The charcoal foundry (Build your own metal working shop from scrap)

Engineering & Transportation

Gingery, David J.

Engineering

Metal Shop from Scrap

The design is especially planned for the developing home shop with limited equipment. There is still no need to look for help in custom machine work. The charcoal foundry will furnish the castings, and you can machine them on your home made lathe and metal shaper. The miller itself will do some of the machine work on its own parts.Extremely rigid in construction, its lathe like characteristics make it very versatile. Included accessories make it possible to do large diameter turning, boring, and facing operations, and it can make its own cutters and holders.The work table is 2 3/8 inch x 12 inch, with a 3/8 inch "t" slot, and it travels a full 12 inches. The carriage travels 6 1/2 inch in line with the spindle with the tail stand in use, and 8 1/2 inches with it cleared away.The spindle center can be raised as much as 6 inches above the work table, and the transmission is designed to follow the vertical travel of the spindle without changing the belt tension. There are eight speeds in two ranges, from 43 RPM to 2430 RPM.There is more detail then the lathe and shaper, but we are still using the same simple methods. All of the castings are within the capacity of the charcoal foundry, using the one quart pot, and there are detailed instructions for machining the parts. Additional discussion on patterns and molding bring the project within the ability of a novice. You really can build it in your own shop at home.

Milling Machine: Build Your Own Metal Working Shop from Scratch, Book Four

Crafts, Hobbies & Home

Crafts & Hobbies

David J Gingery

Built entirely of home-made castings and standard hardware items, this drill press will make a valuable addition to your shop. It drills to the center of a 12" circle with a quill feed of 2 1/2". Both its spindle and countershaft are mounted in ball bearings. A single lever belt tension mechanism changes speeds quickly A low speed of 260 RPM enables you to drill 5/8" holes in steel. Its table is adjustable radially for angular drilling. Quill feed is by cable winch or roller chain so there are no racks or pinions to make or purchase. The machine is carefully planned and designed with the home built 7" swing lathe in mind. All of the castings are within the one quart pot capacity of the charcoal foundry. There is still no need to have any work done at the local machine shop and still no need to purchase any expensive tooling or accessories. Though building a drill press may be the most difficult project in the series to justify, considering that a very serviceable imported mac

The Drill Press (Build Your Own Metal Working Shop from Scrap Ser. : Bk. 5)

Now that you have a machine shop you need accessories for the machines. This manual will show you how to tool up your shop to produce the things you want. Making your own tools and accessories is rewarding both in product and pleasure, and it helps greatly to develop your skill.An angle plate, a set screw chuck and an expanding arbor are only the beginning. A clamp dog, threaded mandrels and simple hand reamers are needed in all shops for many operations. Certainly any lathe is improved by a two or four jaw chuck, and a center steady rest for the lathe enables you to do machining operations on the tail end of the stock as well as expanding the capacity of the lathe.Building a worm wheel dividing head will enable you to do precise indexing for gear making and other dividing jobs on your milling machine. This one functions as a rotary table for the drill press too. This is an accessory seldom found in a home shop. You will be amazed at its simplicity, durability and accuracy.Learn basic gear calculations and how to prepare the blanks, index them and mill the tooth spaces. Make your own gear tooth cutters from ordinary lathe tool bits at a fraction of the cost of commercially made gear tooth cutters.Add change gears to the lathe to cut all standard threads from 8 to 80 per inch, both right and left hand and internal or external. A threading indicator is added to the carriage so that you can do accurate threading without reversing the motor to return the carriage after each pass. You'll find that the gear driven fine feeds are much better than the original round belt carriage feed drive on the home built lathe.You won't want to stop here for much more is easily possible. ..........

The Dividing Head & Deluxe Accessories

The main purpose for publishing the "Metal Shop From Scrap" series was to present methods for building such equipment as is normally found in a machine shop. lathes, shapers, milling machines and their accessories fall into that category easily. A bending brake can certainly find plenty of use in any sheet metal rather than castings, forgings or other structural forms. It is well that we included in the series for it has proven to be one of the more popular titles.This is a welding project rather than a casting and machining project, though obviously some of the members of the brake could be designed as castings. You can find much or all of what you need to build the brake at the local salvage yard. This is a light duty portable leaf brake. Of course heavy work will require a larger, heavier piece of equipment, but you will find the basic principles here.Simple operations such as cutting squarely to a line with a hacksaw or drilling a hole precisely on location require a measure of skill. The ability is gained through understanding basic principles and by practice. "Learn to do it right and apply what you know!" You'll find a worthwhile series of productive exercises in this project, and the result will be a compact sheet metal brake that will greatly expand your shop capability.

Designing & Building the Sheet Metal Brake: Book 7

Science & Math

This is the monster furnace that uses natural gas to melt up to twenty pounds of cast iron in a crucible. Both body and top of furnace lift up to allow safe removal of the white hot crucible. You get all the details on the furnace, burner assembly and operation. It will easily melt brass and cast iron. You should have experience with molten aluminum before moving to the "hot stuff." Although not necessary, you'll probably want Dave's book on centrifugal fans to build the blower. Top quality. 5 1/2 x 8 1/2 softcover 108 pages

Building a Gas Fired Crucible Furnace

Book by David J. Gingery, Gingery, David J.

Milling Machine (Build Your Own Metalworking Shop from Scrap Series)

David J. Gingery

David J. Gingery Publishing, LLC

The Drill Press

The Dividing Head is also known as book 6 from the best selling 7 book series, 'Build Your Own Metal Working Shop From Scrap'. This project really proves the worth of a simple lathe fitted with only a face-plate and centers. You'll make some valuable accessories for the lathe and you'll be a better machinist when this one is done. Now that you have a machine shop you need accessories and tooling. You also need practice on your new equipment so here's a book full of projects. Build a four jaw chuck, a steady rest and other useful tooling. Build a worm-wheel dividing head and add change gears to the lathe so that you can cut accurate screw threads from 8 to 80 per inch, both right and left hand and internal and external. Make your own reamers and learn how the master machinist of 100 years ago made his handful of tools do any job he was assigned to do. These are all items that many of us can't afford early in our shop careers, but you can make them yourself now that you have a machine shop.

The Dividing Head & Deluxe Accessories (English and Spanish Edition)

Designing and Building the Sheet Metal Brake

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Books by Gingery, David J.