Author Topic: My latest project. Gingery horizontal mill  (Read 22522 times)

Offline Gadget

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My latest project. Gingery horizontal mill
« on: November 23, 2009, 10:47:54 PM »
I have just started building of a horizontal milling machine using the Gingery plans. I have already built the lathe but sold it quite a while ago. I will be adding photos when I have something to show.  So far I have nearly completed the bed pattern. I hope to pour it in two weeks (visiting kids over Thanksgiving weekend so no project work then)
I might shoot a video of the melt and pour when I get to that point.
« Last Edit: November 24, 2009, 12:26:32 PM by Gadget »

Offline Bernd

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Re: My latest project.
« Reply #1 on: November 24, 2009, 09:51:22 AM »
I might shoot a video of the melt and pour when I get to that point.

That would be great to see. I've got the searies of books put out by Unka Dave, as Lindsay would say.

I was going to go that route. The farthest I got was making the aluminum foundry.  :dremel:

Bernd
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Offline chuck foster

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Re: My latest project. Gingery horizontal mill
« Reply #2 on: November 28, 2009, 10:26:20 AM »
making a horizontal milling machine.............now that sounds like a BIG project  :bugeye:
i will be watching this project unfold.

do you have any pictures of the lathe you built???

chuck  :wave:
hitting and missing all the way :)

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Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #3 on: November 28, 2009, 05:10:05 PM »



do you have any pictures of the lathe you built???

chuck  :wave:

I looked for the photos a few days ago. I have one I have to blow up but it will be grainy. I am not home at this time but when I get back I will post it.

Offline Gadget

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Gingery horizontal mill first bed pour.
« Reply #4 on: December 06, 2009, 08:26:19 PM »
This is the first attempt at casting the Gingery mill bed. My sand hasn't been used for a couple of years and was bone dry. I put too much water in the mix and had a steam blowout. The sand should be just about right by next week when I try agan. I used the gas burner today because I don't have enough oil. I also don't have a vent hood yet and the melt had to be done inside, too cold outside.

http://www.youtube.com/watch?v=_Qo68Ocvw_E

Offline chuck foster

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Re: My latest project. Gingery horizontal mill
« Reply #5 on: December 06, 2009, 08:46:29 PM »
that's too bad about the steam blowout  :( 
can we possibly get some info on your furnace, my dad and i have talked about doing some casting but that's all we have done is talk.

hope the next pour turn's out better.

chuck
hitting and missing all the way :)

skype:  aermotor8

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Offline Bernd

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Re: My latest project. Gingery horizontal mill
« Reply #6 on: December 06, 2009, 09:32:16 PM »
Nice neat shop you got there Gaget. To bad the pour didn't turn out for you.

Chuck, Gingery's series of books on the aluminum foundry might be a place to start, plus a couple internet searches will give you some answers. But why do that when we have an expert right here that knows how.

Bernd
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Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #7 on: December 06, 2009, 09:57:53 PM »
I knew I got the sand too wet but decided to pour anyway. I'm sure the sand will have dried out enough by next week to get a good pour. I have been casting for 20 years off and on so I'm sure I will get it right.

Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #8 on: December 06, 2009, 10:03:35 PM »
that's too bad about the steam blowout  :( 
can we possibly get some info on your furnace, my dad and i have talked about doing some casting but that's all we have done is talk.

hope the next pour turn's out better.

chuck
My furnace started out as the Gingery electric furnace. I used it that way for about 12 years but the element burned out and I decided to convert it to propane. I can post some burner photos later. I have both propane and waste motor oil burners both of my own design for the most part.
The blower is from an old Royal vacuum cleaner which is why it is so noisy. The hinged lid and cart was just pieced together as I saw the need.

Offline Gadget

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Successful casting of the mill bed.
« Reply #9 on: December 13, 2009, 06:39:00 PM »
This is the second attempt at the Gingery mill bed casting. My sand has dried out enough for a pretty good pour. Top and bottom surfaces are nice and flat. No rocking on a flat surface. I also modified the air inlet of the burner. I have much better control of the air flow now.


http://www.youtube.com/watch?v=hqXfmLxRqCw

Offline Powder Keg

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Re: My latest project. Gingery horizontal mill
« Reply #10 on: December 13, 2009, 06:45:40 PM »
Great show!!! Thanks for posting:o)
Wesley P
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Offline chuck foster

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Re: My latest project. Gingery horizontal mill
« Reply #11 on: December 13, 2009, 07:40:49 PM »
looks good..............i'm glad the second pour worked  :thumbup:

chuck  :wave:
hitting and missing all the way :)

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Offline Darren

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Re: My latest project. Gingery horizontal mill
« Reply #12 on: December 13, 2009, 08:08:49 PM »
Great to see it worked for you this time ... I'd like to be able to cast ...  :clap:
You will find it a distinct help… if you know and look as if you know what you are doing. (IRS training manual)

Offline Stilldrillin

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Re: My latest project. Gingery horizontal mill
« Reply #13 on: December 14, 2009, 03:45:48 AM »
It`s a great feeling when things go right.....  :ddb:

Well done!  :thumbup:

David D
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Online Brass_Machine

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Re: My latest project. Gingery horizontal mill
« Reply #14 on: December 17, 2009, 03:20:25 PM »
Very Very cool.   :nrocks:

Eric
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Offline dsquire

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Re: My latest project. Gingery horizontal mill
« Reply #15 on: December 17, 2009, 03:37:37 PM »
Gadget

Glad to see that the 2nd pour went better than the first. At least in casting you can reuse any bad parts unlike in machining operations. It will be interesting to follow along with the rest of the build as you progress. Thanks for showing us this.  :ddb: :ddb:

Cheers  :beer:

Don
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Re: My latest project. Gingery horizontal mill
« Reply #16 on: December 17, 2009, 03:41:40 PM »
GREAT JOB Gadget 

This looks like a very interesting project to follow,,,,,, :clap: :clap: :clap: :clap: :clap: :clap:

Regards Rob

Offline websterz

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Re: My latest project. Gingery horizontal mill
« Reply #17 on: December 17, 2009, 07:39:44 PM »
Go Go Gadget Furnace!!  :zap:


Sorry...I couldn't help myself.
"In the 60's, people took acid to make the world weird.  Now the world is weird and people take Prozac to make it normal."
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Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #18 on: December 17, 2009, 08:37:41 PM »
Thanks guys. This weekend I will be pouring another bed casting for a friend, then on to the mounting bases.

Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #19 on: December 26, 2009, 05:41:22 PM »
I had a busy day today. I cast mounting bases for the Gingery mill for me and a friend. I had to shake out the first pair to get enough sand to cast the second. I didn't quite have enough for two large flasks.
Anyway, all four castings turned out quite well. The bed surface has been hand scraped true flat so the next step is to surface the mounting bases and mount them to the bed.

Offline cjoscelyn

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Re: My latest project. Gingery horizontal mill
« Reply #20 on: December 26, 2009, 07:03:15 PM »
Really looking good! I built the lathe and mill in the mid eighties when the Dave Gingery books first came out. I learned a lot from the series and really enjoyed metal casting, it get's addictive.

Charlie

Offline Gadget

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Re: My latest project. Gingery horizontal mill
« Reply #21 on: December 26, 2009, 07:12:32 PM »
I also built the lathe in the 80's but never got around to the mill and shaper.

Offline Gadget

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Gingery horizontal mill update
« Reply #22 on: January 10, 2010, 04:42:02 PM »
I poured the first of two mill head stands today. This was the most complicated patterns in the build and it turned out as close to perfect as I think I will ever get. It's a split pattern with deep thin pieces that have to be pulled from the sand. I had my doubts that I would be able to pull the patterns without damage but they pulled very nicely.
I also cut the bed ways and got the first two bolts inserted. The rest will be easy now since the ways will not move when doing them.

Offline Bernd

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Re: My latest project. Gingery horizontal mill
« Reply #23 on: January 11, 2010, 09:27:27 AM »
Some very nice looking casting. It'll be interesting to see this machine from begining to end.

Keep up the great work and posts.  :thumbup:

Bernd
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Online Brass_Machine

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Re: My latest project. Gingery horizontal mill
« Reply #24 on: January 11, 2010, 09:01:18 PM »
Very cool. I love to see people casting their own stuff. Building your own mill! Now that's classic! My hat's off to you sir!

Eric
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