The most expensive hole || Guts' Dragonslayer from Berserk (Part 8)

in the last part of this build I attempted to machine off all the weld but it ended up as one of the biggest and most frustrating catastrophes of my career when I had finally resolved the issues I ended up accidentally cutting the chain link in half now let's see if I can redeem myself and get this project moving along again well as you can see we're here in my office again now I know it's only been a few weeks since the last time but I've totally revamped the decor in here it's still a work in progress but we're getting there here let me show you real quick I've got all my little knickknacks kind of gather in the corner over here and redid All the movie posters and flags and all that stuff this wall back here is kind of a red wall now you can see the little mock-up I've got there of the Cross it's gonna be a giant version of that little neon cross eventually shockingly expensive for a six foot tall neon cross who would have guessed got my buddy down here wondering what in God's name I'm doing and what I'm talking about now the real reason we're in here to talk about today's video sponsor raid Shadow Legends raid Shadow Legends with a totally free turn-based MMO style mobile game with many different game options including PVP and PVE now Ray had asked me to literally spell out this game for you so let's get to it R is for the ridiculous amount of Champions there are already several hundred champions in the game with more being released every single month so down here you've actually got this index of Champions where you can browse all the different factions and all the different Champions within them regardless of whether or not you actually have the Champions now this is Ella guys the champion I'm trying to get it's pretty mean looking but I'm mainly interested in this weapon kind of hard to show it here but it's kind of like a pull sword maybe a glaive or something like that honestly I'd like to build this thing someday leave me a comment down below if you'd like 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in half thing I was sitting here wondering how did I not calculate that out correctly how did I not think about the fact that I would drill through the bolt and I realized I actually did consider that in fact I actually did plan it out I planned the whole depth precisely I planned out the threaded portion of the handle precisely I made sure that I wasn't going to hit that bolt but that what happened is all the issues with cutting the hand guard in half I ended up removing quite a bit of extra material in that process uh you know inadvertently through a large theory of screw-ups and then when I had the welding nightmare where I had to re-weld it uh nine hours straight basically I took so many Milling passes you know there were light passes but it ended up being quite a bit and so the this material is quite a bit shorter than it was planned out to be is what I'm trying to say however the icing on the cake is I was supposed to drill the hole an inch and a half exactly and while I was drilling it I was like oh let's just over drill it a bit to give myself a little bit extra room right because you know uh the the drill bit doesn't have a perfectly Square end on it it's rounded over right so I wanted a little extra clearance for the handle you know so on and so forth not thinking back months ago when I actually planned out the dimensions of the thing and long story short multiple screw-ups leading to a much larger screw up so I'm gonna deal with this thing later I'm gonna finish up the Machining here there's not much I can do about the that bolt for the moment I'm probably just gonna weld it inside the hole that's probably the best bet all right let's get going on tapping this and then we can do the circular decorations on either side of the hole and that should pretty much finish up the Machining at least oh there's one more detail that makes this bolt cutting incident much more serious than I initially realized the issue is I was using that bolt to hold together the two halves of the handguard so that when I welded it it didn't you know warp up the pieces didn't warp away and well you can probably guess now there's clearance I don't know if you can really see it yeah it's quite a bit of clearance under there that end is picked up so same thing on the bottom you can see daylight through there I can't really tell them the viewfinder but it's not good uh that's gonna take another whole plan yeah foreign [Music] well that hits keep on coming I don't know how many mistakes I can make in a row but I'm definitely setting the world record here I'm actually not even sure what happened I'll have to review the footage what I was trying to do is I was trying to feed the table away from the truck so that I had clearance for the tap so I could move the table over and I think I did it the wrong way so the blade of moving towards the machine I'm not really sure how I could have done that but I think I threw the wrong lever when I was trying to fix it so then the table started going this way and it shatters a tap it may have broken before then I'm not even sure but it all happened in a span of you know one second I guess but uh uh we got a trashed call it it's all destroyed on the outside there the cap well I guess I don't have to worry about damaging it with that pipe wrench anymore that's the uh the end of that I've never seen it to have this big break before and honestly I'm shocked that the machine didn't break or something didn't break in the machine because that had to have been a lot of force but everything the machine seems fine it runs perfectly I just got to replace that collet and I got to get the other half of that tap out there that is gonna be awful can't wait [Music] look at these threads [Music] well the good news is this might be salvageable you can see right here when the tap kind of Twisted to the right it must have torn up partially torn up some of these threads right here the rest of them do not look bad just some on the right side so let's see if I can try to like remove these and then run a new tap through it so I started the camera a little bit late but a random Pro tip if you ever break a tap off like that especially one that big the thing about Taps is they're very very strong but very very brittle so I just use a punch and a big hammer and I just hit it enough times that it basically shattered the tap into little tiny pieces and I was able to pull them out so at least that's one problem down I just realized in a viewfinder you can see the holes the vertical hole where the eye bolt went through I guess that would have been noticeable to me at some point so it probably wouldn't have been a catastrophic and fatal failure later on Maybe all right I don't know if the top handle within the way of the camera I just suddenly realized the angle may not work but I've gotten the task started this is a new tap I think I followed the previous hole it seemed straight in both directions so I'm just going to continue to hand tap it here extremely difficult I have to use this pipe on the um on the handle here it's kind of like carving its way through all of the debris in there and the kind of partially torn threads and everything I'm pretty sure I've already ruined this tap as well I heard some cracking so I'm just gonna keep going until I can at least clean it up enough to take a look all right we've got a few threads in there it looks uh pretty salvageable I'd say you can see a little bit of damage right there at the bottom doesn't look too bad you see the teeth on the tap are broken off at the end here right about there I'm gonna go a few more turns just to make sure I've gotten through the bad stuff and then I'll swap out the tap just so I don't ruin a third tap by the way these Taps are like 250 new that is one expensive hole that's all I can say [Music] [Music] foreign [Music] well fatality number infinity I broke uh the end of this tap wrench off uh that's fantastic all right I'm using my biggest adjustable wrench here I don't know if you can see how big it is it's a 24 inch hopefully this gives me enough torque and hopefully this tap doesn't break all right this chat's got several chip teeth it's getting really hard to turn I'm afraid I'm gonna break it I think we've gotten enough I've got like four or five threads we're probably over half an inch deep now so I'm gonna put you to a better tap and hopefully I don't break that one too easier well I say that while holding a two foot long wrench so [Music] okay well that was uneventful thankfully you can see we've got threads all the way to the end there looks pretty good you can see the damage right there not awful we have plenty of thread plenty of strength all right let's handle these two little circles on either side here real quick and then move on from there so I was just about to finish up for the night after putting these two circles in there and I realized how well you can see that but they're off I'm somehow keeping the street going here that one is too far to the right that one is too far to the right I haven't confirmed this but what I think happened is I originally did the math that these two circles would be an inch and three quarters from the center hole so when I had this Center hole lined up with the spindle I zeroed out my display over here and then you know I've been doing all my work based off of that location I think when the tent broke it shifted the whole thing over slightly and I didn't realize it so I was still thinking you know it was zeroed out on display was the center of this hole and it was not it was probably slightly to the right and then so I just counted over into three quarters put one here it went back here inch and three quarters you know put the other Circle and they're off so uh yeah uh luckily they're nice and shallow I guess what I'm gonna have to do is I'm gonna have to unclamp this whole thing I'm gonna have to realign everything perfectly again I'll re-weld both these circles skim it off again and then put new circles in in the right location should only be like three or four hours of waste of time I should be used to it by this point all right so it is now almost two weeks later I actually ended up getting really sick with a sinus infection and after my long train of repeated mistakes I was kind of burnt out so it all coincided for a nice little break but here we are again we gotta weld up the improperly placed circles I would like to take it but given on the incredible amount of problems trying to weld on the other parts of this I'm just gonna make it and then I'll Mill it flat again for like the ninth or tenth time and then I will attempt to correctly place the circles you know again side note if you look very carefully you can see the blue outline just part of it of where I had laid out the where the circles are supposed to be earlier of course I can see it now but when the blade was over in front of the spindle and I had the cutter sticking out I couldn't actually see that little blue line that would have told me that I was off so whoops all right so here we are we are all done I didn't bother filming any of it because it's exactly the same procedure I just weld out the circles and I did it twice actually because there was some minor defects milled the whole thing flat and then put the circle back in the funny thing is I almost screwed it up again the second time I had basically done the math wrong I don't know if you can really see this but there's two blue marks these are the outside of the handle when it's attached and so I need this gap between the handle and the circle to be the same as this and I mean as you can see it's very close same over here I actually had it off by I don't know it was fifty thousandths of an inch one point two five millimeters not crazy but you probably would have noticed it and I definitely would have re-welded this and redone it again so yeah I guess like a lucky uh checking and rechecking this time all right so that is one major screw up that I have resolved let's work on the one where this thing is lifted up off the surface I've got a pretty good idea how I'm gonna do this now since it's literally been weeks and weeks since I scooted up originally I had plenty of time to think about it let me uh get this set up and I'll explain what I'm about to do oh the cat here on this thing I wonder how that happened do you know anything about this yeah I don't think so all right part of the noise my air compressor is filling up in the next Bay but my idea is to get this thing to kind of squash back down is very similar to how it was held in the first place you know this part of it anyway I'm gonna drill a hole all the way through both pieces and ideally I would just bolt it together so I can kind of you know squeeze the whole thing together and then just weld over the top with a plug weld grind it all smooth and you'll never see problem is this thickness is not enough I had used a half inch bolt before and here's one of the nuts you can see it actually does fit I mean barely I could could potentially make a hole there but the problem is you know how do you tighten that here's the socket for it and it is actually larger very slightly larger than the width of this thing so that is not going to work without some major hassles so what I'm gonna do is I'll drill the hole and I will insert a modified bolt I'm going to cut down the head of the bolt so it's not so wide and then I'm going to squeeze the whole thing together with a press and I'll weld the boat in place while it is squeezed together so it'll stay that way eliminating and that'll eliminate the need for a nut and the clearance for it and the associated socket so should work it's just going to be trickier all right one final note as much as I hate to do it we're going in dry on this one I can't risk oil contamination of this hole because it's going to screw up my weld and I'm just done with all that for now all right all right so I drilled the whole half inch and then I drilled an additional recess 5 8 of an inch so I'll have a shoulder you kind of see it down there a shoulder for both the sit against this is what I made it's just a bolt Allen head bolt that I turn the head down and then I cut it to length so the idea is foreign it's just under the surface there and you can just see it it's uh just under the surface on the bottom I cut it a little shorter because you know as these plates compress together I'm you know it's going to take up that gap on the bottom so this is looking pretty good now I need to press this together somehow and I have an idea for that okay well this took several hours it actually took uh two nights or so I ended up in order to kind of squeeze these together I had a bunch more clamps than this I'm just leaving these here for the time being you can see how tight these are you see the bend in this clamp it's on there really really well and I use my torch to heat up the whole thing to basically red hot in fact I can really feel that actually is almost painful having my hand that close I actually wonder how hot this is uh it's pretty hot it has literally been like 10 minutes since I stopped so yeah it's up there I don't know if I actually explained but this is actually the bolt here I'm trying to get my hand too close that is really hot I'm actually it clamped the bolt down into the recess there and then I welded it from the underside can you see that yeah yeah there's the weld right there you can see the tack weld at the end but I think we got it as good as we're gonna get it now let's see this it looks like there's a gap but I literally could not move the clamps at all yeah that is I don't see any daylight through there I think there's just a slight chamfer on the bottom of the Guard piece and it makes it look like it's off the surface but I don't see the bottom here any daylight I do not see any daylight at all that's about as flat as it's gonna get I see a little daylight over there but that's the guard ends right there it's very dark so daylight is actually under the sword itself all right instead of worrying with a visual here I figured I'll take a piece of paper paper is you know four thousands of an inch thick or so and let's see can we slide it under the guard can't really see what I'm doing just the tiniest bit only maybe the last little bit the corner of the paper and then it stops it's really just that Outer Edge I've lift it up slightly but I think that's as good as it's gonna get uh I don't know what I could have done better I basically use every clamp that had enough reach to actually get to the to that location there a big hydraulic press would have been good but I don't really have anything like that and even if I did try to get this sword onto it would have been a nightmare I guess I'll call it good for now I'll let this thing cool down for like uh you know about a week and then we'll take these clamps off and see how it goes all right so I got all the clamps off let everything cool down it didn't really move too much I don't think I actually moved at all so my little welded bolt trick seemed to work well with the top and bottom and I'm actually going to try using this long End Mill to just face the top of this off I've never tried anything like this before it could be disastrous so I made sure to use my most expensive cutter that's brand new never used it ever so I guess we'll see how it goes discovered that my cell phone actually has some pretty excellent low light capabilities so I ended up switching over to that for the shot I love how trippy this looks it's almost mesmerizing and of course since I had my cell phone out might as well add some slow-mo action to the shot okay uh machine the top and bottom I had to touch up the weld on both sides and then re-machine it again it's actually like two days later now but I think I'm pretty happy here I did find it kind of interesting the way the light plays on the machine parts you can actually see where the welds were they they're like wrinkly looking you see up there I mean it's perfectly flat a few of like glass because it just looks wrinkly you can see how perfect that is kind of funny over here it's like a little duller because I guess the machine must have some more wear in this part of the travel and then it gets you know shiny over here and then dull again so it's just uh you know we are in an 81 year old machine but it's just interesting how it kind of shows up like that all right so last screw up to be fixed here is the chain link that's on the other side of the sword so let's get this unclamped let's flip it over and let's see what we can do there all right so we need to weld this thing back on from the inside I've got it positioned perfectly and let's see if this works all right if I found a nice bright light in here you can see the the remnant of the bolt sticking down through I'm gonna flood this whole area with that anti-spatter stuff I'm gonna weld it maybe it's actually pretty deep if you look at it from this way I'm not even sure if I can reach it but ideally I can weld it and then I'll run the tap through it again to clean up the threads if any spatter gets in there because otherwise it's going to require much more severe Solutions all right as you can see at the very bottom of that hole there's like three significant tacks on there at the bottom of the hole there you can kind of see those BBS very hard to get the light and the camera at the same time let's see if they're stuck all right it doesn't appear to I think there's maybe one that stuck Let's uh let's run that tap through there real quick and see if we can clean that up oh yeah I got this sweet uh Greenfield tap wrench this is an old school one it's probably three times heavier than the one I broke so tool upgrade yeah not too bad it's just a little resistant I'm not even using any lube because trying not to contaminate that area again in case I need to weld it but that's it I just bottomed out pretty good all right now we are on to the pommel I am going to be carving it out of this three inch square stock here I was originally gonna do the angles with a band saw and by angles I mean these angles here as you can see from my highly technical blueprint I've used a bents on the past it works out pretty well it's a little bit finicky trying to get all the angles exactly the same but it's no big deal however my bandsaw is in the bay through that door which is unheated and it is currently negative six degrees and I really don't want to deal with it so in the interest of using this milling machine a little bit more kind of working out some of the bugs a bit more getting more familiar with all the changes I've made I'm just gonna do it here I figure it'll come out really accurately too because for example I'm making this first cut here this is yeah flip this around these are the short cuts at the end that's pretty much what I'm starting with and I've got a stop on the end here so that I can just flip it you know three times after my first cut and then all the cuts will be exactly the same dip exactly the same uh you know position and so forth so it should be very accurate with minimal work if we we spring over here for a second you can see I've already faced off the end it's nice and flat it's perfectly perpendicular to all the sides just to give me a good starting point all in all should be pretty simple operation it's just gonna be once I get the the shape of the thing all these angles done I can't really show it to you here but the the 45 degree chamfer to all the angles as well maybe I'll put it up on the screen if I edit this later I will probably take the stock and put it in a v-block so it's angled at 45 degrees and then just repeat the cuts something like that but uh stay tuned we'll see how it goes foreign so I happened to catch this during filming but this is how I usually do things I keep a large variety of source material images on my phone so while I'm working I can check and recheck if something looks correct boy that is tight all right here she is Fresh Off The milling machine Burrs and all you see the surface finish is not that great but I wasn't shooting for a good surface finish still a lot seem worse especially considering this is mild steel it tends to be pretty gummy and leave a kind of nasty surface finish yeah I'm uh pretty happy with this I'd say it looks pretty good we've got everything we need all the bevel the done everything kind of lines up just about right okay so this sort of a jump cut here due to a lack of filming but I ended up just cutting the pommel off of the larger piece of stock Milling the cut and flat and now I am drilling it so it can be threaded to attach to the handle itself all right so one of the handiest things about tapping on a milling machine is this little tool right here this is a spring-loaded tap follower it's actually pretty tough but it's designed to go into the the center hole on the back of any tap so you can just kind of do this and then you can press down the spring and keeping tension and now you can you know manually turn the tap and it will go in perfectly perfectly perfectly straight normally I have a power tap uh this is a big tap it's just a lot of torque and I'd rather just do it by hand I suppose no real reason for the machine can probably do it I've just never tried it I'm only tapping you know one hole here so who cares how long it takes probably hell if I put the tap wrench on first foreign all right final step here is just a little countersink and we're good to go all right that's it nice clean tapped hole the thing you've actually done other than just hand sanding it uh to give it a final finished look let's go get on that right now in fact [Music] [Music] all right that's about it for this pommel here I would say we're done uh sanded it out to 120 grit uh it's probably as far as I'll go it's slightly rough but clearly the dragon slayer is not some polished piece of Fine Art so I'm calling this good it's pretty consistent finish everything kind of lines up pretty well I intentionally softened up all these lines and bevels just to kind of make it so it doesn't look quite so machined I mean it's still pretty straight and nearly perfect but you know goto didn't have access to a milling machine so it needs to look somewhat natural and besides the fact that I basically screwed everything up numerous times like introduced enough imperfections that I would say were looking pretty good here this is a happy chunk by the way this is a solid six pounds almost on the dot and I did make this removable so that you can unscrew it and throw it at your opponent to end them rightly of course Tiny side note here but this actually took me three days worth of hand sanding to get it to look like this problem is when you're ascending say one of these little bevels if you put a little too much pressure say on the left side like right here this line moves outwards and then it doesn't match up with this line on this side of the bevel and then so you get a sand this one a little bit but now they're both you know a little bit off like this part is wider than it is down there so you gotta sand it down there a little bit more sand it down here a little bit more on and on and on and then finally when you get everything perfectly matched up it looks like you know it's pretty good like it is now but then you realize that this line is off so then you have to do more sanding and then you know on and on and on I just kind of I would spend an hour on it I'd come back to it later I'd see a new flaw I'd sand that out you know try it later and on and on and on and on and on but I think I've got everything that looks pretty solid I would say it's a little wavy here and there but honestly I'm a rabid perfectionist and at this point I know I'm done because I'm slowly making the piece worse and I think once I'm making it worse I have reached the limit of my capabilities and we are officially done so all done on to the next thing all right so I heard to be a real YouTuber you gotta pick your merch in every single video so here we are I paid a really excellent artist to make me some 80s inspired phm designs and she gave me four of them I was gonna pick one but honestly I like them all so here they are I got this one right here I've got this one as well very nice I really like the color scheme on this one but I think this one's my favorite it's kind of got like outrun slash Motley Crew Vibes definitely right in my wheelhouse all right that's it see you on the next part

Channel: Pretty Hate Machining

Views: 33,549

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Id: QY8fmxtkLck

Length: 36min 42sec (2202 seconds)

Published: Sat Mar 25 2023