Machining A Big Part for the Mark Twain Zephyr Train - Heavy Milling on the Horizontal Boring Mill

[Music] hello welcome to topper machine i'm josh topper what i have in front of me is the bottom of a diesel electric locomotive which i'm guessing is a switch engine i don't know what it was torched out of but based off of what i'm seeing here i'm guessing a switch engine um it's a four inch thick car body deck um and what we're gonna do is we're gonna trim this down um quite a ways and then we're gonna throw it up on the boring mill and face this whole thing down to one inch thick um it's uh right now it's four inch and this is actually for the mark twain zephyr which is being restored about seven eight miles from here and i do work for them quite frequently with the locomotives i do the mechanical and the electrical troubleshooting some track work things like that so with that let's get this thing preheated set up my guides and start torching [Music] [Laughter] all right so it's all cut out and next thing will be to get it up on the boring mill and we'll have to set up the angle plates and stuff but still a heavy chunk but it'll be a lot lighter when i'm done taking taking three inches off of what's there all right here it is set up on the boring mill um i didn't shoot any of that just because i knew it was going to be a fiasco and it went up there it's up there it's clamped down i'll walk you around show you the the setup and the cutter we're going to use and then we'll start cutting so you got to get creative sometimes on the boring mill these angle plates i actually built years ago for another job specifically for one job and i haven't touched them since and now they're being put back into service in this job and i had to make some custom clamps plus some other clamping and i think we're in good shape and then this is that cutter i use a fly cutter i made that uses the opposite corner of the cnmg inserts that wider angle you can see that now we need to take this thing from the full four inches down to one inch so we got three inches to cut off this thing that'll be fun so let's get going [Applause] [Music] wow [Applause] [Music] think foreign [Music] so [Music] [Music] oh up [Music] that's pretty nice finish that's our first pass there taking 125 thousandths um i'm not sure what rpm that is because this machine never had the the tag on it to say what rpm was but i select one that i feel was good and i feel it's a good speed um i was feeding eight thou per revolution 125 deep i'm going to try taking 200 this next pass and see how it goes [Music] [Music] them [Music] so so i left off last night i got 3 and 5 16 total thickness so i still have two and five sixteenths to take off and this is a time consuming job but that's okay it's way better than building a new one for the application so i'm gonna get my insert changed out and we'll start milling again [Music] [Applause] [Applause] [Music] [Music] [Applause] [Music] well that cut went a little better um i took 125 thousandths in a pass this time um for depth the cut and i sped up my spindle speed a little better and it actually handled it better decreased my run time per cut so i think i'm going to run with that and we'll just finish this thing off [Music] [Music] [Music] wow [Music] bye [Music] [Music] well we're down to an inch and a quarter that's two passes left i've been taking an eighth inch a pass i slowed my spindle down just a little bit and i actually sped up my feed i'm taking 12 revolution and everything's cutting really well the inserts lasting longer everything's doing really good at that speed and feed so we're gonna keep going with that [Music] all right so i changed my mind i'm gonna finish this tonight because i got about hundred thou to go and my wife's upset with me and i'm tired of being filthy so let's get this job done and out of here [Music] [Music] [Music] foreign [Music] okay truck [Music] two two two [Music] well there you have it the truck bolster for the mark twain zephyr started out as a um flame cut piece out of a nw2 locomotive that got scrapped four inches thick um in all total we took about a thousand pounds of material off of this thing between torching and milling all with the horizontal boring mill with a cnmg insert and a you know homemade uh fly cutter worked beautifully did the job perfectly so with that i've got some cleanup to do so until next time get out in your shop and get it done right the first time [Music] you

Channel: Topper Machine LLC.

Views: 12,464

Keywords: manual machinist, machine shop, topper machine, metal planer, metal shaper, sawmill, shop built sawmill, DIY, homemade, monarch lathe, Bridgeport milling machine, lathe work, boring mill, HBM, drill press, metal lathe, milling machine, welding, press brake, #marktwainzephyr, #zephyr, mark twain, mark twain zephyr, restoration, train, locomotive, diesel electric, wisconsin great northern, wgnrr, Heavy machining, material removal

Id: TgBWCUGq3mo

Length: 14min 27sec (867 seconds)

Published: Fri Dec 24 2021