drftnmaz Posted August 6, 2020 Share Posted August 6, 2020 Was enjoying reading Adoom's Meuser lathe thread and it dawned on me that I should post up some of my machines, but because I live the no phone life I rarely have a camera near to take pics, but I'll try harder... First of all I'm no machinist, I am completely self learning the good old kiwi way, I buy old machines, cram them into my garage and use trail and error, and there sure is alot of ways to discover error when 0.1mm makes a huge difference hahaha First up is Emily my 1973 Bridgeport mill with a not so 2J head... I brought this machine with no motor, normally they have a motor with a spring loaded CVT-type pulley with a fat belt so you can adjust the speed across a large range, the old motor had burnt out and the quote to re-wind was too high so machine then left in the corner and the motor missing, I offered cash and then picked up a week later with my little truck It came with Piccodrive 2.2kw VSD and Nikon Digital readout, power feed on one axis, but I had no idea of wear, and couldn't find a replacement motor in NZ, But I was stoked to finally have a mill, next I sectioned off a area in my shed and poured some self leveling concrete for a base, moved it in using a engine crane and stuck it to the ground with windscreen urethane, sorry no pics as this was a couple years ago now 9 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 6, 2020 Author Share Posted August 6, 2020 So i couldn't find a 'proper' motor, so next I looked for a flange mounted 2.2kw motor to mod up, but didn't find anything suitable in a decent price range so I went to my brothers air conditioning work and talked them into letting me hunt through there old motors, I found a 1hp Horizontal mount TECO NZ motor with a adjustable belt pulley, which they kindly donated to me... So then I went about making a horizontal motor conversion mount to run vertical, I had a drill, a grinder and a welder to work with... so I mainly used 50x5mm angle iron and made a cage of sorts to mount it and spread the load the best I could, then I undid the adjustable pulley and wound it as wide as it would go then welded it solid, this was then just wide enough to fit the factory belt which by luck was still in the head of the mill! Then I wired it up and added a front mounted potentiometer for speed control, not realizing that Emily had 2 gears (high+low) and they run in opposite direction to each other so would require forwards+reverse, my VSD is mounted at the rear and quite hard to access so rather than mess with that I wired in 2 3phase plugs on the side and swapped to suit direction wanted, this got old really quick so I hunted out a NOS 3ph forward/reverse switch and fitted that, it's amazing how often you need to switch gears! Recently I added the clear lexan cover for the wiring on the motor so I can show the kids about 3phase (the old cast one was about 1.5kg's!) I did end up buying a more suited 3hp vertical motor but never fitted it because the 1hp I can stall out if something goes really wrong, but i think the 3hp would cause more damage... one day if i have a job that needs power i'll fit it but until then i'm happy with the 1hp. 6 Quote Link to comment Share on other sites More sharing options...
Popular Post drftnmaz Posted August 6, 2020 Author Popular Post Share Posted August 6, 2020 I'm not so good at taking pics, might try again later with better camera and better lighting. Here's how she sits now, clocked many hours of slinging chips and twirling spirals, brought what tools I could afford along the way, shattered a few china tools and blunted a few english ones! Nikon DRO is so analog I love it, but has skipped on me before and made me have to restart which sucks, the last pic shows a extra 3phase connector, this runs off to my compressor which shares the VSD with Emily because it's rare I need them both at the same time. She's still got play and I haven't tried the auto downfeed function so still lots of future repairs and maintenance when I figure out how 15 1 Quote Link to comment Share on other sites More sharing options...
sheepers Posted August 6, 2020 Share Posted August 6, 2020 fuck i love Bridgeports. i worked one of these machines for years when i was toolmaking. there is nothing you cant do with one of these and a few attachments. good score! 1 Quote Link to comment Share on other sites More sharing options...
rusty360 Posted August 7, 2020 Share Posted August 7, 2020 Your not wrong Bridgeport's for life. 1 Quote Link to comment Share on other sites More sharing options...
Popular Post drftnmaz Posted August 7, 2020 Author Popular Post Share Posted August 7, 2020 On 06/08/2020 at 13:17, sheepers said: fuck i love Bridgeports. i worked one of these machines for years when i was toolmaking. there is nothing you cant do with one of these and a few attachments. good score! Yep bridegports are gold! When i was hunting around I found alot of copies of the classic bridgeport and all of them just seemed to change the taper for the tooling so I thought getting the real deal was a pretty safe bet! It's truly amazing what you can make it do when you get it right! Today's yarn is what I call my subaru compressor (it's not subaru at all) but it has a electric motor in the middle with a shaft/crank out each end which spins 2 horizontally opposed pistons each, got it free from a mall that was upgrading the plant room, no idea what it was actually used for but think it was more a backup unit for starting a generator or something... anyway it shares the VSD with Emily and currently has no over-pressure cut-off but does seem to stop making boost around 120psi which is perfect, also think it might have a cracked piston because pressure can leak back through one of them, more future repairs /piston welding one day... next yarn up is my round making mate Charlotte the Colchester, just trying to find old pics from the trip home, but I think they are lost :/ 12 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 11, 2020 Author Share Posted August 11, 2020 I hunted high and low for the old pickup pics of Charlotte but think they are lost, I have one corrupted hard-drive left to try, but for now you'll have to suffice with my words... I've always wanted a lathe, probably more so than a mill, about a year after getting Emily I spotted a old Colchester roundhead on trademe that wasn't too far from my house, so I went and checked it out (knowing nothing about lathes haha) and fell in love with the shape and style, it was a $1 auction on trademe and bids were only at ~$60 so the place selling it got annoyed and chucked it outside in the rain thinking it was now going to scrap :/ I dried it best i could, got part numbers and wrapped in a tarp, waited till the end of the auction and thought i'd get it for sub $500, but of course there was a bidding war... I ended up getting for around $960 if I remember right. I quickly sold off a bunch of old JZ engines in the corner of my garage to make some space and then took Julie (my nissan atlas truck from the first post) to pickup the new lump of metal, they had a forkhoist so it was a simple pickup. My new addition is a 1964 Colchester Triumph 7.5" Roundhead and was apparently 1045kg's, I got a PDF scan of the manual for free from a friendly chap in England which was pretty handy! So now i was home, i had some room to store her but didn't know how to get off my truck and into the garage, so I called my buddy who's always up for one of my crazy missions and he as normal said he was keen,(wes, some of you will know him as 1ofaknd?) he came round after work and we used a engine crane/hoist to lift her just enough to drive the truck out of the way and drop to the ground, this was super sketchy! (and trust me i've done my fair share of sketchy things with helicopters and jet engines!) at one point I thought we'd lost it and it was gonna wreak the truck on it's way down, But we got lucky and then shoehorned her into my garage... (she's wider than the door so had to do a spiny twirl move to get her in place) Now for the fun bit! getting her going, I knew the drive gears for the autofeed and thread cutting were missing so that side of the machine will be ignored for now as I need to learn the basic's first. I removed the old motor, was meant to be a 5hp or at worst a 3hp, but what I found was a really old 1.5hp that was physically massive and had no provisions for running at 230V, it also had a small pulley so was driving the machine much slower than the speeds on the front plate. This was removed and a 3hp/2.2kw modern chinese motor brought from trademe ($160?), second hand but didn't look like it was ever used, once I had it home and inspected I found it had lots of end float (like 2mm), so stripped it down and shimmed it up so the spring washer was actually controlling the end float now, pretty happy with such a easy fix! Next up a brought a brand new double-A V-belt pulley(rare for me to buy new bits!) from bearingandengineering.co.nz but of course the center hole needed to be enlarged to the 28mm?? shaft, a job super easy on the lathe, but it didn't go yet, so i strapped it down to my rotary table and tried the best I could to get center then drilled out, was close enough lol, then instead of cutting a keyway I drilled a hole and tapped a thread, then using a high tensile bolt wound in from outside to locate it to the keyway Then i mounted the motor to the factory plate, and realized i'd need to buy new longer belts to suit my new pulley size, and I'm too cheap for that when I didn't even know if the machine worked at this stage! so I then made some 3" spacer blocks to raise motor and use the old belts, was abit messy but it worked. 4 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 12, 2020 Author Share Posted August 12, 2020 Whipped the back off and snapped a couple of pics of the china 3hp power machine, can see the 12.9 grade m10 bolt used for locking to the keyway, the end being ground down to 6mm? to suit (that reminds me, I should make a proper one with the lathe! planned to change the pulley size but quite happy with it now) 1 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 12, 2020 Author Share Posted August 12, 2020 Next up was the gearbox... It had a sight level that was so dirty I thought the glass was stained, so I popped the top off and had a look, to my surprise the insides looked perfect, except the oil and a slight black grime on the outer edges of the oil level line, so I drained it out and emptied 4 or 5 cans of brake clean in there and got it looking decent, also got the sight glass good enough to see through, I figured out the ~equivalent oil needed was the typical tractor type oil so found a 20L container on trademe with only 2-3L missing for cheap so snapped that up and filled her up with fresh oil, took about 10L, again no pics but I found this one on the internet that is the same, ignore the writing... Next up it was time for a power source, I hunted around and found this water pump controller that also stepped 1PH to 3PH and was rated for 3hp, it was being $1 reserved on trademe so I took the gamble and got it for $25, at this point I was super dubious, but after a quick look through the china manual it seemed like it would do the job, and now it works a treat, I do have to run it in maintenance mode because it wants a pressure sensor or some such, but specs are unknown so I plan to try use this later as a safety cut-out. mean score and way better than using Emily's vsd on the other side of the garage. By now I had the basics sussed and had read the Colchester manual to try and figure out how things went... so I started playing with levers etc and noticed the clutch wouldn't disengage, luckily on the back there was some description of it's Matrix clutch so I pulled it apart and measured and cleaned and reset it, got it going but ended up changing specs slightly to reduce drag when disengaged, this old stuff is made to last! 6 1 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 19, 2020 Author Share Posted August 19, 2020 Next up I powered the motor up to half speed and slowly engaged the clutch lever and she started to spin! so I tried all the gears and found only one to be noisey, I guess this is the speed it spent most of it's life at... it's got 8 gears and it was number 7 (700rpm) so if I need to do alot of work at that speed i'll pick another gear and add more frequency to the motor, although I haven't tried over 70hz yet, would prefer to get the motor balanced if I was going to run it at 100hz or similar. Then I twiddled the levers and spun the handles, clocked up a piece of steel and had a go at cutting, this wasn't pretty, not only did I not know what I was doing (all I had done is read a couple old lathe books) but everything had lots of wear so it wasn't long before it went wrong and I wound it into a area with lots of lash and it dug in... ok time to step back and assess... I pulled apart everywhere i could find wear and shimmed the best i could with what i could find in the workshop and with a bunch of trail and error got her to a usable state, and i was finally in the world of making round stuff Here's the shed from outside, pretty boring but keeps my tools mostly dry And the old Wiring and step down transformer for the missing light (would love to find a factory light but not easy in nz) This is all bypassed atm. And found a old pic of Emily in my messy workshop, (it's not always this bad!) can also sorta see the oil burner heater behind the bonnet, and the start of a bbq next to it. 1 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 19, 2020 Author Share Posted August 19, 2020 So now I guess your wondering what I use these machines for... well the mill I do make a couple products that pay it's way, the lathe however I generally only use for fun or mates projects, seeing as i'm learning I don't like to think i'm any good at it. So onto some of the toys... Decided I needed some 2stroke in my life so started small with a Goped for the kids, tried to keep it simple as possible, friction drive, no clutch, push start etc The kids have to pass their license test on this before they are allowed to drive the gokart... When the oldest nephew was young I promised him we'd build a gokart for his 10th birthday so after years of collecting parts and learning about the triangle of speed (fast, reliable, cheap, you can only pick 2) we had a free 100cc honda motor from a waterblaster, a bunch of steel from old school tables, a free seat (think it was a poolseat???) and we slowly came up with a design and started building it every school hoidays, but then his birthday got close so i finished it off, I donated some gokart wheels I had, spun up some spindles to suit the fronts, ended up having to buy a accelerator cable, a chain link, a clutch with 10t sproket, the rest was all scraps and things i'd build to suit. And this is what we built, a 3 wheeled kart that teaches you lots about driving haha, Can see young josh lifting a wheel in the 2nd pic! Next post up is Lockdown turbos, what i've been spinning up while work has dried up thanks to china. 5 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 21, 2020 Author Share Posted August 21, 2020 Those of you that know me in person will probably know that I love turbo's, and have a little collection, about 5 years ago I had a friend with a balancer at home I would commission to build turbos that i'd sell off for extra money for drifting, but one day he sold all his equipment and I stopped, but kept collecting some while trying to downsize the common ones. Then recently my buddy @Atex blew the turbo on his van, so after abit of research I found they ran a early Tdo4 turbo, so i found a really cheap Tdo4HL from a airtrek and offered it to him, a week later he asked me to machine the turbine housing out for him, I hadn't done this before but after seeing some pics I decided to give it a hoon and ordered some new cutting tips for the big boring bar I was yet to use.3 days later I had the pieces in front of me, but the cutting tips were lost in the mail, but I was keen so pulled out the mini boring bar and devised a plan to make it work, I put the turbo in the lathe being held at the V-band/turbo end and then bored out the exit to 52mm so i could then flip the turbo around and hold from that end, then I could clock it up and machine the important end, boring it from a 39/47 wheel to 46/52mm, tbh this was pushing the limits of the material in the housing but I like a challenge! Got it to fit, learnt a few lessons, wasn't my best work but hey it's only a l300, sent it on the courier the next day and he fitted it the day after, then I explained how to adjust fueling, later that night I got a video of it pulling 18psi, and a excited atex enjoying the boggie. and some afterwards pics Compressor went from 10T 35.5/49 upto a 15T 45.6/52mm so she moves alot more air now! The 4d56? turbine housing is 4cm, and the old airtrek one was 5cm 7 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 22, 2020 Author Share Posted August 22, 2020 Well that wasn't so hard... So due to the lack of paying work atm i'll move onto my own turbos (silver linings aye!) first up is a turbo for my B6t BD mazda which I'm trying to get back on the road, factory they come with a VJ6 or VJ13 turbo, but these are mostly dead by now so everyone replaces them with a common VF10 from a subaru, these have the same awesome 9 blade turbine but a bigger inducer(7.5mm) on the compressor, I've run these before they are well suited, but then there's a size bigger again called a VF8, this changes to a 10blade turbine and another 5mm on the comp. Vj6 = Turbine 43/52-9 Comp 32/52mm VF10 =Turbine 43/52-9 Comp 39.5/52mm VF8 =Turbine 46.5/52-10 Comp 44.5/56mm So many years ago I got someone else to machine my b6t turbine housing to fit the VF8 turbine, in hindsight I think I'd rather build a hybrid of the vf8 comp on a vf10 turbine wheel, but let's just concentrate on moving forwards not changing the plan! So i decided to tidy up the housings, first up the intake to the turbo, I forgot to take pics, got caught up with the mission at hand, but the internet can supply this pic to show the factory intake (50mm) I made a 10mm bolt on plate (would have gone 8mm but couldn't find any in the workshop) then clocked her up on the lathe and made a 15degree taper from plate to wheel, bringing it to ~62mm then did a bunch of angles to make a bell-mouth of sorts, I will weld a 3" pipe to it that will goto the afm/filter, but won't do this until I can mock up in the car because I think I may have to angle that pipe... Next up I put the turbine housing in the lathe and tapered the exit from 48mm to 52mm(about the limit while still having a decent amount of flange to clamp) only ~5degrees of taper so hard to see in a pic, then I cut up my old dump pipe to get the flange, bolted it to the housing still in the lathe and bored out the flange to match(was 48mm), I also moved the washers between the flange and housing to space them apart so i could oversize this hole as the flange has some movement and I didn't want a lip if installed crooked by accident, also used a taper here to help the gasses to keep expanding and promote turbulent flow Next up the turbine housing had a meeting with Emily, the wastegate hole was machined from 15mm to 22mm and offset upwards a couple mm, then flapper from the scrap td04hl housing was fitted (31mm replacing the 25mm) the arm was then welded to extend it so the flapper could fit, then re-drilled on it's new center, the flapper was put in the lathe and pin height adjusted to suit then welded into the housing, housing also needed a touch of clearance on side, but I don't have a die grinder atm so had to do it on the mill with not much room to do nicely... (you can see in this pic the first taper I did on the turbine exit, I went back and redid this to go almost all the way to the tips) Now that wasn't so hard... up next I wanted a challenge, something I didn't know if it was possible... I have a few hx40's kicking around so wanted to put one of those into a small housing, but of course can't spend any money so have to find something in the collection 1 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 26, 2020 Author Share Posted August 26, 2020 I wanted to put a hx40 into a smaller housing for use on a diesel, hunted through all my garrett housings and only found one that was suitable(saab 900 t3 0.63), but I wanted to save that housing for something else, all the 0.48's i had didn't really have enough meat on the sealing surface on the dump pipe... So I'd sorta given up until I remembered I had a Chinese hx30 on the shelf, it could be genuine but due to the fact the compressor snapped off the shaft and other small things I'm pretty sure it's from china Now those of you that know turbos will know hx30 is alot smaller than the hx40 and the turbine housing uses a V-band connection to the center, and a hx40 uses the traditional 6 bolts (like garrett etc) SO i thought this wasn't a possible combo, but after many measurements and checking I decided to give it a hoon... top is 14cm TS holset housing, middle is partly machined 8cm hx30 housing, bottom is 0.63 garrett t3 Here is the hx30 after the first lot of lathe work, v-band turned down, and inside from a 52/65mm wheel to 64/76mm turbine, The housing is clearly designed to take upto the 67/76mm wheel but machined to suit any size at the factory Next up it went to see Emily and had the 6 flat areas machined and then milled and tapped to suit the normal hx40 spacing+retainer plate, It will also require a spacer/clamp plate but I don't have right size steel for that and it's too hard to buy anything in auckland during lockdown And I thought it best to update the front housing while I was here, this is one of the smaller hx40 compressors, 54/82mm, more often this turbine would use the 60/82mm comp wheel. ,, 6 Quote Link to comment Share on other sites More sharing options...
drftnmaz Posted August 31, 2020 Author Share Posted August 31, 2020 Next up I got some time to work on the drift car, poor thing hasn't been driven in over a year now... so while I was under the bonnet I thought I should tickle up turbo, It's a KKK K26 from volvo penta, (the marine series of volvo, hence the awesome green you see on alot of my turbos) specs just in case anyone cares is the common 53/64mm turbine(s200 to kids these days) and the comp is 51.7/81mm, not the best match for a sr20de and not the turbo I originally choose and fitted but it's on there and working. (it's a long story) Here's what the turbo housing looks like factory, they cast a ~25degree taper in and the machine the throat from the other side because this cover is used from 42-57mm inducers.| I marked it up and then removed, measured and worked out a 18.4degree angle will make the inlet 68mm and taper all the way to 1mm from the tips of compressor, I then hand finished it, which makes photo's look rubbish, and also dented it on install because it's rather thin at the edge now ## If anyone wants there turbo machined for cheap then hit me up, as long as I can fit it in my lathe then i'm happy to help. 6 Quote Link to comment Share on other sites More sharing options...
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