Hulett Ore Unloader in 1:32th

[Ray Dunakin]

Wow! Just...wow!

[Design-HSB]

Bernhard, I really like the development, and I am happy to be able to follow the construction progress.

[Bernhard]

Thank you for your interest and the motivating comments!

In the meantime, I have made some progress. The front plates of the towers are too big for the rivet punching machine. I therefore have to solder in a few rivets as pins.




The rivets on most of the angle profiles are punched. However, I drill holes in some angles for the exact positioning of add-on parts.

[Bernhard]

The first angle profiles are fitted, ...



... then the first front panel can be test-fitted to the frame in its unfinished state. A few more angles as well as reinforcing and joining plates are still missing.



My dynamic colleague stood next to the tower to give you an impression of the proportions.

[Bernhard]

Mounting plates are soldered onto the rear panel, onto which the bearings of the drive shafts are later screwed.



I drill the core holes for the M1 threads on the CNC machine.



I cut the threads by hand on the conventional milling machine. I have a small collet chuck in which I can clamp the tap. The collet chuck has a cylindrical shank that I can hold in the drill chuck of the milling machine. I close the drill chuck so far that I can just turn the collet chuck and move it axially. Then, with a lot of feeling, I can insert the thread exactly vertically without breaking off the fine tap.

[Bernhard]

Once the front and rear panels have been prepared, they are glued to the frame of the front tower.



Fix well and then wait for a day.




You can already see the result.

[Bernhard]

Now two side plates have to be built. This requires a few angles ...



... and CNC-milled sheet metal.



The finished side plates are attached to the tower with pin rivets.

[Bernhard]

I also need two supports for the platform on the left side of the tower.





And this is the current status.



Now only about 200 more parts are missing for this foot, all of which still have to be made. So, here we go.

Bernhard

[1-32]

Hi Bernard.
Totally fascinating how all this is coming together.
cheers

[finescalerr]

Wow. -- Russ

[Hauk]

As I might have said before: A work of great beauty.

A big inspiration for getting serious with my own machining. A couple of practical questions: what type of brass do you use, and where do you buy your sheets of material? I am also very curious about your spindle and feed speeds.

[Bernhard]

Thanks Kim, Russ and Hauk.

Hauk, I use two types of brass:

• Ms 58 (CuZn39Pb3) hard for flat and round material. The material is very easy to machine.
• Ms 63 (CuZn37) semi-hard for sheet metal. The material is easy to cold form.

I purchase the material from a local dealer.
I am relatively careful with the cutting values when milling. Under no circumstances should you use the values recommended by tool manufacturers for industrial use. I run the spindle at a maximum of 10,000 revolutions. Otherwise, because it is only air-cooled, it heats up too quickly.
I normally work with 2-tooth cutters with a diameter of 3 or 4 mm at a feed rate of 50 mm/min.
You have to work your way up a bit from the bottom. The optimum cutting data certainly also depends on the stability of the machine.

Bernhard

[Hauk]

Thanks Kim, Russ and Hauk.

Hauk, I use two types of brass:

• Ms 58 (CuZn39Pb3) hard for flat and round material. The material is very easy to machine.
• Ms 63 (CuZn37) semi-hard for sheet metal. The material is easy to cold form.

I purchase the material from a local dealer.
I am relatively careful with the cutting values when milling. Under no circumstances should you use the values recommended by tool manufacturers for industrial use. I run the spindle at a maximum of 10,000 revolutions. Otherwise, because it is only air-cooled, it heats up too quickly.
I normally work with 2-tooth cutters with a diameter of 3 or 4 mm at a feed rate of 50 mm/min.
You have to work your way up a bit from the bottom. The optimum cutting data certainly also depends on the stability of the machine.

Bernhard

Thanks a lot for the info!

I see that you too use very slow feeding, and it seems this is the key to success when milling metal on relatively light CNC-routers.

[Ray Dunakin]

It already looks impressive!

[nk]

Wow wow wow even without those 200 parts