Making a BIG Boring Bar | Shop Made Tools
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- Опубліковано 14 жов 2021
- In this video we are making our BIGGEST shop made boring bar! We have a job coming up and none of our boring bars are big enough so we are going to make one. For making this big boring bar we are using a piece of 150mm diameter old ram shaft material off a Hitachi EX1900 excavator cylinder. We show the step by step process starting with turning the OD down to size on the lathe and then lots of milling machine action. The finished boring bar is 125mm (5“ inch) diameter and 1100mm long with a massive 900mm working length!
Check out this big boring bar being put to the test! • Testing the BIG Boring...
In this video we are using:
- Everising H-360HA horizontal bandsaw
- Hafco TM-26120G Lathe
- BM-63VE Milling machine
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I gotta ask when's the last time you two bought a doggo toy?
@@ThePirateGod since his birthday a few months ago 🤣
I can't wait.
@@CuttingEdgeEngineering That's one lucky doggo.
no thank you mate look forward to your videos every friday love the content
It's the "that's not a knife" scene, but for machinists!
Machinist Dundee 😂👍🍻🇦🇺
Brilliant!
@@CuttingEdgeEngineering you need to say that in the next video! “How you going guys Machinist Dundee here from CEE!” 😂😂😂
You call that a boring bar. This is a boring bar.
I was about to make comment exactly about that. Couldn't help it.
I can only imagine that stopping work to add all these detailed explanations are a pain in the butt, and time consuming to do/edit, but It's really interesting, and much appreciated. Thanks and keep it up, folks.
thanks mate, you're right 🤣 and why we only do 1 job video a week
Thanks to both of you for the work you put into these vids. What you do is interesting and its well presented, and sometimes you smile! Homeless is a bonus.@@CuttingEdgeEngineering
I found myself in a boring bar once. I quickly finished my drink and left to find someplace more exciting.😀
I am a third-grade teacher in Texas. The reason I watch every one of your videos is because you exemplify the thinking that I teach my kids every single day -- be a problem solver in every facet of your life. You have many complex machines at your disposal, yet you still have to come up with unique ways to complete each job (thinking outside the box), not simply "throw it on a machine". Thank you for sharing your expertise. Keep up the amazing work and by the way, your wife's camera work is some of the best on UA-cam.
You remind me of teachers I had fifty to sixty years ago. I left school at 18, was at work at 11, got my education in my thirties and forties. Now I get to enjoy watching others do what I did for so many years. I've been retired for a bit over two years now, ahead of any desire I ever had. We got told we could do anything we set our minds to accomplish. I hope you can impart that to many of your students.
Who does your translation Kurit speaks a difference language ***I like watching him work but I mute the sound**i only understand a few words. ***DR KEL
I left school Easter 1960 with just a secondary education, started work in construction, my father was the works superintendent and when every he came out of his office my name was the first he called. I was taught to drive every item of plant on the job and would jump from one to another as needed. If it broke, I had to help fix it. I also spent time as the boy at each of the trade depts, learning their trades. When I asked why every trade and father said it's always good to know what another man's trade has to do before asking them to do it. I then helped build a Tunnel Boring Machine and mastered the controls, I'd already had spent time with the surveyors so understood lines and levels. The TBM was fitted with the first Line & Level guidance system and gained knowledge of that helping install it. So, when mining started I had it off pat and only needed to find how the TBM reacted and became one of the three shift operators.
After 20 years of tunnel building and many different types of ground and been promoted to tunnel foreman. I called up a consultant company for information and they offered me a job as Senior Inspector of Works this commanded a salary package equal to a graduate civil engineer with as in my case 20 years' experience. So, for the next 15 years I traveled to many parts of the world working on major tunnel projects with that same company. I took a 4-year absence from them to work on a major High Speed Rail project, before returning to the old company until I retired in 2015.
I put my father's training to good use by talking to contractors to solve problems, I also suggested to the workforce on a faster, easier, safer way of completing tasks. Most mining crews work on a piece work system and are payed on amount of tunnel completed. I would stop them getting into bad habits as rework would slow production, I was rewarded by being able to sign off work and not write pages of reports.
The, “Everyone was amazed at how big that was look at that fucking thing!” Got me 😂😂😂
😂👍 thanks for watching to the end
"Fucking deep penetration" got me. I managed to hold it together until that line.
Love the end of every video always a good laugh and a happy puppy! Great videos guys keep up the good work!
Her laughing at the "8 inches" got me. Sounded like something the wife would do!! Au Mate!!
@@CuttingEdgeEngineering that bar is an absolute bloody UNIT
Thanks Kurtis and Karen for the ongoing great content 😊
Always welcome mate! Keep watching and we will keep making them 😂👍
You know it's serious when you need a crane and forklift to move the tooling! I was particularly impressed that your bandsaw went through that hardened shaft without leaving teeth behind.
My thoughts exactly. I thought the Induction hardened bar would have turned the saw blade into a blunt butter knife.
Homeless gets a new friend, toothless.
That bandsaw really is something else.
Did anyone else choke on their beer when he said… “Took us about 6 hour, so about half a days work”.
I don't drink
Thank you for sharing.
No I work twelve hours at least occasionally
I work 9 hours, sometimes 10h. So about half a days work 😃
With this amazing interesting work and his huge knowledge, it's a gift to work 12 hours a day
I’m impressed every time I watch these videos. What can be done with steel amazes me and Karen, your excellent with your camera work. Together your a class act …..an Aussie class act !!
Hey Gary thanks for the great comment we both appreciate it 😎👍
Gary, well said. I could not agree more! 😀
This is machining’s version of “That’s not a boring bar, this is a boring bar.” Lol!! That is a monstrous boring bar. That would sit at the front of my shop as a show piece haha.
Thank you Kurtis and Karen. Karen’s videographer skills improve with each video. I’m guessing that machine set up is a time-consuming operation.
You're right, really time consuming. It would take me about 10mins or so.
I think it's one thing to use tools to do precision work, but making your own tools to do precision work is taking it to a whole other level. You're like the medieval blacksmith making his own forge and anvil and tongs! Awesome work!!!
Thats one of the best parts of engineering. I work in a jobbing shop and the amount of custom everything we make is great. It's still really handy to know how to hand grind tools.
Bloody Hell, your 'scrap' pile is worth more than most companies inventory 😂
Great video.
And my girl always says that I keep too much stuff. I had to explain to her why I didn't throw away the am radio from an old chevy. And that box of tubes for tv sets.
And one day someone is gonna want it and spend insane money for it
@@michaelvangundy226
tubes for T.V.,’s...?
hahaha...!
I thought I would never hear those words together again... hahaha...!
I am 58yrs young...
Michael, that aint nothing, my wife still has shoes from when we first got married 46 years ago
@@greggb1416 you got me by 7 years ,, how about 8 track tapes ..or even the home phone with a party line
It's incredible to me that the tool post can support not only the weight of that bar, but also the tool pressure generated with 900mm of stick out. I'd have thought that that would absolutely wreck your carriage. Amazing job Curtis! Love learning new things from ya.
I don't think he'll be taking 5mm cuts with it. 😃
@@unklian9221 So ya think he'll limit himself to 1/8 banana cuts???
I've been doing this for fifty years, mostly retired now, still get great pleasure seeing you taking up where I left off, although I did at a substantially smaller scale. I worked a few years with a shop that made, straightened, and repaired boat shafts for a fishing fleet out of Morehead City, N.C. with shafting well on the same scale as your boring bar. We made most of our own tooling, as you do, out of scrapped out work. I really enjoy seeing "homeless" running around in the shop, reminds me of my younger days.
Even the outtakes show how much smoother Kurtis has become with the narration and intros. I'm just a computer nerd, but I've been enjoying the whole catalog of videos. And I see Homeless has begun to "drop it" on command.
Kurtis is is so precise on the controls, i bet that he could circumcise a gnat with that forklift!
Bloody brilliant as usual, mate. Your lathe must have a very *rigid* toolpost to support that amount of overhang to allow such a huge bar to cut without deflecting significantly. Or am I missing something?
Anyhow, congratulations to you for showing us another way to help us backyard blokes to improve our tool inventory, and also much admiration for Karen for her brilliant camera work; lots of people make videos, but hers really highlight how good your work is without being flashy. Good on yer both!
Im wondering the same thing... It seems rather small for that tool...
being that big perhaps that makes it so rigid that the overhang effects nothing
Very unlikely that bar is going to flex but that does seam like a heck of a lot of leveraged force transferred onto the tool post. I have to admit I was expecting to see the bar fitted onto a bigger lathe, either way he has shown he knows exactly what he is doing I have little doubt he has considered and knows exactly that the tool post will handle that beast of a bar. I look forward to seeing it do what it was made for.
I used to use a shop made boring bar that was significantly larger than this one. I do not recall the actual numbers (if I ever even knew them) but an estimate from memory, is that is was probably about 4 inches (200mm) in diameter, and over 12 feet (3 to 4 metres) long. It was entirely round, did not clamp into a tool post. Instead, we removed the compound and put into it's place a saddle made to clamp the diameter of the bar. We were boring steel cylinders that were about 6 feet (almost 2 metres) deep. There was no noticeable deflection, and it is difficult for me to imagine that our cutting inserts would not be destroyed if there was enough force on them to flex that bar. What the weight of that bar did do (with that leverage it had due to it's distance from the saddle) was try to tweak the carriage on the bed, making the friction rather high on the ways. That is why the boring bar was so long - half of it stuck out the back side of the saddle, toward the tailstock. That way the weight was carried evenly, it was balanced. The biggest issues were that the cutting tool would wear (we used diamonds and ceramics for their hardness over carbide) as you can imagine, the linear distance of the inside circumference and length of cut. The other issue, was getting the feed and speed right, along with the cutting tool geometry, such that the chips would break, insead of a bird's nest from a continuous chip hundreds of feet long. Imagine machining propellor shafts on container ships!
@@SodiumInteresting that's what she said .. 😅😅
All that leverage (moment-arm) secured by one center bolt in the tool post. Man, that's amazing.
Homeless is so loved by so many people, he would have a home almost anywhere in the world if ever needed.
The ceramic insert cutting the induction layer was awesome to watch!!! Even with the flood cooling, you can see insert glowing red!!
Great vid again guys, I love how you "Clean as you go" Curtis, some workers make so many excuses why they wont do it when it takes no time to do and try to convince you it's quicker to do it all when finished then piss off home and leave a mess behind, frustrates me no end
The out takes are priceless.. You are so confident and exacting when you tell us about the job, the tools and equipment that you need to use. It helps us see not only the degree of difficulty in the work, but also how hard it is to make these video...
I got say, I really enjoy watching you build this stuff. I’ve been a heavy equipment mechanic for about 25 years. I’ll be buying my first line bore machine in the next 6 months. You have really inspired me to move more towards machining and away from the mechanicing end of things. Now to figure out how to get started in that direction. Thanks for the great videos.
This could be the best ever. Great machining, filming, editing, skills and humour. I'm a 60 year old civil engineer from Scotland but I think I want to emigrate and be an unpaid apprentice in my retirement. Paul
Even if you don't need something highly specialized, given the borked state of the supply chain, being able to make your own tooling has a LOT going for it.
It is very common is the machinist world for machinist to make their own tooling, you get exactly what you want.
So I've just watched this (entire) video again after 3 months, and the thought come to mind; It's one thing to correctly "machine a part", but it's a whole next level of attention to detail and tolerances to "machine the tool that MAKES the part" ! Well done Kirtus
This is another outstanding piece of work! Your videographer/video editor must be a machinist at heart - she does a superb job of capturing every step that's of interest, and edits the videos beautifully. Of course, your skills as a machinist and tool designer are excellent. All in all, some of the best material on UA-cam. Congratulations!
Hey George thanks for such a great comment mate!
It’s finally Friday! Made it through another week! Kurtis comin in hot making his own tools! Bad ass! Cheers Karen and Kurtis! Have a great weekend, give Homeless a scratch for me. Much love and respect from Florida!
cheers mate you have a good weekend too 😎👍
When Kurtis’s Boring Bar weighs half as much as my lathe... that’s some tool !
Todo bien por aquí.
Saludos desde Madrid, España, Unión Europea.
Gracias por las clases de maestría que nos regalas.
Feliz día.
вот честное слово, моя жизнь никогда не будет прежней. ТАКОЙ держалки (как она там правильно называется) для резца я еще не видел..
thank you very much
Can’t wait to see it in operation, nice use of callipers to remove metal splinters
And I thought he was just measuring the size of the splinter!
@@robfinch3277 that too ... was just clamped anyway
Again, the best hour of viewing pleasure of the week! Homeless must have the most incredible dog chewy toy collection in Australia.
An interesting project. I'm always amazed that you can do with steel what I'd only hope to be able to do in wood.
The camera work and editing was outstanding and a pleasure to watch.
Thanks to Kurtis's lovely wife for the great editing! From the bloopers at the end of your vids, it's really fun to watch and learn from the best! That means both of you!!!!!!! 😃👍👍👍👍👍👍👍👍👍
That is one beefy boring bar, and was so cool seeing that juvenile frilled dragon in your yard!
Thanks for watching mate
It blows mi mind to watch your expertise on the different machines, for a young man you have the knowledge of an old machinist, Most shops would say nope we don't have a tool that big, you just make one. Great job.
Never knew milling boring tools could be so fun to watch until the out-takes. Very... exciting.
This man is a national security for Aussie.
I'm still amazed every time to see someone take such pride and care to do the best job possible. If only everyone did.... Very nice nice work!
He is a "PROFESSIONAL"!
@@boondocker7964 There are professionals... and there are Professionals.
Also gotta say great camera work again, especially the slow-mo's
This is rather boring... Lol
There's people that do a job because they need to and then there's people that do a job because they want to.
That's what makes the difference.
I know everyone says don't use coolant, but like you've i've found that my ceramic inserts last way longer with the coolant than without.
Especially on my custom regrinds, i've found that they last roughly 30% more than without (standard diamond regrind with a diamond paste edge lap cleanup pass).
Excellent work!!! Nothing but the best, even for the shop.
When I was younger I performed the same activities as you. Now after 10 years I'm a nurse, but I still watch your videos to remember a time.
I watched a compilation video of lathe crashes and CNC crashes. It really shows how incredibly talented and skillful you are. None of them touched anything near the sizes you deal with safely, daily.
Homeless at the end of outtakes "piss off your not having it back" 😂. Great vid again guys. That's a tough bit of bar.
Some say he still hasn't dropped that toy...
That's a lot of energy working on that tiny tip taking down the hardened layer... Brave action
Yeah it's amazing what tooling is made to do
I’m just glad it didn’t explode. Ceramic tooling freaks me out. I tried my coffee mug on some 4140…. it didn’t end well
My neighbor across the road is a machine tech. He built the hydro power station that I ran for nine years. He is a very handy person to have around.
Never seen a ceramic insert before, very interesting....thanks. BTW: I have a right angle drive for my bridgeport that fits on dovetails and quill. Very useful. I use it mainly for fluting rifle barrels.
Seeing no change in a DTI when your moving your tool that far is so satisfying.
I had to make "specialty tools" out of parts in the automotive industry during my time. AWESOME job at what you do in your field making specialty tools for your line of work. Thanks for the great detail you and the wife do making these videos. They are going to be excellent training films for up and coming machinists. Congratulations, and keep up the great work. Can't want to see you test it...
PASH I BYTHZI QESH TU E SHKEL MIR QE BUZQESHI DHOMET NA........
@@MsALDARI can you translate this into English ?
Another fantastic video, they take me back to 1964 when I started work as an Apprentice engineer. I am retired now but still to see things made.
Machinist, Watchmakers, and engravers are the most ingenious people. When I can’t find it I’ll just make what I need😊
The right tools for the job is so important. And the right tools in the hands of a master is, and makes magic.
While there’s little to laugh about these days, thank God we’ve got you three to put a smile into our day.❤️
Very good use of used stock. I keep old parts around my work shop for make up equipment.
Love to see big shop made stuff. This would be a medium sized boring bar in my works collection. Your lathe looks really well looked after aswel. Horrible to see, especially older machines, that have been abused over the years. Great video again
Three things I look forward to on Friday: Friday, reaching the end of the working day and sitting down to watch what Kurtis, Karin and Homeless have been up to.
I love how the dog seems to know the squeaky pigs are for him even before you gave 'em to him. :)
The bar is not boring at all, it is a very interesting piece of workshop paraphernalia.
It surprises me that the sheer mass (moment) of torque on the tool carriage doesn’t overload it, then you put more load on it by applying cutting pressure. Heavy duty stuff, for sure.
Excellent vid, as usual, Kurtis.
Funny, I didn’t find this at all boring. Nice selection of bars there. I am, admittedly, amused by a boring bar you have to use the crane on! Have another great weekend, Team!
Absolute perfect precision every time, no 'dogging' it up tight or 'that'll do', just perfect workmanship.... you would make a surgeon think 'Have I put it all back in the right place/'
It’s a great looking boring bar. We made lots of them for the company I worked for for the past 18 years. We made some that were several feet long -yep not a typo. We found that actually after seven diameters hanging out there there isn’t much you can do to stop the chatter. play with the tool geometry and depth of cut and stuff. One thing we did is we filled some of the bars (which we deliberately used hollow material for) with this muck that we had from our hone so it made the bar really really heavy, but it deadened some of the vibration.
Try fixing a length of wood to it.
That's about 8 inches 🤣 Karen, I'd have been as red as a cherry blossom in embarassment... Nice one Kurtis! Always appreciate the effort from you two!
She says "How heavy is that?"
He replies in typical machinist/mechanic highly technical terminology "Fucking Very!"
Sometimes I wonder if it takes longer to make the vids than it does the parts!!!
Yall never cease to entertain and educate and inform... Keep up the great work and give the pup a scritch (technical term ya know) between the ears !
Cheers from North Carolina USA!!!!
The time to make the video out of the footage.
1. You shoot the footage which takes at least as long as the job itself (obviously)
2. You end up having 4-10 hours worth of footage, sound and stills.
3. Editing that kind of material with all the bits of information embedded will take at least two days, usually a lot more.
So, it definitely takes longer to make the video than it takes to do the job itself.
Again, a polar bear sized thak You goes to the giggler.
Your set up is brilliant. That dog Is so sweet AWWW. I have a Corgi pup and an old Jack Russel. They rule my life with an iron paw. HA HA HA.
A boring bar that big isn't boring, it's exciting!
i always find it interesting how much this guy knows since he is not that old and has tons of knowledge about lots of stuff related to his job.
He's at least 70, maybe 75!
Great video. You guys are a riot. I kept hearing AC/DC singing "we've got the biggest boring bars of all" and then you go off in the out takes.
It’s amazing to me that the tool post can hold that much weight, and yet stay in place while boring
Keep it up, I enjoy watching your vids.
Looks good for a 600mm bore, can't beat a bit of mass to deaden things and the counter balancing overhang must help some.
900mm deep bore, that will be interesting to see.
Outside my experience to predict, but so much leverage if it got pushed too hard.
Using the calipers as tweezers was sick!
Beer o'clock and new shop tool! Excellent!
First comment Cheers mate!
"Necessity is the mother of invention" I loved watching Mr Safety try to destroy his chew toys.
Amazing what a guy who knows what he's doing can make with high quality steel parts, some sharp tools... and a nice supervisor/doggie!
Never watched a boring bar made start to finish; thank you! Shop made tools are cool, but it's a PITA to have to make them for one job.
thanks for watching!
That was not “boring” at all? Thanks for explaining the diameter to working length ratio.
Wonderful job on the boring bar. I've got the same ones at my own job, we've got a Stanley hollow spindle lathe, and there's a couple homemade 100mm bars (4 🍌's) that were made by an old New Zealand machinist. 🐑
Awesome! Some of the best tools are shop made
Great episode! Your commentary about ceramic inserts, right angle head and so on is extra interesting. Thanks for this; wonderful to see giant tools being made!
Glad you enjoyed it!
Kurtis is an master engineer an advanced skill level ..
Thanks, that was very interesting. I like that you show the setup details. Every part of this translates across to normal size work as well so even though it is massive, all the methods are relevant to the rest of us.
Glad it was helpful!
Love the design. Sure it's going to work great. For future tools look at building a big boring bar holder that can bolt to the saddle directly instead of onto the tool post. Will give the bar more clamping stability so you'll be able to take bigger and longer cuts. Unfortunately weak point in the whole operation there is the shaft the tool posts mounted to and may allow vibration with heavier cuts. Awesome work and keep up the great content
That’s so awesome you made this boring bar out of salvaged materials you had on hand instead of buying raw material. Great idea Kurtis.
Well done my friend very very accurate job, job with a heart, but the real help and motor behind is that lady on the back ground, they say behind a successful man is good woman.
I made one almost identical to that one about 10 years ago, just on a smaller scale. Great minds think alike. Lol.
вот это резцедержка, огонь) Постоянно смотрю ваши видео) очень классная мастерская, респект бро) Надо что бы Негода запилил ответ)
Жаль мало русскоязычных коментариев есть про что поговорить
Everything is Cool while Listening to Sabaton! Stormtroopers is FIRE🤙
Good to see machining done the traditional way. In this modern age of cnc/cim, its refreshing to see. Keep the videos coming - especially the out takes, they're hilarious! 😂
I don't know anything about engineering, but that was amazing.
As each new vid I watch I’m that much more impressed with your skills Kurtis being self taught...mate your a self taught engineer that’s real impressive mate the knowledge is amazing and to build it into the business it is today is even more so...well done mate
Thank you mate cheers!
Congrats from an electronics guy to a machinist.
That thing is an absolute beast! You make it all look so easy, however, I know that it all comes from years and years of experience and hard work. As always, great video!
I'm really interested to see how this performs, especially with finish cutting. I'm inclined to suspect it will not be able to do good finishing due to vibration. It is possible to mount a fixture onto slideway though instead of using tool post, that does provide more stability.
Video of testing the bar coming on a few days 😎👍
I’m curious what the deflection is on the tool post and how well it will transit.
@@francisschweitzer8431 yep. We have made home tools, but it didn't work so well, we have a bigger tool post too. But that could be material. We are cutting inconel and required to get finishes of under RA 0.4 at times, so we made a base to sit on the slideway and that works a treat.
Great DIY tool making and super great filming and editing. A bit of everything - even a Bearded Dragon.
The falling chip drop shot is a work of art...
I loved the calipers to remove the chip from your hand!
It hearts my feelings when i see no chamfers on shelves of milling's bar face.
My feelings are fine thank you 😎👍
@@CuttingEdgeEngineering that is wonderful news!
For someone who is self taught, you are an impressively clever bloke Kurtis.
My jaw dropped when I saw the soft jaw system. Definitely doing that at work.
Right on, this will go well with my last couple beers for the night! Cheers 🍻
Cheers mate and have a good one