Drawer Bracket

[Don52]

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


2. Weldment Front


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


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

4. Facing Flange


5. Turning Flange

[Don52]

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

6. Flange complete


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


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

8. Parting end off


9. Parting completed


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


When I was done, I used the same tool to clean up the top face of the flange (not shown).

[Don52]

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


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

12. Center drilling 1 Inch hole


13. Quarter inch Drilling of 1 inch hole


14. Undersize drilling 1 inch hole


15. Boring 1 inch hole


The last picture #15 was a mock up, because I forgot to take a picture of the boring operation.

[Don52]

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


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


The lathe work on the part is now complete.

18. Lathe turning done


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


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

[Don52]

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

21. Drilling .25 inch hole


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


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


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


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


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.

[Don52]

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


The last step was Drilling the 1/4” cross hole.

27. Drilling .25 inch cross hole


And here is the part all done.

28. All done


I actually had to make two of them.

29. Two parts done



-Don

[Aeronca41]

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

[Don52]

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

Thanks,
-Don

[ryanjones2150]

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?

[Don52]

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


31. Looking in Hatch

-Don

[Don52]

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

[ryanjones2150]

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

[Don52]

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
-Don

[Don52]

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

[ryanjones2150]

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