Thank you for signing up for Makercise emails. You get early access to project videos.
Enjoy.
hi I'm Cressel Anderson this is Makercise in this episode we'll
cast some pulleys and we'll complete the lead screw drive train for the lathe project
note that these parts were cast before I completed my internet of things kiln project
After I made the pulley patterns, I molded them in the drag however
the drag was upside down so when I rolled it those little tabs were at the bottom
that's not right th ey should be on the top so I remolded it and fixed it and
then I proceeded to ramp up the cope that's the top part.
I cut the gates between the sprue in the patterns and then I remove the patterns. I used a
weird channel design here I thought it might help with filtering out some of
the dross and impurities
once again i use the epsom salts put it in an
aluminum foil ball and pushed it down into the molten metal the magnesium
sulfate is supposed to release gas that will bubble through the aluminum and
liberate the hydrogen that's dissolved into the aluminum thereby eliminating
porosity in the cast part
I release project videos early to Makercise email subscribers
if you want early access go to: makercise.com/signup
to turn these pulleys down i used an arbor I drilled a hole into the pulley
and then I turn down the end of the shaft so that it would fit the pulley
turning a few thousands with this lathe is kind of challenging
I use a nail to gauge how much have turned the handles and that way i can really ease in on the
diameter that I'm looking for
eventually I got a pretty good fit and i use super glue to fasten the pulley
blank to the arbor
initially I was going to turn off the edges but I decided the
"Saws-all" was a little faster
even after getting rid of the tabs i noticed a lot
of chattering it was because of a gap between the shaft collars and the inside
of the headstock
so I adjusted the shaft collar spacing and tighten everything up
that made it a lot more rigid for turning
at another point, some chatter re-emerged
I decided the bearing cap bolts needed to be tightened a little bit and you can
over tighten them but you can also get them dialed in where it improves the
rigidity of the headstock
after i turned the front face and side of the pulley i
used a small propane torch to break down the super glue
then I was able to flip
the part around and super glue it on to finish up the other side
I turned this lathe pulley five months ago
if you want more "real-time" updates on
this project you should follow me on your social media platform of choice
the first pulley had a three-eighths inch hole in it
it goes on a shaft that I'll turn later in this video
the second pulley however has a half-inch hole
this is so it can mount on the half-inch shaft that sticks out from the left of
the leadscrew just below the headstock
I used a file to knock down some of the roughness left behind
and then again i use super glue to afix the pulley blank to the arbor
I cast a small diameter pulley that mounts on the left side of the spindle
this is the first stage of the reduction pulleys I drilled out the center with a combination of bits
including a spiral bit, countersink bit, and a spade bit, then I drilled and
tapped a hole for the set screw. I mounted on the spindle and turn down the outside on the lathe
I hand turned a bit of a crown onto this tiny pulley and that is
intended to help the belt track more towards the center of the pulley I
really need to do this on all of them but just in the interest of time I ended
up leaving both of the larger diameter pulleys without a crown
I really need to go back and add it to the larger pulleys because I noticed a
bit of wear on the belt for the time being it's working all right
once the pulleys were roughly finished I needed to turn a shaft for the
intermediate pulley to mount on I flip the spindle around long ways so i could
use the other end away from my arbors as the stock from which I could turn the
shaft for the intermediate pulley
after i got the first two segments turned I had to loosen up the headstock
and slide down the spindle so I could finish turning the spindle
I readjusted the tool post and then I cleaned up the inside shoulder of the
spindle I dressed up the part of sandpaper and file and then I used a
hacksaw to cut off the part
After turning my first steel part on the
Gingery lathe I cut threads using just a regular die.
i threaded the other end of
the shaft for a washer and nuts that would hold the intermediate pulley on the shaft
check out the bonus footage after the credits it expires in September
I lined up the intermediate pulley and i used a point on the end of
the shaft that made a mark so that i could drill and then tap a hole into
which I would mount the shaft
I use flat vacuum cleaner belts versus the round
cross-section belts described in the book it's just what's available
I added the belts and it all seems to work just fine
the only thing is I really need to add crowns on those intermediate and lowest stage pulleys
I've actually already used the automatic feed to bore the tailstock
It works pretty well
I hope this project inspires you to exercise
your inner maker. If you liked the video click the like button.
Check out makercise.com and sign up for the emails so that you can get
advance notice of project videos
follow me in real time on social media
thanks for watching
so this is my excuse for why I don't get out more lathe videos
these are my two favorite girls...NO...my wife...
I've got three favorite girls [laughing off camera]
[off camera] She's puking on you.
Ooop! This is awesome!
I'm gonna be at Maker Faire Atlanta October 1-2 if you're
within driving distance swing by
I'm gonna have the lathe as well as some other projects available for display
I'd really love the opportunity to meet you and talk making
I've been active in the shop both on the lathe project and on woodworking
On the lathe front, I have the tailstock bored, I've recast the faceplate, and I expect to be turning
between centers within a week or so
On the woodworking front, I cleaned up some of those poplar boards that I slabbed earlier this year
I took a chalk line and ran it down one side Used a circular saw to trim off the
live edge on these boards they've been drying in the basement for about five months
then i use my table saw to trim off the other side
I use my $40 craigslist jointer
to face joint one of the sides and then I sent it through the planer to
make some pretty decent stock.
I made a side table there won't be a video it was
really just for me to prove that I have what it takes to make some furniture
I used general finishes charcoal and amber dye stain for finishing it
along with a coat of satin spray lacquer
[Laughing off camera] Super-corny...cheesy
So there you have it the excuse for my video publishing schedule
This announcement will expire probably at the end of September. Thanks for watching.