Todays update from Bodgers Lodge

[chris stephensParticipant @chrisstephens63393]

Hi JA, so you are one of our former customers, glad that some still remember the old shop. From memory we only had problems with BMW valve head dropping on the 450/650 range, my own 75/5 has 150+Kmiles and the heads have never been off. You might remember the bike as the one parked out front on Ladbroke Grove.

chriStephens

[Bill PudneyParticipant @billpudney37759]

Well done Sir John, that's exactly like an inside out version of a Norton twin exhaust repair!!

cheers

Bill

[HopperParticipant @hopper]

Nice work yet once again John. I've a BMW fanatic mate who does so many of these he made a jig to mount the head on his large lathe faceplate and cut the new thread after getting the ally welded up. I like the idea of a bronze thread though. Much more durable.

If you are doing a bit of old BM work, one thing to look out for on the other thread that commonly goes: the cylinder/head stud holes in the crankcase. There is a tiny oil way for oil feed to the top end that runs runs right there, so if you install a threaded insert etc it is real easy to block off that oil supply. My mate had one come into his shop that some non-BMW bike shop had done and the result was one trashed engine.

Keep on bodgin' — always a good read.

[JAParticipant @ja]

Chris

I did have an R65 but I only ever used Chopper's side of the shop.

JA

[John Stevenson 1Participant @johnstevenson1]

Posted by Hopper on 05/03/2015 06:06:48:

Nice work yet once again John. I've a BMW fanatic mate who does so many of these he made a jig to mount the head on his large lathe faceplate and cut the new thread after getting the ally welded up. I like the idea of a bronze thread though. Much more durable.

Keep on bodgin' — always a good read.

.

 

I did a couple like this early on but was not impressed by the job quality at the end of the day, even with decent TiG rods the finished thread was gummy and the alloy to alloy fit of head and nut didn't appeal to the 7% engineer in me hence the move to bronze.

 

That angle plate on the mill, first pic is a jig. It's an old plate I picked up from somewhere and the vertical face was made blank. Some one had drilled tapped a few holes in it so I drilled and tapped a few more.

In fact in the first picture you can see a hole top left and what looks to be another at the side of it? That is actually white marker paint saying "XXXXXX Pump Jig" so I can bolt a weird shaped pump on and bore the seal housing out for a bronze sleeve when they corrode, as they do.

 

Underneath that are two more sets of holes for the BMW heads, one RH, one LH, both paint marked.

Before I did this I probably took 20 minutes setting the heads up on normal angle plates and trying to get bolt positions to fit slots. Today I can have one on the machine in minutes.

 

I actually have a book here, one of those with the clear covers inside, fixed not loose and I'm now in the habit of taking pictures of set-ups with my phone then at night print them out, make any notes on the back as regards setup, sizes tooling etc and file it away in this folder. This is because at times I have come across a repeat job only to spend ages scratching my head how I did it in the first place.

 

Anyway thank you all for taking part in this thread. I was not sure how this basically, an industrial thread would be taken on this site but then realised that many methods can be scaled and transposed to smaller jobs and machines.

 

[edit] some spelling

Edited By John Stevenson on 05/03/2015 12:30:42

[Brian WoodParticipant @brianwood45127]

Hello John,

Speaking for myself, but hopefully many others, I have found these insights into your activities illuminating and very interesteing, showing as they do some ingenious solutions to problems that most of us will hopefully never face.

What is paricularly interesting is the 'thinking outside the box' which is refreshing; thank you for sharing all this knowledge with us, many wouldn't.

I think it is very wise to make a proper record of these repairs as you describe, memory is a fickle thing and hours can be wasted in trying to reproduce something obscure, I have been doing something similar to record my own activities which may be of use in the future.

So, please add to the list as they come in, the scaling down to smaller sizes is a very valid argument.

Kind regards

Brian

Edited By Brian Wood on 05/03/2015 11:03:02

[ChrisHParticipant @chrish]

Hi John, would second what Brian has just written, love the "outside the box" thinking, that used to be more common before Nanny told us what we must think and do, but it's rare nowadays!

Cheers,

Chris

[Martin KyteParticipant @martinkyte99762]

An observation.

We have an apprentice in our electronics workshop who when faced with a system that compiles a drawn circuit into code to program a chip having the same function said he thought that seemed like cheating.

It got me to thinking that when in education the we seemed to have been rewarded for complication. The more difficult the thing you did the bigger the pat on the head.

In an industrial environment there are no point awarded by doing things in the most difficult way, in fact just the reverse, but it still leaves us with the nagging feeling that somehow we cheated.

Similarly as model engineers we can learn the 'proper' way of doing something and spend ages longer than the more experienced bloke who just wants to get the job done well and with the least effort.

Martin

[JimmieSParticipant @jimmies]

Years ago I remember being told 'now after you have been told how it should be done, we are now going to show how it will be done'. The difference. Time honoured approved short-cuts.

Jim

[Martin KyteParticipant @martinkyte99762]

Exactly my point. You have to take the intuitive leap such as if you you want to get to there you don't have to start from here. The beginner will see that part on the drawing with a morse taper on it and immediately think he has to machine a morse taper. The old hand would possibly say to himself what can I start from that has a morse taper already on it and is scrap. Bit like the how do I machine a blind hole with a flat on one side. If you check out the answers they are all pretty much how can I convert what I can machine into what I want.

Martin

[Grizzly bearParticipant @grizzlybear]

Hi JS,

Always good to get a glimpse of the real world. Please continue to post.

I'm still chuckling with regard to the Blidgeport.

Regards, Bear..

[John Stevenson 1Participant @johnstevenson1]

Just set a job up on the lathe a few minutes ago ready for Monday morning, bitch of a job. Took about 15 minutes to set up but the bit that's holding it took me a good hour and a half, never though to get pics as it's a job I do a far bit but this stator is far far bigger and heaver than any before [ I think they are testing me !! ]

On Monday I'll photograph it in reverse and then post on it. OK this is a largish rotating stator off a big out runner motor but the method applies to any scale.

[Neil WyattModerator @neilwyatt]

> Ladbroke Grove

Not another hairy biker Hawkwind fan?

Neil

[John Stevenson 1Participant @johnstevenson1]

Damn, forgot I needed to update the inverse rotor post but it will have to wait whilst I find the memory stick.

In the meanwhile this fell on the floor today.

No idea what it's off the the link goes onto a geared motor and drives the yoke. Problem is it was fitted with some special needle roller bearings that ran direct on the 28mm shaft of the link. Link is a steel casting and the pin is hardened and it's not in too bad a condition but 28mm bore bearings with an OD of 60mm are not available.

Add the this it wasn't spotted in time has has walloped the yoke a few times and there is one decent crack into the bearing housing.

So bore the pin out, make a new pin out of EN hardaswhitchestits to 30mm instead of 28 and press in.

Slap some weld onto the yoke, wait for it to dry and bore out to 62mm for a standard bearing.

Looks passable to me so must be brew time.

[KWILParticipant @kwil]

John, if the floor was clean enough (or should that be clear enough?) I could sit there "all day learning by watching old Bill" or really just John. Cheers

[clogsParticipant @clogs]

HI all,

can someone tell me what the correct name for " EN hardaswitchestits" seems like something quite handy to know…

is there a standard list to describe the common use's of the EN types of steel….

great posting, amazing work….

thank clogs

[John Stevenson 1Participant @johnstevenson1]

Well Fridays job and not today and not that relevant unless you have a 12 tonne tablet stamping press in your workshop.

Just thought it looked pretty.

It's a face cam that bolts onto the start of a circular cam that raises the dies up and another set about it pushes them down. Quite slow moving about ? 60 revs per minute but they take quite a load. No spares, machine must be wartime or even pre war.

Other than the base and end joint there isn't another straight line on it anywhere. Could have chopped them out of a big steel ring 260mm in diameter but terrible wast of metal plus still need to do the face which is made up of 2 curves, so carved it out of two pieces of 35 x 35 x 75 on the CNC. Total machining time 38 minutes per piece but that doesn't include prep work, programming or fixturing although by a fluke the tapped holes in the base lined up with one of ARC's 20 x 40 x 80 blocks.

[John Stevenson 1Participant @johnstevenson1]

Last week on the " What did you do today ? " post I put some pictures of of some Bridgy rotors, nothing special about them do absolute loads but in one of the pictures were two armatures out of a very old series fork truck.

 

Even though they are old they love these are they have no electronics fitted just a few big relays and therefore cheap to maintain. Only problem is they use an old series motor and hydraulic system and they are getting quite scarce but can be repaired electrically but the mechanical drive is a problem.

They use a 25 vee spline drive, nothing else uses this and modern drives are involute stub splines anyway and not vee.

 

 

Not particularly clear as they were just included in a shot as opposed to being photographed specially. The one on the left has a ring of original spline at the end but inside it's all stripped out. Right hand one is completely gone.

 

So swing the slotting head round on the Bligeport, fortunately I had the foresight to fit the 4" riser off the old machine as by the time a 12" rotatry table and 8" 4 jaw chuck is fitted it's getting 'real' close.

 

 

Slotting head is off a Beaver but modified to fit this Warco VM40 which is bigger than a standard Bridgy, even a genuine Bridgy slotting head won't fit one of these but these Beaver heads are far heavier built and can be modified to make fit.

 

Rotary table is powered by a Steve Ward rotary indexer so 25 divisions are a doddle.

 

 

Only needed two but did eight so got a few spares for next time.

 

 

Armatures bored out, splined bushed pressed in and the plain ring in front of the fan splines is where it was welding into position. Ends case hardened and polished and they went out at dinner today.

 

Next six should be a lot easier to do

Edited By John Stevenson on 29/04/2015 21:46:17

[Johnboy25Participant @johnboy25]

I see that Scottish lubricant play a usefull part in the workshop from the pictures attached!

[John Stevenson 1Participant @johnstevenson1]

Well after a nice quiet few days at Harrogate it was back to the grindstone, or was that Harrogate all over again ?

Knew this job was coming in as they tried to bump it in the week before, done them before as well. Simple job, sprocket needs boring out to 32mm for a bearing fit and thinning down to 16mm total which means a lump off the boss.

Before I drilled out to 31mm then parted the bit off on the boss, quite a long job as there are 100 of these to do and probably took a couple of tips as well as the boss is 65mm in diameter. Then finished up with some nice heavy washers / spacers but with a 31mm hole.

So this time decided to remove the boss before drilling so I just had the 12mm pilot hole in it and that's 100 gear blanks, free of charge – thank you, but parting this off is even more work.

So took the chuck of the lathe, clamped it into the bandsaw and sawed the boss off. No tips to break and far, far faster as the saw takes 1 minute 31 seconds to cut the boss off.

That's an 8" chuck in the bandsaw but no reason why it could not be a smaller chuck in a hobby bandsaw, or donkey saw. Threaded bar is fitted to the rear of the vise jaws to stop them tapering with the work all at one end.

Took all of the afternoon to cut these, now got 20 finished.

Only 80 to go

[John Stevenson 1Participant @johnstevenson1]

Finished all the sprockets today, real boring day, did I mention I hate production work ?

Anyway got a right good job in this afternoon I can really get me teeth into or would have it if had any teeth left.

Two stage epicyclic gearbox that drives a turntable at the bottom of a special fork truck. The mast can rotate thru 180 degrees so it can pick off shelves whilst the truck is stationary. Real special, mast is 9 metres high in 5 stages and equipped with cameras etc.

First stage on the plate is OK but on the output stage all the pinions are toast. Fortunately all the pinions are the same except the first stage has a smaller bore but possible to get decent measurements.

And the measurements proved what I suspected when I saw these, that they are special, note the fat teeth. So that knocked nipping up to HPC gears and buying three off the shelf gears – damn.

20 teeth but cut on a 21 PCD, so turn a simple bar up to the OD and throw it on the 'gear hobber' which is thinly disguised as a Victoria U2 universal mill.

And ten minutes later we get a stick of gears.

Drilled, reamed, parted off and a tad of surface grinding we have three new gears.

So just a tad less than an hour but in all fairness they now have to go over the road to the hardening shop which will have to be tomorrow now but they can't get a new turntable bearing until Thursday anyway.

A new gearbox from Mitsubishi is £2,200 and 3 week wait so should have some reasonably happy bunny's.

[Martin KyteParticipant @martinkyte99762]

So where were you at the show, cos we could not find you. It's not unusual as we have a habit of missing things.

regards Martin

[Ketan SwaliParticipant @ketanswali79440]

He was hiding behind the Lunar lander

**LINK**

Ketan at ARC

[Neil WyattModerator @neilwyatt]

Oh the memories!

Added to favourites!

[Gray62Participant @gray62]

Ketan, I demand compensation, just wasted 30 minutes of my life trying to land an unimpressive spacecraft on a totally inadequate representation of a lunar landscape – how dare you inflict these forgotten artifacts on an innocent human being !!!

[Author]

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