Reply to thread

Message

Hi All,

Thank for the great feedback! Build Update:

If there's one thing I'm learning about machining it's this - prepare to re-machine, often. Admittedly, I'm an amateur. I found myself examining completed parts and deciding to rebuild this weekend. The original parts (rev. 1) weren't bad but I countersunk the screws too much. Not countersinking was actually more accurate to the original armature. After a rebuild, I'm much happier with rev. 2:
[ATTACH=full]55906[/ATTACH]

[ATTACH=full]55907[/ATTACH]

Since I had the equipment setup for drilling, I built all pieces of the ankle (universal joint). These parts are sitting in place:
[ATTACH=full]55908[/ATTACH]

The next operation was to join the end pieces to the flat bar. This created a challenge though. I did not have a means for clamping the pieces together to allow drilling both pieces simultaneously. So I stopped, went inside, and began to ponder a solution. What I came up with was a custom jig that would hold both pieces in perfect relation, one to the other, and hold them securely to allow drilling. Here's my quick concept sketch:
[ATTACH=full]55909[/ATTACH]

I decided to go with the quicker, simpler design to save build time. Here's some photos showing the progress and semi-final jig:
[ATTACH=full]55910[/ATTACH]

[ATTACH=full]55911[/ATTACH]

[ATTACH=full]55912[/ATTACH]

[ATTACH=full]55913[/ATTACH]

I need to tap the holes and make the clamp. The next update will show the jig in action followed up with (hopefully) perfectly joined bases to universal joint sides. Thanks for tracking the thread!

<blockquote data-quote="CheesyGrin" data-source="post: 164564" data-attributes="member: 11898">Hi All,Thank for the great feedback!&nbsp; Build Update:If there&#039;s one thing I&#039;m learning about machining it&#039;s this - prepare to re-machine, often.&nbsp; Admittedly, I&#039;m an amateur.&nbsp; I found myself examining completed parts and deciding to rebuild this weekend.&nbsp; The original parts (rev. 1) weren&#039;t bad but I countersunk the screws too much.&nbsp; Not countersinking was actually more accurate to the original armature.&nbsp; After a rebuild, I&#039;m much happier with rev. 2:[ATTACH=full]55906[/ATTACH][ATTACH=full]55907[/ATTACH]Since I had the equipment setup for drilling, I built all pieces of the ankle (universal joint).&nbsp; These parts are sitting in place:[ATTACH=full]55908[/ATTACH]The next operation was to join the end pieces to the flat bar.&nbsp; This created a challenge though.&nbsp; I did not have a means for clamping the pieces together to allow drilling both pieces simultaneously.&nbsp; So I stopped, went inside, and began to ponder a solution.&nbsp; What I came up with was a custom jig that would hold both pieces in perfect relation, one to the other, and hold them securely to allow drilling.&nbsp; Here&#039;s my quick concept sketch:[ATTACH=full]55909[/ATTACH]I decided to go with the quicker, simpler design to save build time.&nbsp; Here&#039;s some photos showing the progress and semi-final jig:[ATTACH=full]55910[/ATTACH][ATTACH=full]55911[/ATTACH][ATTACH=full]55912[/ATTACH][ATTACH=full]55913[/ATTACH]I need to tap the holes and make the clamp.&nbsp; The next update will show the jig in action followed up with (hopefully) perfectly joined bases to universal joint sides. Thanks for tracking the thread! <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite1" alt=":)" title="Smile&nbsp; &nbsp; :)" loading="lazy" data-shortname=":)" /></blockquote>

[QUOTE="CheesyGrin, post: 164564, member: 11898"] Hi All, Thank for the great feedback! Build Update: If there's one thing I'm learning about machining it's this - prepare to re-machine, often. Admittedly, I'm an amateur. I found myself examining completed parts and deciding to rebuild this weekend. The original parts (rev. 1) weren't bad but I countersunk the screws too much. Not countersinking was actually more accurate to the original armature. After a rebuild, I'm much happier with rev. 2: [ATTACH=full]55906[/ATTACH] [ATTACH=full]55907[/ATTACH] Since I had the equipment setup for drilling, I built all pieces of the ankle (universal joint). These parts are sitting in place: [ATTACH=full]55908[/ATTACH] The next operation was to join the end pieces to the flat bar. This created a challenge though. I did not have a means for clamping the pieces together to allow drilling both pieces simultaneously. So I stopped, went inside, and began to ponder a solution. What I came up with was a custom jig that would hold both pieces in perfect relation, one to the other, and hold them securely to allow drilling. Here's my quick concept sketch: [ATTACH=full]55909[/ATTACH] I decided to go with the quicker, simpler design to save build time. Here's some photos showing the progress and semi-final jig: [ATTACH=full]55910[/ATTACH] [ATTACH=full]55911[/ATTACH] [ATTACH=full]55912[/ATTACH] [ATTACH=full]55913[/ATTACH] I need to tap the holes and make the clamp. The next update will show the jig in action followed up with (hopefully) perfectly joined bases to universal joint sides. Thanks for tracking the thread! :) [/QUOTE]

Verification