How do I file square? - and what files?

[raynerd]

Hi guys

I`m just about to start my first project, a small carriage stop which looks very simple as it is only 2 fabricated parts made from ally square 0.5x0.5" and 1.5" long. Once upon a time I would have ordered some 1/2" square ally and cut to size but realise that this is not practical and I have a nice 1.5" ally block that I can cut the part from. So I have marked out and ready to cut by hand and obviously without a mill it won`t be true and will need tidying up.

How do I file the sides by hand so that they are true, to size and the edges square. Are there any techniques I should be using and are there any ways of testing or checking? I`ve not filed metal in over 3 years, but I remember in my previous attempts I use to end up with a beveled edge and not a flat surface. I want to check I am doing it correct this time. What sort of metal files should I be using for this job?

Any advice appreciated.

Chris

[Darren]

You might want to consider using the lathe to square things 

[sbwhart]

Chris

I trick an old fitter once showed me was getting the vice at the correct height:- the top of the vice should come level with your elbow when your standing straight with your arms down your side, this way you don't file with to much of rocking action. Just put wooden blocks under the vice to get it right.

Stew

[raynerd]

smashing - so with regards to the filing there really is no trick - I know with rounds you and John showed me how you can clamp a bar to it and file it to the same circle but is there no such tricks with flats?

I mean again, I thought I was sensible taking on this mini project with only two pieces - is this a stupid attempt without a mill? I just presumed it could be cut with a saw and filed true?


Darren - yes, may consider using the lathe to true the bits up. Do you mean putting the job in the tool holder and using an end-mill in the headstock chuck?

Chris

[kvom]

You can chuck the piece in a 4-jaw and turn one side flat.

[Darren]

You can put the work on the compound slide and a milling cutter in the chuck.
Or mount the work in the chuck if it will fit and lathe it flat/square.

If you want to file it clamp it between two pieces of angle iron in the vice.

[raynerd]

Well I have just cut it out from the block and looks like a dog has been at it. I will have a think - I`m going collecting my lathe from Johns tomorrow night so will take it with me and see what he would do - with my kit!

Darren - thanks for the idea regarding clamping between iron as a straight edge.

kvom - don`t have a 4 jaw yet but never thought of that idea, I only thought of "milling" it how Darren explained.

Chris

[Darren]

Before I had machines I used to file with angle iron and an angle grinder fitted with a flap wheel.

It works quite well. Finish off with proper filing though.

[bogstandard]

Chris,

I`m going collecting my lathe from Johns tomorrow night so will take it with me and see what he would do - with my kit!

As I told you by email, I will help anybody, as long as the time frame and whether it suits me comes into it.

I will not be treated as a charity to be called on whenever it is needed. It just so happens I have a major appointment tomorrow with a spinal specialist, so tomorrow afternoon, I don't expect to be able to walk properly never mind discussing how to do something.

The gibs on your lathe have been done and it is all running ok, but because I haven't been feeling too well, and because I have another job that has taken up what little time I have had in the shop (now overun by at least a week), I haven't been able to get the handwheel done. So the lathe can be picked up tomorrow, but the mod will have to wait until another time.

John

[raynerd]

As I told you by email, I will help anybody, as long as the time frame and whether it suits me comes into it.

I will not be treated as a charity to be called on whenever it is needed. It just so happens I have a major appointment tomorrow with a spinal specialist, so tomorrow afternoon, I don't expect to be able to walk properly never mind discussing how to do something.

With the greatest respect, John, I was meaning to seek advice as to what you would do with the piece in my circumstance and with my kit during our prearranged meeting tomorrow. I was not meaning to "treat you as charity"... I sha`nt bring the piece.
Apologies if I have caused offense.

Chris