Tips/Techniques Making the Square Drive hole in a custom socket.

[ChazzC]

Make a 2-3/8” OD plug for the drive end with a hex on one end to match the largest socket your friend has and turn down the other end to match the ID of the pipe for maybe a half inch. Push the plug into the pipe, drill & tap M6 three radial holes into the plug, insert screws and deliver to your friend.

2” Sc40 pipe is 2-3/8” OD x 2.07” ID


EDIT: had to fix OD size, so added pipe info, too

 

[ChazzC]

Older shakey and mostly blind back atcha. Whazzat this braille method you speak of......

Just wanting to learn something.

Braille welding is what you learn if you’re like a guy I know who used to stick weld by closing his eyes right before striking an arc: he claimed he was (mostly) successful.

 

[jorogi]

Also, apparently you have TIG and know how to use it. Which excludes me from your thinking.

But ya, definitely looking for an excuse to use a shaper.

SWMBO - WTF is that new machine you got?

HWMO - It's a Shaper honey! I needed it to make that custom propeller wrench for our son. You know, the wrench he had to borrow because he couldn't afford one of his own! It's for that new 200ft boat he got for his wife and our grandkids.

SWMBO - OHHHH! That new machine of yours did that! Well it's about time you bought something useful! I'm getting very tired of all the stuff you buy for this stupid farm you know!

HWMO - I know, but don't forget that the farm let's me write off the machine I got to look after our son's family.

SWMBO - OK, I didn't think of all that. It turns me on when you do stuff for the kids you know.

HWMO - Ya, I can be pretty thoughtful when I try.

SWMBO - You wanna?

HWMO - Again?

Wake up Sus, wake up

 

[jorogi]

I don't have such a place in my shop. A separate place for misfit tools! I like it!

Um, it's called "under the piles", duh !

 

[Mcgyver]

Drill and hole and file .... you might've been done by now . I've made square broaches, but that takes a day's worth of chin scratching before you even start. silver solder (braze) a big hex shape on top that you can put a socket/wrench on. If your welding resembles a bunch of grapes brazing might be the way to make a neat job of it. I'd drill a hole and then have a plug with a slightly angled shoulder on that would take a nice filet of braze.

 

[140mower]

This is what I came up with for internal work.
Might as well teach them early that they are going to be making a lot of tools to make tools if they want to follow our footsteps.

Edit..... Dan's square tool bit could replace the boring bar....

 

[140mower]

And this is what I use to use the hss directly in the tool post. The groove on the inside of the tee is where I dribble cutting oil down the face of the cutter, it kinda acts like a little reservoir.....

 

[Tecnico]

Weld weld weld..... It seems like that's the answer for EVERYTHING!

I have welders! I just don't know how to make a nice weld!

Lol!

Jussayin’ but don’t you have a bunch of neighbours that owe you favours for fixing their farm equipment? Surely there must be one of them that thinks they can weld and you could give them the credit for the workmanship!

I get the need to break in the shaper but you could train the young’ins how to do the math and run a rotary table to machine a hex on the end of the bar and use a socket to turn the special service tool.

Are there a few bales of hay in your barn I can hide behind, I know a couch has no place in your shop.

D

 

[Darren]

chunk of pipe, a bit extra long, drill a hole clear through near the 'socket' end for a tommy bar

As McGyver says, drill round hole and file it square. Five mins max, done.

if you must have a precision square hole, a chunk of flat bar. mill a 1/2" wide by 1/2" deep slot in from the side. you can close it off with another chunk of bar. This would require welding though.

or, just use a pipe wrench on the pipe.

 

[Dan Dubeau]

Scrolling through my imgur looking for another old pic, I just found one of my broaching toolbit from a few years back. Wish I could find it now .

 

[Susquatch]

This is what I came up with for internal work.

Nice!

Might as well teach them early that they are going to be making a lot of tools to make tools if they want to follow our footsteps.

Ain't that the truth!

Scrolling through my imgur looking for another old pic, I just found one of my broaching toolbit from a few years back. Wish I could find it now .

Why it the rear of that broach round Dan? And how did you make it round?

Are there a few bales of hay in your barn I can hide behind, I know a couch has no place in your shop.

Actually, I do have a couch in my shop....... It's actually a double recliner I got from my folks 30 years ago when they downsized.

The only neighbour farmer who can actually weld better than I can has sold out and retired this year. I'm gunna miss him. We did a lot of back scratching over the years.

The groove on the inside of the tee is where I dribble cutting oil down the face of the cutter, it kinda acts like a little reservoir.....

Clever!

 

[Dan Dubeau]

Why it the rear of that broach round Dan? And how did you make it round?

So you can hold it in a collet. I used a punch grinder (harig fixture) on a surface grinder to spin it round. It's somewhat tricky to use, because you need to hold the spindle brake but it's not too bad (use a bungy, or third arm...). If I can find some time in the next couple weeks I'll make up another one, and do a quick video showing it's use. I know you love videos....but it's easier than words.

 

[Susquatch]

Make a 2-3/8” OD plug for the drive end with a hex on one end to match the largest socket your friend has and turn down the other end to match the ID of the pipe for maybe a half inch. Push the plug into the pipe, drill & tap M6 three radial holes into the plug, insert screws and deliver to your friend.

2” Sc40 pipe is 2-3/8” OD x 2.07” ID


EDIT: had to fix OD size, so added pipe info, too

I didn't realize 2" sched 40 pipe was so close to what I need.

This approach kinda matches my current thinking. I'm quite used to using fasteners to make things where others would simply weld. Machining a hex onto a plug is easy peasy. I likely wouldn't use M6 though. 1/4-20 or 28 is more my style. Q_@151

So you can hold it in a collet. I used a punch grinder (harig fixture) on a surface grinder to spin it round. It's somewhat tricky to use, because you need to hold the spindle brake but it's not too bad (use a bungy, or third arm...). If I can find some time in the next couple weeks I'll make up another one, and do a quick video showing it's use. I know you love videos....but it's easier than words.

Awesome Dan. I would watch any video a member made for fellow members in a heart beat. it's not at all the same as the average youtube shilling for views.

It does defeat the idea of using my new-to me shaper though.

 

[Susquatch]

This is what I came up with for internal work.

I have boring bars like that to hold hss blanks.




But what is this? I noticed the base which looks like it might fit a toolpost T-Slot. I assume it fits your shaper some how. Can you explain that part a bit more?

 

[historicalarms]

Another idea that allows you to use your shaper if your using a solid piece of bar for your tool blank. drill & ream the "working end" as you planned then just cut a hex of any size in the other end that you already have a socket for for the driven end, just a square cutting cutter needed.
Could be done just as easy in any mill but you want to make something to SWAMBO-Justify your new purchase.

 

[Susquatch]

SWAMBO

First time for me. I assume the A is for ALWAYS. I like it. Especially how it rolls off my tongue! Ya, GO SWAMBO!

Another idea that allows you to use your shaper if your using a solid piece of bar for your tool blank. drill & ream the "working end" as you planned then just cut a hex of any size in the other end that you already have a socket for for the driven end, just a square cutting cutter needed.

I'm getting there too. The mill would make it easier if you ask me, but it wouldn't impress SWAMBO.

 

[historicalarms]

I assume the A is for ALWAYS.

Yayup especially in the case of mine, considering how well she shoots...
she can do 10 aimed hits from her levergun in 5 seconds on a good day, 5.3 on a poor day...either day I loose.

 

[140mower]

I have boring bars like that to hold hss blanks.

View attachment 62026


But what is this? I noticed the base which looks like it might fit a toolpost T-Slot. I assume it fits your shaper some how. Can you explain that part a bit more?

I take out the lantern style tool post and put this in in its place, the big nut keeps it from spinning..... It's more rigid than the normal shaper boring bar holder and takes up less space......

 

[Susquatch]

I take out the lantern style tool post and put this in in its place, the big nut keeps it from spinning..... It's more rigid than the normal shaper boring bar holder and takes up less space......

I see! More tools for my tools! Love it!

 

[Downwindtracker2]

I'm afraid there is more than a little truth to my joking about the braille method. Welding will trigger migraines in me unless unless I use shade # 11 . Then it's pretty hard to see anything. I was doing a fair bit of welding .062 1 1/2" square tubing yesterday and I'm suffering. I'll have to replace the battery in my helmet, I think.

Last night I went looking for shaper posts on a forum, I found an long thread on an English forum. There was quite a discussion on making internal gears mixed in with how to fix 10" Eliot (sp) feed ratchet and Adept hand shapers.