Popular Post sentra Posted November 24, 2015 Popular Post Share Posted November 24, 2015 This is a story post, not a question or anything, keep your non constructive opinions about my crappy workmanship and setups to yourselves - yes you are a master machinist - i dont care. For years i have been frustrated at my lack of facilities to cut splines due to not having good access to a form grinder, so making and maintaining a hss form hob to spline axles has been in the too hard basket and i have mucked around with adaptor plates and trying to mishmash stuff to work around it. In a pinch the other day i decided to try contour milling a involute spline form with a 60deg threadmill. This worked amazingly well & i Decided to write a story about it. total investment: 1x Iscar 60 deg cutter. $60. (my only arbor is too long, you can hear it struggling in the video later on the case hardened steel) Plan of attack - one million little passes per spline. Microscopic view of resulting stress raisers. meh. overlay chart. looks fine. machine down celica axles outboard end outside dia and length. the reason the transition is not tapered at the stage is that it will be used as a clamping surface as you want to avoid using a center when splining so you can test fit your thing without taking it out, Mill and crummy little indexer setup, see last step. (axle doesnt fit inside indexer past chuck) keep your comments about my awesome stack of clamps to yourself. thats some deep case hardening . (end gets cleaned up in a later op) cutty cutty completed 30 mins later. some knowall threw the plates away for this indexer and was relying on the pin holes in the chuck mount. fark. i put an encoder on it at the 11th hour. next time i will just use a vice and encoder with no indexer. horay/even a broken clock etc. in car in summary, i was amazed how easy and cost effective this is after spending so long humming and harring about it. there is no reason you couldnt do this on a little tormach machine. (or if you were a real sicko on a turret/dro.) two things to note- one for the love of jeasus i cant get camera to focus and they look all weird, however they look sweet as and fit up mint - and two: the cam side pics arent involute correct, "magic of tv." 21 Quote Link to comment Share on other sites More sharing options...
flyingbrick Posted November 24, 2015 Share Posted November 24, 2015 Haha stop saying ur setup is shit. Wish I had access (and the knowledge to use) a cnc setup like that. 3 Quote Link to comment Share on other sites More sharing options...
sentra Posted November 24, 2015 Author Share Posted November 24, 2015 nearly everyone these days would know someone with access to some sort of nc mill, the coords with the above method are as easy as getting the y&z coords out of any cad if you wanted to not bother learning cam. while it is still equipment intensive, it sure beats needed a tool&cutter grinder & (form grinder) and still trying to cut hard steel with hss people are notorious for adding their two cents at the expense the bigger picture, hence the insistance. 1 Quote Link to comment Share on other sites More sharing options...
kyteler Posted November 24, 2015 Share Posted November 24, 2015 Should have just done it once, done it right first time. You know what they say The early machinist has to set up the shop and do everything for everyone. 1 Quote Link to comment Share on other sites More sharing options...
kyteler Posted November 24, 2015 Share Posted November 24, 2015 P.S. I don't know anything about what you've done but I see it works and it looks good so I agree with your method. Good work, xoxo 1 Quote Link to comment Share on other sites More sharing options...
danger Posted November 24, 2015 Share Posted November 24, 2015 You're so dreamy, David. Quote Link to comment Share on other sites More sharing options...
Steelies Posted November 24, 2015 Share Posted November 24, 2015 dave you make me sick with your brain skills. Quote Link to comment Share on other sites More sharing options...
sheepers Posted November 24, 2015 Share Posted November 24, 2015 you just make me sick. 1 Quote Link to comment Share on other sites More sharing options...
sheepers Posted November 24, 2015 Share Posted November 24, 2015 JOKES!!! no need to have a a baby etc. Quote Link to comment Share on other sites More sharing options...
Testament Posted November 24, 2015 Share Posted November 24, 2015 oh wat. you cheated! I thought you were using old beave for this operation Quote Link to comment Share on other sites More sharing options...
johnny.race Posted November 24, 2015 Share Posted November 24, 2015 Sentra bro, is that your shit in your shed or you bludging off your bosses back I was cutting splines (but 90's) in the shed the day before yesterday and took a couple of pics. WTF is an encoda?? That machine of yours moves the hell fast compared to mine, lol. My setup has stood the test of time though, is able to take over 2 inches through the bore and my homemade machinists jack will bend an axle. There is no downwards pressure on the dead center whatsoever - even when cutting. I dial in a measured amount of preload upwards on the jack during the setup and the cutting pressure cancels it out i have found. Made the cutter myself. 4 tips at around $90 - fuck! If Noah had a setup in the Ark - he'd have copied off mine, haha! I am not a machinist and have had no formal training whatsoever. But if you have a passion for something though ... it negates most of the formal training shit institutions stuff into ya. Hilux axle for a stockcar. Churr! 5 Quote Link to comment Share on other sites More sharing options...
sentra Posted November 24, 2015 Author Share Posted November 24, 2015 hey man thats awesome !- the gear im using is works, how did you make your hob? Quote Link to comment Share on other sites More sharing options...
jakesae101 Posted November 25, 2015 Share Posted November 25, 2015 i love me some backwoods engineering theres a dude on a NZ hunting forum that does some wicked stuff with just a lathe to make black powder guns ect http://www.nzhuntingandshooting.co.nz/f53/making-sharps-barrel-my-lathe-16567/ http://www.nzhuntingandshooting.co.nz/f53/hawkins-plains-rifle-project-8740/ 2 Quote Link to comment Share on other sites More sharing options...
Popular Post johnny.race Posted November 25, 2015 Popular Post Share Posted November 25, 2015 hey man thats awesome !- the gear im using is works, how did you make your hob? Mate, I brought a couple of HSS cutters from off TM. I had familiarized myself with Diametrical Pitch's ummmm lingo and stuff and read that DP24 was the DP used by most (all) of the OEM's who's axles I sought to cut new splines into. I learned my first lesson about HSS vs Induction hardened hard shit. You mentioned this above, lol! Where the fuck were you sentra when I was cutting my teeth into this new venture? So after finding out how much the tool resharpening pricks wanted to redo my cutters - it was onto the net to see what others were doing who did resplining on a more regular basis. I saw a commercially available indexable one that was cost prohibitive to me but sowed the seed to make me my own. I think I cut this one out of some 12mm plate or something. It might be 10 - dunno. Turned up a collar thingy and pressed/welded them together. Trued it up in the lathe and beveled the edges to 90 degree's included. I drew it up in TurboCAD (don't laugh - I love it and I am self taught to do cool 2D shit) and cut it out on the table. Had to do all of this twice because I was not as good as I thought i was. Fucked it up the first time but the second time round I stopped at the point i fucked it up and paid a machine shop to complete it. They indexed the tungsten cutter pockets/seats and cut the internal keyway in the collar. They got 3 of the cutters spot on but one of them stands a thou or 2 proud of the others. I have marked this one and use it to touch off. Judicious use of DTI and adherence to my own established procedures has seen me do quite a few axles for cunts. I have a biggish (for home use) old Horizontal Mill dedicated/setup to do just axles. They are worth nothing more than scrap value in today's market thanks to CNC. I fucking love them, the big old grunters, lol. That's my story bro.. My name is axle ... Bigblockpoweredstickcarsthatdontshine 10 Quote Link to comment Share on other sites More sharing options...
sentra Posted November 25, 2015 Author Share Posted November 25, 2015 10/10 yarn, come to nats. 3 Quote Link to comment Share on other sites More sharing options...
cute wee gem Posted November 25, 2015 Share Posted November 25, 2015 Epic! Good work sir sentra. Feel free to add more interesting machinist stuff on here. I do enjoy 1 Quote Link to comment Share on other sites More sharing options...
Ghostchips Posted November 27, 2015 Share Posted November 27, 2015 Would you make unbreakable axle shafts in exchange for money? (trying to decide if i should go hilux diff' or not) 1 Quote Link to comment Share on other sites More sharing options...
johnny.race Posted November 28, 2015 Share Posted November 28, 2015 Would you make unbreakable axle shafts in exchange for money? (trying to decide if i should go hilux diff' or not) Mate, if this question is for me then I can respline 9 Inch, Hilux and BW78 axles - this is all. And even then I only offer to respline when there is meat there that allows a new spline to be cut. I don't offer to build up a shaft using low hyd rods or similar in order to get a certain length. So pretty limited in one respect but good to know for the users of these 'most popular differentials' I can also narrow diff housings (again 9 Inch, Hilux, BW78) and oddly enuff Ford Courier/Mazda1600 housings. I use jigs that run true, my work is decent and I have usually a way quicker turn around on stuff than you will get from an engineering workshop in town. And why is the print about using a Lux diff in small print, lol ... are you a dyed in the wool Hotrodder that has been brought up on nothing but Ford diffs? Haha! Let you in on a little secret ... factory 9 Inch axles have the consistency of cheese a lot of times. Jap iron from the 90's leaves yank iron from the 60's in the dust. The diff heads are a different story though.. 1 Quote Link to comment Share on other sites More sharing options...
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