatch to the engine compartment that would use the ladder shown in the second picture. This is a large boat with twin screws powered by two Diesel engines.


                    30. Hatch
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                    31. Looking in Hatch
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                    -Don
                    Miller Thunderbolt
                    Smith Oxyacetylene Torch
                    Miller Dynasty 200DX
                    Lincoln SP-250 MIG Welder
                    Lincoln LE 31 MP
                    Lincoln 210 MP
                    Clausing/Colchester 15" Lathe
                    16" DuAll Saw
                    15" Drill Press
                    7" x 9" Swivel Head Horizontal Band Saw
                    20 Ton Arbor Press
                    Bridgeport

                    Comment


                    • #11
                      I think that I figured out where the hatch in question is located.
                      It is located in the lower right of the following picture.

                      32. Wide angle view
                      Click image for larger version

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                      Miller Thunderbolt
                      Smith Oxyacetylene Torch
                      Miller Dynasty 200DX
                      Lincoln SP-250 MIG Welder
                      Lincoln LE 31 MP
                      Lincoln 210 MP
                      Clausing/Colchester 15" Lathe
                      16" DuAll Saw
                      15" Drill Press
                      7" x 9" Swivel Head Horizontal Band Saw
                      20 Ton Arbor Press
                      Bridgeport

                      Comment


                      • #12
                        It’s too cold to be out on the water. You’ll catch a cold out there, Don!

                        Comment


                        • #13
                          Originally posted by ryanjones2150 View Post
                          It’s too cold to be out on the water. You’ll catch a cold out there, Don!
                          You could be right.
                          It's 19°F and windy and I am still riding my bicycle outside.
                          The boat is now in its heated winter storage.
                          This picture was taken Jan 22 while the bottom of the boat was being painted.

                          34. Winter storage
                          Click image for larger version

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ID:	613492 -Don
                          Miller Thunderbolt
                          Smith Oxyacetylene Torch
                          Miller Dynasty 200DX
                          Lincoln SP-250 MIG Welder
                          Lincoln LE 31 MP
                          Lincoln 210 MP
                          Clausing/Colchester 15" Lathe
                          16" DuAll Saw
                          15" Drill Press
                          7" x 9" Swivel Head Horizontal Band Saw
                          20 Ton Arbor Press
                          Bridgeport

                          Comment


                          • #14
                            Ryan,

                            My customer did send me the stock that I will eventually use to fabricate the brackets that will support the drawer brackets.
                            He didn't send me the drawings and CAD files yet, because he still needs to check some dimensions on the boat itself.
                            The long bars are 36" long.
                            The two round bars are 1-1/2" and 2-1/4" in diameter.

                            33. Drawer support hardware
                            Click image for larger version

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ID:	613494
                            Miller Thunderbolt
                            Smith Oxyacetylene Torch
                            Miller Dynasty 200DX
                            Lincoln SP-250 MIG Welder
                            Lincoln LE 31 MP
                            Lincoln 210 MP
                            Clausing/Colchester 15" Lathe
                            16" DuAll Saw
                            15" Drill Press
                            7" x 9" Swivel Head Horizontal Band Saw
                            20 Ton Arbor Press
                            Bridgeport

                            Comment


                            • #15
                              Another good job already on the in/out table. Sweet!

                              Comment

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