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  1. your lowest force non-boring option would be to...

    your lowest force non-boring option would be to use a trepanning cutter. link to making one. YouTube

    if your not boring very deep just use a long annular cutter. -from both sides if needed.
  2. I don't think that the type of drill, twist or...

    I don't think that the type of drill, twist or spade makes much difference. the cutting edge is similarly shearing metal. It's all cubic inches per minute.

    they seem to think you know your...
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    I would not squeeze it in a vise. I would...

    I would not squeeze it in a vise. I would capture it in a close fitting plywood box including a windowed screw-on lid.
    additionally, you might freeze it and work it as cold as possible....
  4. I do two types of work. .010" .25mm wire single...

    I do two types of work. .010" .25mm wire single pass cuts for almost everything.... except that there have been some tiny detail experiments.

    the tiny cuts are a couple square millimeters of...
  5. recommendation for Wire EDM shop, very small random jobs, quick turn around.

    I'm looking to find a shop to take over my prototype EDM work.
    I own a robofil 290 but it's nearing end of life with no oem support and I do not need another.
    I only do about a dozen hours of cut...
  6. do not rely on the rod seals to keep crap out. ...

    do not rely on the rod seals to keep crap out. put something like a coffee can around the entire rod and cylinder. basically an umbrella to prevent anything from contaminating the rod.

    on a...
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    unless you mean interpolating all of the larger...

    unless you mean interpolating all of the larger sizes how are you going to reduce tool number with a small drill and a number of different different mills?

    if you can interpolate them, sure, why...
  8. Dan Gelbart

    Dan Gelbart
  9. Respectfully: I'm happy you asked here before...

    Respectfully: I'm happy you asked here before kludging something up. If you can't make the threads you should tell him your not the guy for that job but that you can help direct him to some people...
  10. removed: door frame, lintel, sheet metal...

    removed:
    door frame, lintel, sheet metal enclosure, z motor.

    http://www.sergisonmachine.net/images/move5.jpg

    http://www.sergisonmachine.net/images/move11.jpg
    ...
  11. Please hear this out. It will sound pretty...

    Please hear this out. It will sound pretty "weird, cheap, farmer, ghetto, etc..." but I have successfully repaired similar splines and they have never gotten loose again.

    I packed the clearance...
  12. as you said, layers. any spring that bend open...

    as you said, layers. any spring that bend open far enough, 30-40 degrees... and is not very long, and not permanently deform would have to be layered to have enough force. and the layers will have...
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    I just spoke to their sales. Very nice people,...

    I just spoke to their sales. Very nice people, easy to talk to. $5k for a 60k rpm E3000 series spindle with everything.
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    very high speed spindles question.

    Background:

    I've been asked for input on designing / retrofitting an very fancy thermal environmental test machine to handle much higher speeds for testing speed sensors.

    They currently have...
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    Stevens Subplates...

    Stevens Subplates

    6x24 will be a special. Maybe find a cheap used one and saw it down? I don't think any tiny vice or tiny tooling will have any locating features for one anyway. their normal...
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    Sapa Extrusion North America Showroom : ...

    Sapa Extrusion North America
    Showroom :

    Production Machining

    I used sapa for a project. They were easy to work with. I've no relation to them or experience with others, I just wanted...
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    Simple gusset plates & rivets like airplane...

    Simple gusset plates & rivets like airplane construction. or rivet nuts and screws. or through bolted.

    Luis & Fab's RV-7A Construction Log >> Blog Archive >> Riveting the Firewall
  18. That will almost certainly be exciting! Tube...

    That will almost certainly be exciting! Tube likes to flex and move. Big cutters like to suck the edges of tube in and that's too much cutter for a bridgeport. When I do stuff that's to big, I...
  19. I'm sure you can make serviceable safe parts. ...

    I'm sure you can make serviceable safe parts. That said, you'll not be able to make them to print. +/- .0005 tolerance on a clearance hole for a bolt... WTF?

    I would use a 2.25" hole saw or...
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    Caterpillar, my employer has their corporate...

    Caterpillar, my employer has their corporate accounts, vending machines in every facility, stock rooms and such from Grainger. And we have a special local sales account guy when you call the local...
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    There is a sticker requiring hearing protection...

    There is a sticker requiring hearing protection after all....
    it's air noise. It's obnoxious. I think I'll try to run mine looser as suggested and see what changes. Mine does not have foam so I...
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    why cut hole in block to weld it? if you can get...

    why cut hole in block to weld it? if you can get at it to tap it for inserts someone can weld it. there are weird angle tiny torches.

    I hate tapping welded aluminum. good luck.

    shrink fit on...
  23. yes! you can treat your tormach like an upside...

    yes! you can treat your tormach like an upside down vertical lathe. put a lathe tool in your vise and put the part in the spindle. you can have multiple cutters in multiple vise locations like...
  24. woodruff key or keyseat cutter. If they are to...

    woodruff key or keyseat cutter. If they are to wide for your groove then grind it to whatever you need. -Which can be done by putting the cutter in a drill and spinning the face against a bench...
  25. -Your heavy vise is only heavy in all the wrong...

    -Your heavy vise is only heavy in all the wrong places.

    I suggest you buy some sort of quality angle lock vise. a kurt, orange, quad-I etc.... something with a LOT more thickness to the base.
    ...
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