Every Job Is A Learning Experience - This One Was No Exception - Manual Machining Long Parts
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- Опубліковано 23 кві 2024
- Every job can teach you something. Some lessons are ones you should have thought about ahead of time.
This video, I talk about what I learned doing these weld coupons, along with doing another job at the same time. Fun stuff, just another day in the shop.
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I took a welding course in college and we had to prepare our own weld coupons for the bend test. I still have the successful test piece that I welded up 52 years ago.
That broken handle is a prime example of projects breeding projects. Lol
Set up take down? An old machinist friend I used to help did not even remove drill bits from a chuck because, "The next job may require that same drill bit." :-)
Josh, I went to bed last night and when I woke up it was 1970 again. I was running a LeBlonde lathe in the morning and a Kearny Trecker vertical mill in the afternoon. Every couple weeks I was helping to assemble headrest molds for GM. But no, I was watching a Topper Machine video. Just wanted to say thanks for living the glory days again. Keep the videos coming!!
Back in the late 70's I worked in a job shop as an employee and often ran mutable machines, the owners were smiling from ear to ear and raises were few and far between. When you work for yourself being as productive as possible is very important.
I smell what you're stepping in. My boss doesn't give me raises either. He is a tight wad. Lol
I had to make my own coupons for the bend test, got graded on the weld prep too
I love that your shop videos are creating mini Q&A / lesson videos. I'm also glad your work creates repeat customers.
Bummer about the handle but good thing you know a guy who can fix it for you. Maybe he'll even be nice enough to record the process and share it with us.
I think he will. Lol
I did the same thing to my planner. Put a removable attachment for a Bridgeport head. Works great. I use it alot.
I always say if you don’t learn something new every day you are backing up.
Ah, Mr. Bozo is always looking over our shoulder. Thank you.
good to see my mill is just being used as a bench and not getting worn out before i get it lol
oh and when i did my certs i do not recall having a "knife" edge we always had a ? 1/16 or 1/8 root that was not tapered ?
G morning Josh,
When you work by yourself, in order to survive, you have to learn, efficiency OF motion. You do it exceptionally well. I hope that vocational teacher encourages all his students to watch and listen to your videos. If Connor has picked up even 1/3 of what you have taught him, he will be ahead 80% more than others that havent had the opportunity to learn from a Master.
It spit and sputtered snow late afternoon yesterday but nothing came of it. May get dusted tonight and tomorrow but zilch expected to stay. Completing more and more small jobs every day now that weather is more conducive to being out in the shop longer...keep it at 55F all winter.....
keep up the good work and quality lessons...they are appreciated, whether you've been told it or not
Don
I really hope I've done well by Conner. He has done a lot of interesting (to me) stuff.
@@TopperMachineLLC You have done well w him Josh, he has lessons learned from you to carry with him and hopefully pass on to others as well.
great comments Don....cheers from cold Florida, it has gotten into the 60's, brrr,,,Paul
@@ypaulbrown Josh is a super super guy, one heck of a machinist and a superb teacher.
Was 60 yesterday and dusting of snow forecast for noonish. Lite misty rain now so far.
Multitasking.
Like a shear pin, that's a good handle to break like that from little force. There's probably not much else that would be cheap or easy to fix behind it.
They always told me, "If you're going to make an omelette, you have to break a few eggs." They didn't say anything about the handle though... 😁 Just another side project for the day!
Nice one, Josh. Thanks for letting us watch. Cheers.
Yeah, I didn't need another side project though.
Happy April 24 Josh, always great to come and visit the shop via UA-cam ....
Cheers from down South in Florida, Paul
We all have a duty to encourage people into the trades. Direct help like making those coupons is awesome. I truly think all these youtube videos help too - at least show the craftsmanship that goes into making parts. It’s incumbent on all of us in manufacturing to talk it up and make it worthwhile at every opportunity. Oof. Deep thoughts first thing in the morning.
I hope my videos have driven some into the trades. The last several years, or decades, have seen a huge decline. These jobs are in high demand.
Yep - it is insanely difficult to find skilled people for manufacturing.
Well said Stuart !!!
Bring on more coffee !!!
@@TopperMachineLLC I believe there are a number of problems involved in this. Learning machining skills is obviously a prerequisite to this work, but if you didn't learn responsibility, honor, dedication, honesty, work ethic, dependability and critical thinking at home you will never be a good machinist (or good human being). Unfortunately, these virtues are slowly being lost by the lack of role models and the unpopularity of parenting. If we do find an exception we need to give the young person support. I presume that is the case with Conner. Thanks for sharing your experience.
We always used a track torch for things like this
Good morning Josh
Great job on the weld coupons. Suggestion: Ask your tech customer if they would be interested in machining both sides of the bar? They would get twice the use from the coupons and you would double your work. This would save the cost of the material, some setup time and transportation. It was something I did in my previous job. Our machine shop appreciated it because of the material handling, set-up and machinist time.
Just a thought, thanks for sharing.
I already asked. It was one of the first things I thought of. They didn't bite.
Josh
I've been enjoying this 2 video a week format
If at all possible please keep it coming
I'm a mechanic not a machinist but I still enjoy watching the way things are made
Thanks. I will keep trying to do this.
When I went through welding school we had to grind our own coupons
The majority of crank handles I've seen over the years were brazed together because of the same reason.
+1000 for screw machine drills, I even have metric ones.
Thank you Josh!
I really like the lessons learned videos.
One of the most important lessons I have learnt (and taught) is to slow down. Think through what you are going to do before you do it.
Josh I enjoyed the video. I fed my 2 boys and Wife of 14 years as a professional welder. Its great that you are helping the college out but I can't go without saying. Every Welding test I ever took using a torch to cut your own Coupons was part of the test. I'm pretty sure that these are probably practice material rather than part of a welding test. If all the students do is weld, then they are missing 75% of the training they will need in the real world. My grandson wanted to go to welding school until he found out that sparks and hot metal falls on you when you are laying down in some muddy ditch. Or welding in an unshaded place in 113 degrees outside. Some of the tuffest welds I ever had to make were directly above the kettles that melted the lead in a lead smelter. We had to tag team the job 15 minutes at a time. Nuff of me Blowing my horn and telling war stories. Again, another great video. Thanks
I like your story. I agree with you on the students missing out. But, I feel people are getting soft in the trade. I honestly wouldn't be surprised if the new welders have a clue about preparation.
You do damned good work.
Thanks Josh
Only the good machinist take on the hard jobs. That's a nice machine to have in the shop.
Multitasking!!!
always look forward to every video
Great video as always Josh 👍👍
nice job allways luarning from you Cheers
Well done. Good thinking, helping the society💯💢
Absolutely, I almost never tear down a setup until I need the machine for another job. More times than I can count either they need more or there was a mistake and I'm doing a job all over again. And as you know setup can be most of the job, manual or CNC.
Great❤
A couple of pieces of round bar that fit tight in the T slot, then mill two opposing flats for a wrench. Works great on a Bridgeport as a material stop & being round they automatically register on the part, plus chips are less likely to interfere with the material against a round surface
Good
Love the work nearly at 100k
So close!
Hi Josh & it's is Randy and i like yours video is cool & Thanks Josh & Friends & Randy
Dear Josh, I see you are on the keyboard right now checking comments, have a great day my friend.....Paul
Real handy machine that made a cracking job. Like you I used to run a as many machines together to save time. I had the shaper r7nn8ng, vertical mill and lathe, kept me on my ties, but good fun.
Do a good job and then they ask for more. Love the chips on the magnet. Sorry about the handle accident. Thanks for the video. Good to see you.
The crank handle. 😅
Nice work Josh. The broken handle is just more video content. Thanks
It's good that you have other work to do while the welding coupons are being milled.
oh man, busted handle, those cast handles are tough, until you bang them the wrong way.....
every day is a learning day.......as always, great information,,,,,,have a great week Josh.....PB
Great video on how we learn from each job. I learned a lot from this job from your post. If I had to do it I would suggest using a roughing "hog" endmill next time. There is no nead for a great finish in welding bevels, roughing mills are much more efficient for mass metal removal and produce small curled easy to clean chips not long razorlike shards.. Just my two cents for what it is worth.
It would be handy to have the correct sized box-end wrench (what we call a ring spanner here in Australia) at each machine instead of using an adjustable wrench (shifting spanner or shifter as we call it). It would save time adjusting the adjustable wrench.
It only takes money, and I'm working that direction.
Great video as always. Are you gonna make a video on fixing the crank handle? I would love to see that one. Look forward to your next video.
I probably will.
Breaking that handle meant everything else you did that day is good. In my experience SOMETHING has to go wrong.
Yup, one thing has to go totally wrong to make everything else go well.
as always, a little something to help the shop...PB
And women say us men aren't good at multitasking. I say poppycock to them. I can watch TV while eating a bowl of popcorn and operate the remote all at the same time. 😂🏴⚒️
try bacon grease for drilling it works exceptionaly very well and smells like breakfast cooking while your drilling lol.
BUT ?????... Can ya spin 10 plates at the same time too ?? LOL good work Bro.
Maybe an idea for an upcoming video. Lol
Bugger about the handle, but over the years….
I do a fair few metres of weld prep,
Mostly on Biz 80, because the fab guys have bevelling gear..
But also doing edges on Biz 400 strips..
100mm 8 insert face mill eats it all, beautifully.
Your, very interesting adaption, could handle perhaps a 50 or 60mm diam cutter.
A handle is a small price to pay, Better than a lead screw.
Thats a pretty slick set-up Josh. Great way to kill two jobs with one stone.
You mentioned in previous videos your location and how the area is depressed, how are the steel suppliers there. Can you get same day service for material ? Is it a long drive for you to get steel if they cant deliver ? Where i am here in Hamilton, Ontario we are spoiled because we are in "steeltown". We have Dofasco, Stelco/U.S. Steel and plenty of handlers. Cheers.....Mike
My local supplier is Minutes away. Most of it comes by semi from 4-6 hours away. Usually 2-3 days. Prices are horrific.
Looks like you has about enough length on that endmill that you could have double stacked and cut two pieces at once. That would have taken making a couple clever backstops, but could have cut down the run time.
I considered this.
😎👍😎
.
Hi Josh, with the coupons, how would you go if you put three lengths of flat bar on the table at once with the top ones stepped back so that you cut all three at once. You may have to do several passes but save on set up time.🇦🇺
I'd considered it, but setup would take a little more. Maybe a setup gauge to get overlap just right. If this job is going to be a steady repeat, I would definitely look into it.
you could put a bucket on the floor and there would be much less to shovel.
And have melted shards of metal stuck inside the bucket. No thanks. I'd rather sweep and shovel.
@@TopperMachineLLC I was thinking of a metal bucket
@@incy55 I have not seen a metal bucket in a long time.
I see you are still using the "temporary" air hose attachment devices - zip ties. I know - they are only temporary if they don't work. Also I hope that spanner you are using is a left hand metric adjustable shifter (wrench in USA). In Australia water runs counter clockwise down the plug hole so we have to use left hand shifters. Same for plain head screwdrivers. Phillips screwdrivers are ambidextrous. Retired mechanic/machinist. PS. You're not the only one. At 72 yrs old I still learn new things/lessons every day.
Temporary Permanent is the correct term. Lol
@@TopperMachineLLC Keep up what you are doing Josh. You are making a difference in many people's lives. May the Good Lord continue to bless you and your family.
It's very nice to see people fighting to get the Trades alive... Newer generations tend to believe everything just magically appears in the stores (online stores 🙂 ) and machines can do everything so they can spend the day doing office "jobs" and binging Netflix. Great work!!
While I agree with your first statement, your second is so out of touch with reality. Younger generations generally don’t believe things magically appear in the stores- the real problem is upper education’s propaganda that you can only get a high paying job with a university degree. High schools need to do a better job educating our young people that the trades will pay way better than most white collar jobs AND give great benefits.
Man, Jose, I have to tell you this is a horrible take. Have you tried being an apprentice in a trade today? I was able to skip a few notches and start off getting paid more because I came with a DD-214 from the Navy, but I had to take a significant pay cut from my last civilian job to get started in my industry. Sure I enjoy my work, and I feel more fulfilled-- but I am in my 30s with a family and I'm making less money, working more, and in rougher conditions just for the opportunity to turn out in A FEW YEARS when I can start making good money. Add that onto the pile of constant inflation and lagging pay scales throughout all blue-collar sectors, and I completely understand why an 18 year old would absolutely laugh their ass off at the idea of going to work in some dirty machine shop, or some construction site out in the elements for a quarter of the pay they could make in an office where they can watch Netflix with their feet up on a desk. Pay people better and these kids will show up; pay peanuts and you'll only hire monkeys.
Unfortunate about the crank handle. Hope you do/did a video on repairing it, it would be interesting to see how you go about repairing it.
I will
I love your product placement ads- but you failed to get the logo fully visible so it said "Anchorlu"
Oops.
A much slower method of beveling VS plasma or Oxy-fuel but there's also no cleanup required. No dross or globs to remove. A much cooler method though :) Nice work
I've been wanting to get a set of screw machine stubby drills. Do you have a preferred brand? Do you like 118* or 135* tips?
I generally order something fairly good. Nothing fancy, but good quality.
nice work. but I still having a hard time with you machining weld coupons. the students should be prepping their own stuff when I took welding school we used an ox fuel tack cutter you learn more than just welding to be a good welder. I know our tech school here just a ban saw set to your desired bevel and the with of the flat bar standing up. you get 2 bevels every cut plus you end up with 4 sets of bevels from 2 plates so the students get more practice out of the material and we all know how much steel is. keep up the good work. but I feel there's a better way this feels like a waste.
I agree, but people have gotten soft.
You got me, whats the difference between a screw machine drilll and a jobber drill or an aircraft drill for that matter... I can't see one on the pictures I have found.
and a plus side to the breakage, atleast it was only the handle...could definitely have been worse. so yey for snappy handles.
Screw machine drills are short, jobber are mid length, and aircraft are long.
@@TopperMachineLLC ah cool thankyou ...was a lot easier than I thought it would be lol
I'm curious why you didn't set up a couple extra stops while you had the last long piece still clamped and run 2 or 3 short pieces at once?
I explained the curvature of the hot rolled and why I didn't.
Did you retrofit that J-head onto that machine, or is that a common fixture? I've never seen a setup like that before. If you did it, you're a genius, and I'd love to see some video on the process, if it exists.
Check out the older videos of it. I explain the story of it.
@@TopperMachineLLC Give me a hint...
Josh, just curious as to why you didn't just put the 2 4 footers together and do them as an 8 footer?
I could have. Hindsight.
I learned you need to buy a ratchet wrench for the mill
Lol, I have several.
would it been possible to stack two pieces staggered to cut both at once?
Yes, I just wasn't sure the 1hp head could handle that much.
Because of the testing nature they want the precision of a mill over a grind or plasma cut? Real world would be those methods plus rust! I guess those techniques are a later test.
Have you worked with new welders? My God, they are princesses. Can't even change their own consumables. Won't be long and they will expect everything ready for them to just come in and burn for a couple minutes and go home.
If they're not careful a robot will take their job!
You must be doing it right for the college to A. ask you to do the job and B. come back and ask you to do more of the same.
Despite my years of training as an armchair machinist I do not recall anyone mentioning the life span of a cutting tool. To my eyes, that cutter took a bit of a flogging, cutting along the same portion of the face again and again. Would it be beneficial to the useful working life of the cutter to raise /lower the quill from time to time to even out the wear ?
Solid carbide. It's still good and probably last quite a while longer.
Your first lesson is a double edged sword, don’t tear it down right away because they might order more, but if another job comes in do you bill them for the tear down of the previous setup? Hard to balance it especially in a shop that does mostly one off, but occasionally repeat work too
Exactly. But I could have waited a few days as I had nothing going on it for a while.
'Screw machine drill' - never heard that term - anyone know what it's called in the UK? Looks like a stub drill, but that's based only on length.
Stub works here too, but they were designed for screw machines.
Don't know about you, but the lessons I learn usually involve a 2x4. Seem like that's the only way I can learn. Not being a welder, I am curious to know why they are referred to as coupons?
IDK where the term came from. Test coupon. That's all I know. Might have to look that up now that you peaked my curiosity.
If your stock sizes are 8 foot and 4 foot respectively, couldn't you just add an extra stop to the middle and run two 4's at once when necessary?
No, I explained the material curvature in the video.
Lol you liked my last comment and I'm only 1/3 of the way through the video Ha Ha LOL almost like real time feedback :)
Shame on you. Breaking the rules. Lol
Well that's an aw s___ you didn't want, but easily repaired. If that's you worst, no biggie.
I had a few choice words besides that one.
I know it's the wrong kind of metal but they look like giant chipper knifes :)
I've milled some.
Where are you located ?
Northern Wisconsin, Spooner to be exact.
As a non machinist, couldn't you have taken out the last 8 foot piece and loaded up the 2 4 foot sections and continued on? After all, it's only welding coupons.
Probably
What the heck are your videos getting a lot shorter in time or is it me? It seems like the video was three minutes long. Maybe it's me losing track of time.
Mid week videos are shorter, I'm still trying to do longer on Saturday.
!NO RUNNING IN THE SHOP!