Quote from HMS-776 on May 26th, 2012, 06:34 PM

Is anyone working on injector bobbins or SS430 wire?

please watchthis thred for the wire.

http://open-source-energy.org/?tid=81&highlight=wire

im having some made... but we all will need to pitch in to get it i think?!?!

~Russ

Quote from HMS-776 on May 27th, 2012, 11:11 AM

FIREPINTO AND RUSS

I noticed the Google Sketchup drawing of the VIC has only 13 cavities. I also noticed in your video Russ that you said something about there only being 13 cavities.

I ran the calculations on paper and also using a multi-layer coil calculator. Both showed that 14 cavities are needed to achieve the 11.6K ohms per coil. Just wanted to make sure you guys know. I also measured Stan's original 430 SS wire at .0055" which tells us it is single build 36AWG wire.

I have ran a lot of numbers and done a good amount of research over the years on this coil, if you want any more info let me know. I am happy to share!

ok, so i have been looking this over and thinking about this.

on my bobbin with 14 cavity's i still have room for more wire in each slot. if i divide the last  # 14 slot out i could get the wire on there...?  

my slots may be ever so slightly wider?

i have some derlin now and am going to make it to spec and see what we come up with...

i also have some ss wire samples on the way. there triple build i believe.

im also ordering some triple build wire for the secondary.

let me know your thoughts! :)

thanks for the info.

PS. to get it to fit... how wide do the slots need to be? if we use 13?


~Russ

Quote from scot on May 29th, 2012, 03:50 PM

Quote from Jeff Nading on May 28th, 2012, 05:13 PM

Quote from scot on May 28th, 2012, 05:06 PM

Hi peoples,
Sorry i haven't been around, Russ, have solved the problem with the tapered cavity in the water injector. No special tool required I remembered that tapered endmills are made for milling release angles on molds amoung other things. It will require a 1 degree taper per side, part # oet-59124c  at  J & L Industrial Supply.
I think that the .010 slots can be done on an edm so the injector can be made as per drawing and not in 3 more pieces as i thought i might have to do before.
 I saw Bruxxus wrote about the length of the threaded area for the head and i think it's a good point but also think since this is experimental and only plan on making one injector for now chances are it will fit most small single cylinder engines. We must remember that point when we need 4 or more.
 One more thing, i saw that Globalkast has a complete vic circuit board is that anything anyone knows about?
Thanks,Scot

Hey Scot, Dude YOUR THE MAN :cool::D:P. That is great awesome and stupendous news, can you tell I'm excited :D:D:D. On the circuit from Globalkast, yes.:D

Hi all,
Was re-checking the math and I sent some disinfo.
I don't know if we should delete the post or what?
Sorry about that.
Here is what the real answere is - 2 degree angle on each side, part # OET-59323K
for a tappered end mill at J & L Industrial Supply.
Sorry again, Thanks, Scot

scot, i really think that we can do this with out the VIC driver...

i have a feeling this is a different animal than the "water bath" vic and electronics...

we dont need to "auto tune" the injector... its all the same once setup and tuned. (i would think)

also, could you post your dezighn changes here on the forms so we can ponder the ideas with you?

i know we talked about being able to adjust the end...

let me know if you want to chat some time!

~Russ

Thank you Russ, you're doing a great job!

Quote from Lynx on June 2nd, 2012, 01:03 AM

Thank you Russ, you're doing a great job!

blessings bro! could not do it with out the support! and its a WE attitude not a Russ attitude! :)

thanks for the post!

~Russ

The injector bobbins are now in Blender format.:)  I haven't checked to see if the scale is correct after the importing and exporting.  Mostly because I dont know how.:P  The outer bobbin needs a little push back to center too.

There is a new thread in the 3D section with files:
http://open-source-energy.org/?tid=565


Nate

Quote from ~Russ/Rwg42985 on June 1st, 2012, 11:58 PM

Quote

Either way, I am SUPER stoked about all this and can't wait to see someone holding a finished injector here in 2012!

its already half way done... :) ~Russ

Hi Russ,
I don't know about half way done but we be gettin there.
By the way that insulator in figure 2-4 is not the right one for this injector body.
I think that page is mostly for the needle.
If the Chinese deel is too expensive or time consuming or whatever let me know,
call if you want.
Thanks, Scot

Quote from absolutelynobody on May 26th, 2012, 09:05 AM

Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z    FLASH MESSAGE    Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z

ABORT MISSION.... REPEAT.... ABORT MISSION....   LATEST INTELLIGENCE ON ATTEMPTED MISSION
SHOWS POSSIBLE STUNNING DEFEAT OF PLANNED OBJECTIVE   ABORT MISSION....  ABORT MISSION
....  STAND DOWN UNTIL NEW OBTAINED INTELLIGENCE CAN BE USED TO ENSURE SUCCESS OF
MISSION...                END MESSAGE
 
Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z    FLASH MESSAGE    Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z

Hello again. Second post.  A few thoughts to pass along to you big guy (Russ).  Sorry about the theatrics above, but I
wanted to get your attention before something very bad could possibly take place.  ( the above type message is used
by the military during hostilities/wartime to get vital information to command leadership immediately )  I watched your
most recent videos regarding the WFC Injector Assembly.  I don't have a lot of time anymore, so I will be very brief
(for me) and to the point.  Please do not take my writing style I am about to use as being rude, I just need to get my
points across quickly.   Here goes.  Russ, what are you going to screw that injector assembly into?!?!  Are you going to
to screw it into a 1960's or 1970's VW type 1 (beetle) air cooled engine like Stan did?  What point am I trying to make?
I would sure as hell HATE to see you and other people out there WASTE a lot of time, energy AND money to produce
a WFC Injector assembly that will not fit on perhaps 75% of the car engines on the road today.  My point is that I have not
heard one word as to what you plan on screwing that injector into for testing once it is done.  And unless you have a
horizontally opposed 4 cylinder air cooled VW engine like Stan was testing on, how do you know it will fit on what you
will be using as a test mule?  Have you even decided what vehicle/engine type you will be using for testing?????  The ton
of bricks should be hitting you right about now.  I may be wrong, but you could be trying to make something that won't
fit anything that you have, and buying/being forced to use something else for testing is just going to cost you more cha ching!!!
My personal suggestion is for you to get out your lathe again and get a piece of round steel and turn it down to fit the
outside dimensions of the WFC Injector dimensions.  You can MARK where the water fitting, the electrical ground connection, all
the stuff that would be hooked up to it, by using your caliper to get a very close mockup of what the finished injector would
look like.  Once again, just a shell.  And take that shell over to your car and pop the hood.  Take out a spark plug, and slide
your shell on down into the spark plug hole.  The heads on the engines today are a LOT different than what Stan was using.
As you know the plugs on most modern engines are not exposed.  They are located down, sometimes way, way down in
holes cast into the heads in a attempt to position the plug in the best possible place for combustion.  Now let me ask you,
does your mockup shell slide into your engines spark plug "well" ???  Now if it does, will the port where the water fitting
attaches to the injector clear the head??  Remember your shell will not have threads on it, so you will have to remember
that once the injector is screwed into the head the WATER PORT will be approximately one half of a inch (length of threads)
closer to the cylinder head. Does the water port still clear the head??  How about the ground connector??  One other MAJOR
THING to take into consideration is that the plug Stan made has "flats" machined on the side of the injector body so that a
combination wrench or a crescent wrench can be used to tighten the injector.  This area is located BELOW the water fitting,
so a socket cannot be slid down the injector to tighten it.  So with the injector sitting in the spark plug hole will you be able to use
a wrench to tighten it?? Now take out each plug one by one and check to make sure the injector will fit EACH spark plug hole
 correctly without any clearance issues.  Just because the injector fits one spark plug  hole correctly DOES NOT mean it
will fit the others.  Will the injector as Stan designed it fit on any engine that you have?? Stan made
his to fit the old VW engine, it's now more than twenty years later, and to say engine designs have changed would be putting it
very mildly.  You are more than likely going to have to change the design to ensure a fit on today's engines.  If you plan on
testing on a small engine remember the diameter and threads per inch are normally different than a automotive engine.
 One other thing while I am thinking about it.  Stan went to a lot of trouble to make a homemade injector circuit to fire his injectors.  
I hope you do not intend to reinvent the wheel.  In order to inject water at the correct instant for ignition/combustion to take place
use the on board electronics for fuel delivery  ( we're talking water here!!!) and ignition. If you have already taken all of these details
into consideration and have solutions for them please disregard this post. I just thought of another problem you are going to have.
 I am going to have to look into seeing if there is a solution readily available.  I am now out of time. You can believe me or not believe me,
you just have to believe that I am absolutelynobody.

The easiest way to solve this problem is to buy a VW that is the same Year Make and Model Stans car was so you can insure you have the same engine. Once you perfect everything on that move on to perfecting it on other vehicles.

Good day to you all!:) Thank for all the work you have all put into making this water fuel injection technology closer to being a reality!

I feel there are a few things that we have been missing that I have not yet seen people incorporate into the VIC for the Injector Spark Plug.
First as many of us know Stan explains his water fuel injection technology in great detail in his book The Birth of A New Technology. The chapters I have found to be of great importance to his Spark Plug Injectors are found in chapters 6 & 7. In these chapters Stan goes through the water spark plugs with great detail. My reason for writing this is to point out a few things Stan mentions in these two chapters that I feel we have not applied to the water fracturing process which takes place in the injector spark plug.

First the VIC used to fracture the water in the spark plug injector is found on page 6-5  Figure 6-1. I believe this is the VIC used to fracture the water, none of the other VIC's we have previously built and experimented with are used to actually Fracture the water to create Hydrogen and Oxygen gasses in the spark plug injector. I feel that this VIC many not be complete until you add all the components into it as shown on page 7-20 figure 7-8 (VIC Matrix Circuit). I believe that this extra component is the spark injector tip.

Second on page 7-19 figure 7-6 is an example of a circuit used to create a resonant voltage effect. I believe this circuit actually takes place in the injector tip due to the electrical compression that takes place as the electrical waive travels toward the injector tip. On this same page in figure7-7 you will see the figure of the voltage charging effect. What I am trying to get people to understand is that there is a voltage charging effect in Stans water injector not just a resonant charging effect (Please see page 7-19 figure 7-7 #627 voltage across the plates). What the voltage charging does is just as Stan shows in his seminars as you increase the voltage amplitude you increase the strength of the electrical opposing charges placed on the H2O molecule. How it works… You start out with a small electrical amplitude and step it up in stages in each pulse, as you do this the bond between the molecules weaken more and more until they disassociate from one another. This disassociation occurs within each and every pulse by having a voltage step charge.  Along with this voltage step charge there is also a resonant step charge that takes place along side the voltage step charging pulse train. The resonance has the same step effect as the voltage charge effect. The resonant step charging effect starts with a lower resonance and steps up until it hits a prime resonance point; it does this within each pulse. This is why the circuit on in figure 7-6 is called a resonant voltage effect.  As these two pulse trains take place simultaneously your end result is an efficient gas producing process which produces enough HHO to run an engine. I believe the voltage charging effect is created from the injector tip, the closer the water gets to the tip the higher the voltage and resonance amplitude become until the water is instantaneously fractured into Hydrogen and oxygen gases (Please see page 7-22 figure B).

Lastly on page 7-23 figure 7-13 (VIC Secondary Switch-Off Coil-Array) you will find a secondary coil which has many additional components compared to the typical secondary coils people have experimented with. It appears that this secondary coil has the ability to have multiple voltage settings. I believe Stan designed this so he could have one unit that would work with any vehicle. This secondary coil allows for higher voltage options which would be needed in larger engines. Stan said as you higher the voltage you higher the gas output.

I hope this helps some of you! These are some of the beliefs I have regarding Stans work please share your ideas and opinions as it allows us to learn new things from one another.

UNITE WORK TOGETHER SUCCEED AND BE FREE!

Thanks for all you do,
                   Tyson   HHO4Life

Quote from scot on June 3rd, 2012, 11:48 AM

Quote from ~Russ/Rwg42985 on June 1st, 2012, 11:58 PM

Quote

Either way, I am SUPER stoked about all this and can't wait to see someone holding a finished injector here in 2012!

its already half way done... :) ~Russ

Hi Russ,
I don't know about half way done but we be gettin there.
By the way that insulator in figure 2-4 is not the right one for this injector body.
I think that page is mostly for the needle.
If the Chinese deel is too expensive or time consuming or whatever let me know,
call if you want.
Thanks, Scot

correct, the 2-6 is the correct one. and i also agree 2-4 is the only drawing of the Positive probe.

i would like to see one made with that macor ceramic and may need to be so if the other one dont work or whatever... its just so expensive!!! lol

thanks Scot! ill give ya a call this week one night.

thanks for all the help! ~Russ

Quote from HHO4Life on June 4th, 2012, 08:46 PM

Good day to you all!:) Thank for all the work you have all put into making this water fuel injection technology closer to being a reality!

I feel there are a few things that we have been missing that I have not yet seen people incorporate into the VIC for the Injector Spark Plug.
First as many of us know Stan explains his water fuel injection technology in great detail in his book The Birth of A New Technology. The chapters I have found to be of great importance to his Spark Plug Injectors are found in chapters 6 & 7. In these chapters Stan goes through the water spark plugs with great detail. My reason for writing this is to point out a few things Stan mentions in these two chapters that I feel we have not applied to the water fracturing process which takes place in the injector spark plug.

First the VIC used to fracture the water in the spark plug injector is found on page 6-5  Figure 6-1. I believe this is the VIC used to fracture the water, none of the other VIC's we have previously built and experimented with are used to actually Fracture the water to create Hydrogen and Oxygen gasses in the spark plug injector. I feel that this VIC many not be complete until you add all the components into it as shown on page 7-20 figure 7-8 (VIC Matrix Circuit). I believe that this extra component is the spark injector tip.

Second on page 7-19 figure 7-6 is an example of a circuit used to create a resonant voltage effect. I believe this circuit actually takes place in the injector tip due to the electrical compression that takes place as the electrical waive travels toward the injector tip. On this same page in figure7-7 you will see the figure of the voltage charging effect. What I am trying to get people to understand is that there is a voltage charging effect in Stans water injector not just a resonant charging effect (Please see page 7-19 figure 7-7 #627 voltage across the plates). What the voltage charging does is just as Stan shows in his seminars as you increase the voltage amplitude you increase the strength of the electrical opposing charges placed on the H2O molecule. How it works… You start out with a small electrical amplitude and step it up in stages in each pulse, as you do this the bond between the molecules weaken more and more until they disassociate from one another. This disassociation occurs within each and every pulse by having a voltage step charge.  Along with this voltage step charge there is also a resonant step charge that takes place along side the voltage step charging pulse train. The resonance has the same step effect as the voltage charge effect. The resonant step charging effect starts with a lower resonance and steps up until it hits a prime resonance point; it does this within each pulse. This is why the circuit on in figure 7-6 is called a resonant voltage effect.  As these two pulse trains take place simultaneously your end result is an efficient gas producing process which produces enough HHO to run an engine. I believe the voltage charging effect is created from the injector tip, the closer the water gets to the tip the higher the voltage and resonance amplitude become until the water is instantaneously fractured into Hydrogen and oxygen gases (Please see page 7-22 figure B).

Lastly on page 7-23 figure 7-13 (VIC Secondary Switch-Off Coil-Array) you will find a secondary coil which has many additional components compared to the typical secondary coils people have experimented with. It appears that this secondary coil has the ability to have multiple voltage settings. I believe Stan designed this so he could have one unit that would work with any vehicle. This secondary coil allows for higher voltage options which would be needed in larger engines. Stan said as you higher the voltage you higher the gas output.

I hope this helps some of you! These are some of the beliefs I have regarding Stans work please share your ideas and opinions as it allows us to learn new things from one another.

UNITE WORK TOGETHER SUCCEED AND BE FREE!

Thanks for all you do,
                   Tyson   HHO4Life

all very good info Tyson, i have also grasped all that already. good post as a lot of others did not see this and its a good deal for them to see that there is much more to stans work and its all kinda interwoven! :)

team work! :)

~Russ

Quote from HHO4Life on June 4th, 2012, 08:46 PM

Good day to you all!:) Thank for all the work you have all put into making this water fuel injection technology closer to being a reality!

I feel there are a few things that we have been missing that I have not yet seen people incorporate into the VIC for the Injector Spark Plug.
First as many of us know Stan explains his water fuel injection technology in great detail in his book The Birth of A New Technology. The chapters I have found to be of great importance to his Spark Plug Injectors are found in chapters 6 & 7. In these chapters Stan goes through the water spark plugs with great detail. My reason for writing this is to point out a few things Stan mentions in these two chapters that I feel we have not applied to the water fracturing process which takes place in the injector spark plug.

First the VIC used to fracture the water in the spark plug injector is found on page 6-5  Figure 6-1. I believe this is the VIC used to fracture the water, none of the other VIC's we have previously built and experimented with are used to actually Fracture the water to create Hydrogen and Oxygen gasses in the spark plug injector. I feel that this VIC many not be complete until you add all the components into it as shown on page 7-20 figure 7-8 (VIC Matrix Circuit). I believe that this extra component is the spark injector tip.

Second on page 7-19 figure 7-6 is an example of a circuit used to create a resonant voltage effect. I believe this circuit actually takes place in the injector tip due to the electrical compression that takes place as the electrical waive travels toward the injector tip. On this same page in figure7-7 you will see the figure of the voltage charging effect. What I am trying to get people to understand is that there is a voltage charging effect in Stans water injector not just a resonant charging effect (Please see page 7-19 figure 7-7 #627 voltage across the plates). What the voltage charging does is just as Stan shows in his seminars as you increase the voltage amplitude you increase the strength of the electrical opposing charges placed on the H2O molecule. How it works… You start out with a small electrical amplitude and step it up in stages in each pulse, as you do this the bond between the molecules weaken more and more until they disassociate from one another. This disassociation occurs within each and every pulse by having a voltage step charge.  Along with this voltage step charge there is also a resonant step charge that takes place along side the voltage step charging pulse train. The resonance has the same step effect as the voltage charge effect. The resonant step charging effect starts with a lower resonance and steps up until it hits a prime resonance point; it does this within each pulse. This is why the circuit on in figure 7-6 is called a resonant voltage effect.  As these two pulse trains take place simultaneously your end result is an efficient gas producing process which produces enough HHO to run an engine. I believe the voltage charging effect is created from the injector tip, the closer the water gets to the tip the higher the voltage and resonance amplitude become until the water is instantaneously fractured into Hydrogen and oxygen gases (Please see page 7-22 figure B).

Lastly on page 7-23 figure 7-13 (VIC Secondary Switch-Off Coil-Array) you will find a secondary coil which has many additional components compared to the typical secondary coils people have experimented with. It appears that this secondary coil has the ability to have multiple voltage settings. I believe Stan designed this so he could have one unit that would work with any vehicle. This secondary coil allows for higher voltage options which would be needed in larger engines. Stan said as you higher the voltage you higher the gas output.

I hope this helps some of you! These are some of the beliefs I have regarding Stans work please share your ideas and opinions as it allows us to learn new things from one another.

UNITE WORK TOGETHER SUCCEED AND BE FREE!

Thanks for all you do,
                   Tyson   HHO4Life

I agree as well Tyson, good observations, information and good post:cool::D:P.

the time is now...

here is some photos of the injector Scot it building for testing.

Quote

Russ,
This is the best i can do and i didn't do it all myself.
The first two shots are the center section of the injector partially done.
next two are the same with the length and diameter to size.

The 3d drawings are very helpful!

i saw that someone had put up a resource for a .010 end mill.
Hoping you can put this on your sight for me and thank all the necessary people that have
contributed Thank you

Thanks, Scot

[attachment=1712]
[attachment=1713]
[attachment=1714]
[attachment=1715]


looking good!!!!

the ceramic part is in Alan's hands and will be shipped to me soon. ( he is in hongKong)

bob (a follower of the work at hand)  has got the end mills for the tapered cavity (custom ordered) and will be sending one to me. ( donated it)  i will pass it to Scot to finish the part!  

its coming along and as Scot mentioned! thank everyone that is involved!!!! its a blessings and every one is amazing!

thanks!! ~Russ

Quote from ~Russ/Rwg42985 on June 9th, 2012, 03:09 AM

the time is now...

here is some photos of the injector Scot it building for testing.

Quote

Russ,
This is the best i can do and i didn't do it all myself.
The first two shots are the center section of the injector partially done.
next two are the same with the length and diameter to size.

The 3d drawings are very helpful!

i saw that someone had put up a resource for a .010 end mill.
Hoping you can put this on your sight for me and thank all the necessary people that have
contributed Thank you

Thanks, Scot

looking good!!!!

the ceramic part is in Alan's hands and will be shipped to me soon. ( he is in hongKong)

bob (a follower of the work at hand)  has got the end mills for the tapered cavity (custom ordered) and will be sending one to me. ( donated it)  i will pass it to Scot to finish the part!  

its coming along and as Scot mentioned! thank everyone that is involved!!!! its a blessings and every one is amazing!

thanks!! ~Russ

Good to hear Russ, thanks Alan, Bob, Scot, Russ and everyone :cool::D:P.

Quote from ~Russ/Rwg42985 on June 9th, 2012, 03:09 AM

the time is now...

here is some photos of the injector Scot it building for testing.

Quote

Russ,
This is the best i can do and i didn't do it all myself.
The first two shots are the center section of the injector partially done.
next two are the same with the length and diameter to size.

The 3d drawings are very helpful!

i saw that someone had put up a resource for a .010 end mill.
Hoping you can put this on your sight for me and thank all the necessary people that have
contributed Thank you

Thanks, Scot

looking good!!!!

the ceramic part is in Alan's hands and will be shipped to me soon. ( he is in hongKong)

bob (a follower of the work at hand)  has got the end mills for the tapered cavity (custom ordered) and will be sending one to me. ( donated it)  i will pass it to Scot to finish the part!  

its coming along and as Scot mentioned! thank everyone that is involved!!!! its a blessings and every one is amazing!

thanks!! ~Russ

Wow that looks amazing!  Awesome work Scot!   The time really is now.:cool:

Nate

Quote from ~Russ/Rwg42985 on June 9th, 2012, 03:09 AM

the time is now...

here is some photos of the injector Scot it building for testing.

Quote

Russ,
This is the best i can do and i didn't do it all myself.
The first two shots are the center section of the injector partially done.
next two are the same with the length and diameter to size.

The 3d drawings are very helpful!

i saw that someone had put up a resource for a .010 end mill.
Hoping you can put this on your sight for me and thank all the necessary people that have
contributed Thank you

Thanks, Scot

Wow Russ and everyone's working at light speed.  Amazing what a good team can do.   Replicating all of this work to have everything in hand is a major milestone.

Glad to see I'm not the only one making an injector....Good work scott, you must be a machinist, or know a machinist...

I have been working on one this weekend.
So far the only thing that has slowed me down is a learning curve. I've never turned metal on my lathe before. I made a mistake with the spark plug threads (also my first time threading), I think my major diameter was off so it messed up the threads with each pass, after 3 passes I stopped. My lathe does not do metric threads anyways. Once I get more practice threading I will fix them...

[attachment=1722][attachment=1721][attachment=1720]

Since this is my first time turning metal I decided to simplify things. I am not using a tapered center rod, and I am not using a ceramic insulator....I am using my own design which still maintains all the .01'' gaps.

Info about my injector:

The center rod is .125" (1/8). The .01 gap between the electrodes was obtained using first a 1/8 drill bit, then a .135 reamer followed by a .145 reamer. The injector tip is not tapered but the area is nearly the same so capacitance should be close. I'm using delrin as an insulator since this injector is only a proof of concept piece. I hope to have the injector done by the end of the week!

[attachment=1730]

Here's a pic with the center electrode in place. So far so good!

Hi HMS- 776,
I'm no machinist just do it for a hobby.
Sometimes the best thing to do with threads is to ruff them out on the
lathe then run a die over them. If your lathe doesn't do metric you can choose
a thread that is very close, cut that and then run the right size die over that and it will make your thread right. Of course the distance of the thread cannot be too long
But what your working with is ok.
 If you need help let me know Glad your doing this too we need all the experimental testing we can get.
Thanks,Scot

Hey Scot,

I noticed you said we could get the .01 slots cut using an EDM. I looked up the EDM and it seems like something which may be more expensive to use than typical CNC, and something a lot of machine shops might not have?

Do you know where to take the injectors to get the slots cut?

Electrical discharge machining

I was wondering if we could use some kind of cutoff wheel (like something used in a dremel tool) but I don't think they are that thin....There are also diamond bit wheels that are thinner, but I'd have to get some to see what the thickness is.

I purchased some #80 drill bits and once I got them realized how small they really are. Not anything that would drill through plastic or ceramic...Decimal size is .0135 inches.

nice work guys!!!!!

looking really good!!!

Here is a photo of the slots Scot had made. maybe he can explain here how he did it!

[attachment=1731]

looks really good!!!!

~Russ

Quote from HMS-776 on June 10th, 2012, 09:49 PM

Hey Scot,

I noticed you said we could get the .01 slots cut using an EDM. I looked up the EDM and it seems like something which may be more expensive to use than typical CNC, and something a lot of machine shops might not have?

Do you know where to take the injectors to get the slots cut?

Electrical discharge machining

I was wondering if we could use some kind of cutoff wheel (like something used in a dremel tool) but I don't think they are that thin....There are also diamond bit wheels that are thinner, but I'd have to get some to see what the thickness is.

I purchased some #80 drill bits and once I got them realized how small they really are. Not anything that would drill through plastic or ceramic...Decimal size is .0135 inches.

Hello HMS-776, I possibly have an answer for you, don't know if you want to spend the time to build the edm, but it might be worth looking at and maybe used in some of our experimentation, linked here,
http://www.lindsaybks.com/bks9/edm/index.html
 I have bought many of there books
http://www.lindsaybks.com/index.html
through the years and is how I built my lathe, also leaned how to cast aluminum, Jeff.:D
PS. I also used the # 80 drill bits to drill the holes in brass nozzles I made, for the hotends I also made, on the 3d printer.

Yeah scot please let us know how you cut those slots.
That is some great work btw;)

Quote from HMS-776 on June 11th, 2012, 07:49 AM

Yeah scot please let us know how you cut those slots.
That is some great work btw;)

Hi All,
I'll try to make this clear as possible it wasn't all that complicated.
First thing is I new is that I wanted to scrape those slots with a tool like on a
an old shaper machine because I would have the room to do it that way. And I
could use the compound on the lathe to give me a horizontal movement across the
face of the part.
 One problem was indexing the part so it could be divided into six equal parts or
slots. I also have a milling machine with rotary table so I took the chuck off the lathe and put it on the rotary table and marked the chuck in the mill at every 60 degrees. Put the chuck back on the lathe and put a mark on the lathe to indicate
against the chuck. Now I could turn the chuck by hand to each position to be cut.
 The next issue was I needed a tool to cut the slots, that was the hard part.
After a couple of tries what I ended up with was a 3/16 round high speed tool
steel.
 First step was to grind a flat spot on the tool steel about .100" back and .050 deep. That became the facing edge or the cutting edge, angle is not critical, straight is just fine. This i did on the bench grinder.
 Next I put the tool in the lathe and set the cuttin edge down facing the floor.
Then I used a home made lathe grinder from a small drywall router could have used my Dremel but for some reason I forgot I had it. It the Dremel has a mount made also to fit the lathe. Will show pics if you want. Then I cut about half way
through with the grinder about .050 deep.
 Then i turned the tool cutting edge up facing the ceiling and at an angle that gave me a slight taper toward  the back of the cutting edge for clearance, so basically your grinding a long taper rectangle, the flat that was ground is the front and widest part of the rectangle and also the cutting edge. Hope that's clear. Grind
untill you reach .010" wide at the face edge.
 I had to make a holder for the cutting tool to fit my lathe.
Then shim it to center it to the lathe.
 Now with the part in the lathe, that too takes a special part because the back of the injector is larger than the front. Set the lathe speed around 450 just to give it enough resistance to not move when milling your part, and set the chuck at the mark on the lathe and a mark on the chuck.
 Move your tool so the cutting edge is against the outside edge of the part, set a dial indicator at zero, if you don't have a dial indicator for your carriage now is a good time to make one. Move your tool away and move it to the center of the part,
you can indicate it here too on the .400" dia. that you will be cutting through.
Back to the center, move your tool in .001" and back out your cross feed through the part. You should see the metal curl in front of the cutting edge, I used a magnifing glass to see. Move the tool back to the center and take another .001" cut. Repeat untill you have cut down .010" , move the chuck to the next position and repeat the process again.
 Use cutting oil and feed slow and smooth. My tool was still sharp after finishing the job.
 Any questions feel free to ask.
Thanks, Scot
















 

Excellent post Scot :D:cool:, I know it wasn't easy, great work on this, thanks, :D Jeff.

AHHh HAAA!

Scot, your explanation makes perfect sense. Seems easy enough to do except girinding the tool (like you said) will be the hardest part! Thanks for your contributioins! They are appreciated very much by all:)