Making 'Hex' recesses... Technique '2' - MVAgusta.net
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 13 (permalink) Old 09-29-2012, 02:43 PM Thread Starter
Senior Member
 
BG Wells's Avatar
 
Join Date: Aug 2009
Location: Lisburn Northern Ireland
Posts: 4,587
Making 'Hex' recesses... Technique '2'

Ok so I showed how I make Hex recesses using a 'rotary broach' which I also showed being made. http://www.mvagusta.net/forum/showthread.php?t=48542
This tool has it's limitations though...as 'broaching' anything above 5.5-6mm hex puts a lot of 'load' on the lead screw/ rack and head bearing of the reasonably small engineering lathe I have. Therefore I have developed a 2nd technique which is very effective (in fact I use this technique most!)..although it too has it's limitations (due to the opening capacity of the vice jaws).....in which case you could use a small 'press'.
It involves making 'broaches' in a similar way to the last but using sections (50mm) of 10 & 8mm allen keys. And some re-machined brass plumbing 'stop ends'..from your local hardware (home depot...B&Q..etc).
As before the 'broaches' are 'dished' ...machined and 'tapered' to achieve the 'end' being 3% larger than the required 'hex'...eg 5mm hex needs a 'broach' 5.15.......6mm hex needs a 6.15 broach.
A corresponding hole (again 3% larger) is bored into the work piece...then 'chamfered'.
The 'broach' with it's 'machined' plumbing fitting (removal tool) together with the 'workpiece' are then 'pressed' together in a sturdy vice. The end of the 'broach' is then held between the jaws of the vice and two spanners used in opposite directions on the 'brass removal tool' and the task is complete.
Below are some shots of the manufacture of this system..it's operation in creating an 8mm 'hex'...and my 'box of tricks' ..all home made for this process which I hope clarifies the process.
Oh, and Dick (racasey) it's not suitable for broaching in stainless steel..I tried it today.
Cheers for now
Brian.
Attached Images
                            
BG Wells is offline  
Sponsored Links
Advertisement
 
post #2 of 13 (permalink) Old 09-29-2012, 05:23 PM
Senior Member
 
quad-turbo's Avatar
 
Join Date: May 2007
Location: Italia
Posts: 4,296
......and people say I'm a magician......beautiful work as always mate

ORBIS NON SUFFICIT
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
quad-turbo is offline  
post #3 of 13 (permalink) Old 09-30-2012, 09:04 AM Thread Starter
Senior Member
 
BG Wells's Avatar
 
Join Date: Aug 2009
Location: Lisburn Northern Ireland
Posts: 4,587
Quote:
Originally Posted by quad-turbo View Post
......and people say I'm a magician......beautiful work as always mate
Cheers Chris.... I'm not great with 'card tricks'...but I can make large chunks of metal 'disappear!' (a lot of them into the bin)
Thanks mate
Brian.
BG Wells is offline  
Sponsored Links
Advertisement
 
post #4 of 13 (permalink) Old 09-30-2012, 09:10 AM
Moderator
 
Donsy's Avatar
 
Join Date: Aug 2008
Location: Australia
Posts: 22,061
New Site Garage
I thought you said this one will be the simple method, great, now I'm more confused. Good job Brian. And Crutchlow almost got there !!!

Dons Nel
Own - Two F4 1000R's 06 and 07.
PayPal :
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

eMial:
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Mobile in Australia: 0438 385 776
Website with MV Manuals for Most models -
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Donsy is offline  
post #5 of 13 (permalink) Old 09-30-2012, 10:17 AM Thread Starter
Senior Member
 
BG Wells's Avatar
 
Join Date: Aug 2009
Location: Lisburn Northern Ireland
Posts: 4,587
Quote:
Originally Posted by Donsy View Post
I thought you said this one will be the simple method, great, now I'm more confused. Good job Brian. And Crutchlow almost got there !!!
Cheers mate!....If I can think of a 3rd way I'll make it the simple one!.
Glad you liked it...
Cheers Brian.
BG Wells is offline  
post #6 of 13 (permalink) Old 09-30-2012, 03:44 PM
Senior Member
 
oldbutspry's Avatar
 
Join Date: May 2010
Location: El Paso, TX
Posts: 694
Wow, that's great! How long do the broaches last?
oldbutspry is offline  
post #7 of 13 (permalink) Old 09-30-2012, 05:48 PM Thread Starter
Senior Member
 
BG Wells's Avatar
 
Join Date: Aug 2009
Location: Lisburn Northern Ireland
Posts: 4,587
Quote:
Originally Posted by oldbutspry View Post
Wow, that's great! How long do the broaches last?
Thanks...,they hold up pretty good Spry..and it largely depends on the 'material' your'e broaching. As I mainly work in 'non-ferrous' metals they last well...and being cheap to buy the allen key sets are easily replaced
Good way of broaching eh??... Thought you'd like it.
Cheers
Brian.
BG Wells is offline  
post #8 of 13 (permalink) Old 09-30-2012, 07:45 PM
Senior Member
 
oldbutspry's Avatar
 
Join Date: May 2010
Location: El Paso, TX
Posts: 694
Quote:
Originally Posted by BG Wells View Post
Thanks...,they hold up pretty good Spry..and it largely depends on the 'material' your'e broaching. As I mainly work in 'non-ferrous' metals they last well...and being cheap to buy the allen key sets are easily replaced
Good way of broaching eh??... Thought you'd like it.
Cheers
Brian.
Yeah, I'm actually quite tempted to try that. It looks a bit easier than the other machining you have posted about.
oldbutspry is offline  
post #9 of 13 (permalink) Old 09-30-2012, 11:11 PM
Senior Member
 
quad-turbo's Avatar
 
Join Date: May 2007
Location: Italia
Posts: 4,296
Quote:
Originally Posted by BG Wells View Post
Cheers Chris.... I'm not great with 'card tricks'...but I can make large chunks of metal 'disappear!' (a lot of them into the bin)
Thanks mate
Brian.
I'm not a magician either Brian but got the nickname 'Magic' from my pool/9 ball buddies

ORBIS NON SUFFICIT
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
quad-turbo is offline  
post #10 of 13 (permalink) Old 10-04-2012, 06:01 PM
Senior Member
 
Kreativ's Avatar
 
Join Date: Jul 2011
Location: Davie, FL
Posts: 1,004
this one i understand lol
Kreativ is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to use all of the features of the MVAgusta.net site, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome