Hmmm... a quality post. Much more so than most of the nonsense than the blow hard tooling salesman puts up and claims is the greatest thing since sliced bread for this newsgroup. You should do more posts like this as it could put some life back into this newsgroup. Can I cheat and discuss this part with my co-workers? Those would be the same coworkers you suspect I'm hostile too but are too lazy to visit with.
Is it a requirement that we have to hold this part in a cheap Chinese Kurt knock off vise to make it?
Hmmm... a quality post. Much more so than most of the nonsense than the blow hard tooling salesman puts up and claims is the greatest thing since sliced bread for this newsgroup. You should do more posts like this as it could put some life back into this newsgroup. Can I cheat and discuss this part with my co-workers? Those would be the same coworkers you suspect I'm hostile too but are too lazy to visit with.
Is it a requirement that we have to hold this part in a cheap Chinese Kurt knock off vise to make it? ==================================== =====================================
Is it really true, you actually cohabitate with another (non-institutionalized) human being? goodgawd.....
Didja take that picture in the bathroom at work? I'd mill the OD as a rectangle, drill the .157 holes and the steps adjacent to the side holes. Also do 2 holes in the middle to hold the drop on the last op.
Turn over, face off the slag to thickness and do the steps opposite the steps in op1 Turn on edge, mill the side steps, drill and tap the 4-40 STI holes.
Mill a pocket in a fixture plate to fit the OD and tap some 6-32 holes. Hold the part in the fixture pocket with screws through the .157s Rough and finish the inside wall.
I would begin with a piece of 3/4" plate for each part, because there's lots of it behind the lathe. ;-) I would square it to the
3"x6" dimensions, face both sides JUST ENOUGH to clean one side complete and make side two ok for sitting flat and drill and tap those two side holes. Next would be clamping the material in some dovetails and machining the profile after drilling the other holes. I would get some bondo and another piece of plate and stick my fixture to the part real quick-like. Once the bondo is hard enough to take a cut I face and square the fixture before flipping the part and using a not-so-big end mill to cut the top edge of the part to the correct height. Some zip strip paint remover makes the bondo go away without bead blasting. Helicoil and deburr at my desk. No print showing super tight tolerances, so if it warps a little I bend it back right. :-0
I would get 1" plate, hold it in a vise by 0.2" and finish the part complete but in stead of 0.157" holes I would tap them 8-32. Then I would bolt it to a plate and machine back with a small endmill (not large facemill) around the perimeter. On my mill I would put 4-40 holes in first set up as (5 axis) but on 3 axis it would be another setup. Then I would check it's flatness and figure out another way if there was a problem :) Jerry
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