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Mobile vice and small anvil / welding table 
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Bought the hydrochloric acid to pickle the mill scale off the table with:

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And started on another tangent related to finishing this off: viewtopic.php?f=15&t=2877

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Sun Jul 07, 2019 2:56 am
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Way back on page 1 I wrote something like the following, but with less detail:

930 table work height
220 vice height
1150 vice jaw work height
50 thick table
240 high drum
160 high hub (to step pipe sits on)
930 - 50 = 880 bottom of table plate
240 + 160 = 400 to start of pipe/tube
880 - 400 = 480 tube plus flange length

But I got the tube cut at 480 itself. So to keep those measurements I will either need to trim the tube by plate thickness, cut a hole in the plate for the tube and weld both sides, or go plate thickness higher.

I've selected the plate and it's 16mm by 250 by 230 so do I go to 946 table and 1166 vice jaws? Or bore a 142mm hole in the plate and weld top and bottom? Or shorten the tube?

For the lower disk and inner disk, I want something with a tiny bit of flex, so I'll be using the only suitable thing I have which is 12mm. The strip is 141mm wide and from an earlier post the lower disk needs to be 102mm min, and not exceed 160mm. But looking again, at 45 degrees to that limitation is a much wider space, over 200 free, so I'll clean up the edges, cut a piece off 140 wide, drill a 14mm hole in the middle, and call it good. Diagonal will be 1.414 * 140 = 198mm, so we're good, perfect even. For the inner disk, about 127mm IIRC. Worst case I'll "hand form" it with a grinder until it's snug, no *real* need for precision on that.

Went down and played with the existing number 4 vice on the bench and don't really want it any higher, so I'll find a way to cut a nice hole out of it to match the tube. Even if I have to hand file it.

Top plate and space for bottom disk: https://twitter.com/FredCookeNZ/status/ ... 9420520449

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Sun Jul 07, 2019 5:45 am
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Now, thinking about the flange and the vice and supporting the piece of 20mm plate that it bolts to securely and stiffly I decided that I should run a couple of thick deep sections across the fasteners in the top plate, and stepping up into the table if there is any (due to balance point), and then to the bottom of the 20mm and bolting securely to that, too.

Roughly marked out (inlined below): https://twitter.com/FredCookeNZ/status/ ... 3395694592

50mm thick table, plus 16mm thick plate, minus 20mm thick plate, equals 46mm step up from fastening surface one to fastening surface two. The remainder of the piece needs to be amply stiff, so minimum width is 100mm. Thus options are:

100x20
100x25
130x20
130x25

Or something smaller and spacers instead of cutting to make the step up. But that would look messy/cheap/untidy/sloppy to me.

100 gives us 54mm of meat remaining and 130 gives us a nice 84mm of meat.

20 requires M10 (5/side) or M12 (4/side) and new taps as I don't feel the 3mm per side that M14 would leave is enough meat left over.
25 with M14 would leave 5.5mm per side which is ample. M12 would yield 6.5 per side which might be even better. M10 7.5 per side which feels excessive.

M14 washers are about 30mm which would look silly even on 25mm stock. Presumably M12 are at most 28mm, likely 26 or so, which would look mint on 25mm stock.

I think I might pull in a favour and get the exact heights dialled in by way of a milling machine. Will give me nice flats for the fasteners and table surfaces alike.

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Centre of gravity calculations.

50x450dia steel weighs in cm (7.85 * PI * (45 / 2)^2 * 5) / 1000 = 62.42 kg or a little less, centred on itself
200x220x20 steel weighs in cm (7.85 * 2 * 22 * 20) / 1000 = 6.9 kg
vice weighs 32kg
vice plus plate = ~39kg centred on the plate.

Datum = edge of table
Units = cm and kg
Moment of table = 62kg * 22.5 = 1395
Moment of vice/plate = 39kg * (45 + 11 = 56cm) = 2184
Total moment = 3579
Distance from edge of table to CG = 3579 / 101 = 35cm, 350mm, 100mm from the other edge of the table.

IE, with the top plate hard up against one edge of the table, it'll still be vice-heavy, especially adding in the ignored under-brace weights.

But given the base is about 400mm wide, and substantially heavy, it won't be a problem stability wise. Excellent.

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Sun Jul 07, 2019 11:16 am
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I have figured out how I want to cut the hole in the plate. I think I can make the internal disk from the 16mm material at the same time as the top plate and get the fit pretty tight on both.

I was thinking of buying and trying to use a fly cutter hole cutter with a carbide bit and hope for the best. Dangerous and would probably take ages and also fail, possibly injuring me/my stuff in the process.

So instead what I think I will do is...

  1. Find the centre of the plate and centre punch that
  2. Mark the plate with vivid/sharpie across more than the thickness of the tube so as to be able to mark ID and OD and the mid way point
  3. Set a compass/divider to the OD radius, the ID radius, and half way between ID and OD radii (of the pipe), and scratch those radii into the plate surface through that coloured layer
  4. Select a drill bit just a little lower in diameter than the wall thickness of the pipe
  5. I can then go around and centre punch every 1.1-1.2 drill diameters until I reach the start or something like that, close, but not too close
  6. Then I'll use the drill bit (probably a split point from my better cheapy set) to drill all of those holes
  7. I may also drill smaller secondaries on both sides of the gaps between the main holes
  8. Finally, I might drill the centre and use a pin and clamp kit setup to allow the plate to pivot around the centre exactly putting all holes just where they're needed
  9. After that I'll enlarge on hole enough to get a metal cutting jigsaw blade into there, and run around splitting the disk from the plate
  10. Then it's clean up, grinding away until the marked line on each part (OD on the plate, ID on the disk)
  11. Then I can drill the disk out to 14mm ready for the draw bar fastener that will hold it all together

I need to remain untempted and not drill the plate for the mounting holes until I'm ready to drill both the bottom of the table and the support bars which I was unable to buy on Saturday as the steel place was closed at 1145 when they said they'd be open until 1230 :-( Can't go this weekend, so will have to be the one after.

It's 9pm now, so I won't go down and make a racket doing that tonight. Maybe tomorrow for a lunch break though. We'll see.

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Mon Jul 22, 2019 9:55 am
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From half way down page one the tube is:

  • 128.2mm ID
  • 141.5mm OD
  • 6.65mm wall thickness

So I'll probably use a 6.5mm drill bit and see how I go, split point, no pilot drill bit, some lube to ease the pain.

Pin wise, I can use anything 16+mm long that has flat ends and is round and the size of a drill I own less than or equal to 14mm. I will have to poke around downstairs and see what's available. Might go down now and have a look around and a mock up of the setup...

Okay, if I pin the centre, it'll be 14mm with one of the fasteners and a block of steel and a step block set to the same height and a clamp around the side. Two tee-nut slots are both obscured and too far from the pivot point by the looks.

Found centre, coated in ink, punched centre, set high-school compass up using pencil as centre in punch and pin as scraper and scraped ID, OD and approx half way. Will measure these more precisely before I punch them.

Checked to see if it made sense to drill in between, likely not, back to back 2mm doesn't even fit, but 1.5 does and is hardly worth using. So will skip that operation.

I am planning to pilot drill with 2.5mm though - will give me a chance to eye-ball the circle and make any corrections before I mess things up with the 6.5mm bit.

Will buy this 14 mm drill bit tomorrow: https://www.bunnings.co.nz/evacut-drill ... _p00409318

https://twitter.com/FredCookeNZ/status/ ... 0588433409
https://twitter.com/FredCookeNZ/status/ ... 7287301121
https://twitter.com/FredCookeNZ/status/ ... 4070237184

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Mon Jul 22, 2019 1:26 pm
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Went down tonight and got stuck in to this thing. Many dents were made. Many holes were drilled. Several drill bits were destroyed. 120+ holes all up :-D

Measured the rings I scribed, and then punched many dents into the mid-way ring: https://twitter.com/FredCookeNZ/status/ ... 0190586882

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Drilled the centre out to 14mm for the final fastener and chamfered the hole on both sides, also for a pivot location to aide in drilling holes precisely: https://twitter.com/FredCookeNZ/status/ ... 6020101122

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Clamp kit and 12mm plate offcuts to hold the pin still while drilling around it: https://twitter.com/FredCookeNZ/status/ ... 0239291392

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Drilled out to 2.5mm then to 6.5mm every second, then all the ones in between until just a few cockups remained (broke off a few 2.5mm drill bits, one small piece is still in there now, and one pilot hole off centre so had to get creative): https://twitter.com/FredCookeNZ/status/ ... 5622419457

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Fully drilled and looking good: https://twitter.com/FredCookeNZ/status/ ... 2448575488

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Jigsaw cutting attempt failure: https://twitter.com/FredCookeNZ/status/ ... 4235767809

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Intent to treat the drill press like a vertical lathe, and plans unfolded: https://twitter.com/FredCookeNZ/status/ ... 1335932928

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Tomorrow I'll separate the two pieces and turn the disk down to a snug fit on the ID of the tube with drill press and grinder.

I may also try to grind out the flange to fit the OD of the tube. We'll see,.

Last thing to do is cut a square of 12mm plate for the bottom washer/retainer plate and drill that to 14mm in the middle, too.

Then I could part off a few pieces of the 35mm engineering round stock and drill and tap them for the ends of the tie bar.

Then it's measuring and welding and buying a few more fasteners saturday after this one coming.

More progress as it comes to hand! :-)

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Tue Jul 23, 2019 11:34 am
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Split disk from flange: https://twitter.com/FredCookeNZ/status/ ... 7614355456

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Giving the disk a hub: https://twitter.com/FredCookeNZ/status/ ... 8935742465

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Machining the disk to size: https://twitter.com/FredCookeNZ/status/ ... 9824238592

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Finished disk, not lathe-quality, but close enough: https://twitter.com/FredCookeNZ/status/ ... 4629268480

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Tomorrow's work, grinding out the hole to fit: https://twitter.com/FredCookeNZ/status/ ... 6228826118

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Broken drill bit cross section: https://twitter.com/FredCookeNZ/status/ ... 8462551040

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Wed Jul 24, 2019 1:34 pm
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And today's hacking:

https://twitter.com/FredCookeNZ/status/ ... 0096632833
https://twitter.com/FredCookeNZ/status/ ... 6345267200
https://twitter.com/FredCookeNZ/status/ ... 9925608448

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No more progress till Sunday or next week, sadly. Next up is cutting the square bottom washer and drilling it in the middle for M14.

And the draw bar pieces.

Will wait for my DIN 875/0 Czech precision square before welding the top flange on. Also need to mill/drill and buy the braces etc. Will keep chipping away where I can.

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Thu Jul 25, 2019 11:09 am
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One more piece done today while awaiting my wife to be ready to go this morning:

Took this: https://twitter.com/FredCookeNZ/status/ ... 0360144897

And did this to it: https://twitter.com/FredCookeNZ/status/ ... 9233113088

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And wound up with this: https://twitter.com/FredCookeNZ/status/ ... 0691049472

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And then did this to it: https://twitter.com/FredCookeNZ/status/ ... 1769272320

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And got this: https://twitter.com/FredCookeNZ/status/ ... 3153758209

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Side effort, the slaggy bit of crappy plasma cut mess I cut off the end: https://twitter.com/FredCookeNZ/status/ ... 6844061696

Still need to buy a piece of big beefy flat bar and a bunch of fasteners, but that's on hold for the mean time, sadly.

So next up will be the tension rod that goes between the disk and the plate, and welding the disk in, I guess.

Also still need to find some 1.5mm sheet to shim the tube around the hub boss.

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Mon Jul 29, 2019 9:51 am
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Bought the last bit of steel for this today (except maybe the wings and wheel brackets etc), ended up with 150x20 flat bar as 130 is an odd size apparently: https://twitter.com/FredCookeNZ/status/ ... 7189277696

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And then came home and cut these: https://twitter.com/FredCookeNZ/status/ ... 4109462528

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Sat Aug 03, 2019 1:24 pm
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