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The Metal Shaper
Build your own Metal Shaper. Exotic is a mild adjective when applied to this shaper. It will cut splines, keyways, gears, sprockets, dovetail slides, flat and angular surfaces and irregular profiles. And all of these with a simple hand-ground lathe tool bit. Obsolete in modern industry, of course, because milling machines do the work much faster and cheaper. But you can’t beat a shaper for simplicity and economy in the home shop.The shaper has a 6" stroke and a mean capacity of 5" x 5", variable and adjustable stroke length, automatic variable cross feed and graduated collars. You will be proud to add this machine to your shop.
The Metal Lathe
Using castings from your charcoal foundry (see Book 1 in the series: The Charcoal Foundry by David Gingery) and simple hand methods (no machine tools needed!) you can build a sturdy and accurate bed for a metal lathe. Then additional castings, common hardware items and improvised equipment will add the headstock, tailstock, carriage and all the remaining parts to complete the lathe. Illustrated with photos and drawings to show you all you need to know about patterns, molding, casting and finishing the parts. The lathe specs. include a 7" swing over the bed and 12" between centers. Adjustable tailstock with set-over for taper turning. Adjustable gibs in sliding members and adjustable sleeve bearings in the headstock. A truly practical machine capable of precision work. Once you have a foundry to cast the parts and a lathe to machine them you can tackle more exotic projects.
The Milling Machine
The Milling Machine is also known as book 4 from the best selling 7 book series, 'Build Your Own Metal Working Shop From Scrap'. Especially designed for the developing home shop. It’s a horizontal miller, but it has the full range of vertical mill capability when used with the angle plate on the work table. Extremely rigid and versatile. The work table is 2 3/8" x 12" with a 3/8" T-slot and it travels a full 12". Eight speeds from 43 rpm to 2430 rpm. The spindle raises as much as 6" above the work table and the transmission is designed to follow the vertical travel without straining the column or changing the belt tension. Accessories included in the project are angle plate, face plate, fly cutter, tail-stand and compound slide assembly with which you can do large swing lathe jobs. Still no need to look for outside help. It’s a miller and more, and you can build it your self.
The Charcoal Foundry
Charcoal Foundry, the first book in the "Metal Working Shop From Scrap Series", gives you plans for building a metal melting furnace and instructions on basic pattern making and molding. All the information needed to set up a foundry in your work shop can be found in this book. Simply stated, if you can build a sand castle or make a mud pie, you can make a sand mold to produce castings for your metal shop projects. The main ingredient in these projects is scrap aluminum and pot metal. The only tools you need to get started are ordinary home shop hand tools, many of which are probably already in your possession. Much of the remainder is found as salvage or cast-off and little expense need be ...
The Drill Press
Drill Press is also known as book 5 from the best selling 7 book series, 'Build Your Own Metal Working Shop From Scrap'. If you have done the projects progressively as the author did you will have done all your drilling with an electric hand drill up to this point. That’s tough and tedious work to say the least and you will really appreciate a drill press. In fact it would not make much sense to proceed to the deluxe accessories without one. You could buy one of course, But anyone could do that.... It drills to the center of a 12" circle with a quill travel of 2 1/2". Two stage speed reduction gives a low speed of 260 rpm for serious large hole drilling. Ball bearings in spindle driven pulley and idler make it smooth and quiet running. Quill feed is by cable or chain drive so there is no rack and pinion to cut.
Sheet Metal Technology
Sheet Metal Technology is written in Dave’s unique style with the beginner or vocational student in mind as he demonstrates how a product idea is conceived, developed and then produced by a single craftsman with basic tools. Subjects covered are safety in the shop, use of tools, layout and pattern development, various ways of forming and joining metal along with edging methods, corner systems and panel reinforcement. You will be introduced to the basic sheet metal shop where you will learn about various methods of forming sheet metal and in some instances even constructing your own tools including a rather unique and functional 24" sheet metal brake constructed of hardwood. The final chapt...
Building A Gas Fired Crucible Furnace
Now that you have established your metalworking shop and progressed in the various skills of the crafts you may want to expand your metal casting operation. Build this gas fired crucible furnace so that you can turn out castings for your projects faster and easier. Designed especially for the home shop foundry. Very quiet in operation. Easy to light and simple to operate. The body and lid raise for safer crucible handling. Operates on natural or bottled gas. Costs only a fraction of the price of a commercially built unit and it will melt aluminum, brass and even gray iron. This unit will really upgrade your shop and you will enjoy the convenience of gas fired melting.
Build a Universal coil winding machine
If your hobby is amateur radio or electronics you will often need coils in a variety of size, type, specification, etc.. Coils are no longer as easy to find as they were 20 years ago so you will have to wind your own. With the help of this simple yet detailed manual you’ll quickly build a machine that can wind universal and honey comb coils, single layer and multi layer solenoids, close wound and space-wound coils, and pi-spaced coils such as those used for r-f chokes and transformers. And the mechanical counter gives you total control of accuracy.
Designing & Building the Sheet Metal Brake
The Sheet Metal Brake is also known as book 7 from the best selling 7 book series, 'Build Your Own Metal Working Shop From Scrap'. I almost left this one out of the series and I would have if it were not for my friends who tell me they are always wanting to bend some sheet metal for a project. This one uses no castings. It’s a welding project using standard structural steel and common hardware items to build a compact portable bending brake. Its a 15" brake as detailed but you can scale up or down in size within limits. Definitely not a heavy duty brake but you can make neat bends in 26 gauge metal to form duct, boxes, drawers, belt guards and dozens of items for your shop projects Some have beefed up the leaves and pivots so that metal as heavy as 20 gauge can be bent sharply.
How To Design & Build Centrifugal Fans For the Home Shop
Build Inexpensive Powerful Blowers For Many Uses. Build a Dust precipitating cyclone, design sheet metal transition pieces, balance a dust collection system, build a static balancing stand and more. Learn how to build a simple manometer and pitot tube and actually measure and fine tune your custom air system. This book will show you how to take pillow blocks, shafting, plywood, sheet metal and other common materials and build a dirt cheap blower that will outperform just about any make-do blower you might find on the surplus market. Let Dave Show you how easy it can be to design a fan that will provide the volume and pressure you need for the system you are building.
