Hi All,
I thought I'd give an update on what is happening with the injector build.
Well the first piece is completed that piece is the center section with the quenching chamber. You can see that in the 3d pictures. The ball and spring is not installed yet. That piece was built pretty much without a hitch, wish I could say the same for the lower case.
It sure seemed like it would be a much simpler piece to build, bore a hole right.
Well I did that but I could not get it to bore without some taper to it. So i found a ream I thought I could square out the hole and get the taper out of it. It was working fine till it got stuck. It was a really old ream and not too sharp like the one that was running it. To make a long story short it came out but not without a few scrapes inside the hole. So back to the the boring bar.
The hole is square now and it's time to put inside threads on the one open end.
No problem right? I bore the hole to the size I think is right, you have to remember that these thread sizes are not the standard issue. I'm not quite done and the lathe decides not to start up, great, I take a week to figure out that it is the start capacitors.
This Lathe weighs 4 million pounds and the capacitor box is in the leg of the lathe along with the motor up against the wall with very little access to unbolt stuff, and I didn't want to move a 5 million pound lathe.
If you wait long enough someone comes along and feels sorry for you or they need something done bad enough that they invest some motivational force to get you going to get done what you didn't want to do plus get some more done that you didn't want to do. And just so happens that's what happened.
I'll spare you the details about all that but I did get the lathe fixed.
So now finish cutting the hole for the threads, no problem, right, wrong.
I'm boring away I'm not taking a large cut I'm looking at the dial indicator to tell me when to stop cutting so I'm not looking at the actual work being done but when I do Auw No, what happened? Somehow I didn't notice that the clearance
on the tool wasn't there and it scraped the bore and tore it up pretty good really pretty bad. The only thing left to do is finish boring the hole I only have about .009
left to cut out it looked really slim that I could salvage this, but no it don't look half bad a little big the first .100 but that should be ok.
Next step thread the bore back .550. This is where the real trouble starts I'm cutting threads with this real delicate cutting tip turning the lathe at 14 rpm everthing looks good. Now comes the time to check the first part to the second part that I'm working on. It doesn't even start, that's ok keep cutting threads.
I take a few more cuts and try the part again, it goes in almost half way. Well what do I do? I'll try lapping the threads in with compound, hmm i don't have any compund, hmm I'll make some. So over to the grinder and get some grinding wheel
dust and mix with oil and whalah lapping compound, more like supper sieze.
I'm being carefull I turn the part back and forth nice and easy it's working yha!
Oops it's stuck, stuck like really stuck, great i'm going to ruin two parts at the same time. Lord help me Jesus really I know how serious this is I'll be good honest.
It comes out, there is some damage to the threads on the first piece but it's ok.
Not making fun here I am a Christian and i do take it seriously.
After resting for a few minutes by the way this process is taking hours I start up the lathe and see something I didn't want to see the part has a slight wobble to it.
Did it turn slightly in the chuck? If it did the threading tool won't match the threads
in the part all is ruined again. The only thing to do is check the alighnment,I turn the chuck by hand for the 80 millionth time and carfully see if the tool is in the groove. I can't see it I'm too blind even with a magnifying glass so what do I do, somthing stupid of course I turn the chuck backward, right, to get the tool back in the open hoping that I can see where it had been. Wrong you don't turn the chuck backward crunch went the tool Nooooo Nooooo Noooo how dumb now what do I do. Wow looks like it's still lined up too bad it's broken time to finally trash this part.
Just a couple more cuts and it would have been done. You know if you look real close you can see that the front edge of the tool still has an edge, no, yes, no, yes who can tell let's try it. Well after all that and i can assure you there was more adventure the part was salvaged and by the looks of it without any outward sighn of trouble.
Hope everyones life is as successfull as this adventure was for me,
Thanks, Scot