Non-Tool Stuff Starts About Halfway Down

I’m trying to figure out whether the stuff I’ve learned in machining videos is correct.

A long while back, I ordered an “as new” OSG carbide end mill off Ebay. Seemed to work okay, and it was really cheap, so yesterday I ordered two more. I also looked at roughing mills. I have a 3/8″ roughing mill, but now that I know about the fun of changing collets, I realize I should try to put together a few mills with the same diameter. I found a 1/2″ roughing mill, and I noticed that the tolerances were not impressive. I think the diameter was listed as within 0.003″ of spec.

That confused me, because–I have not confirmed this yet–I’m fairly sure some of the videos suggested using an edge finder to locate the spindle relative to the work, and then popping in an end mill of known diameter, and using that diameter for calculations when moving the table. If you’re a machinist, you know that a diameter that’s off by 0.003″ is going to give you errors half that big in your work. And that’s more than big enough to be a concern when you’re trying to be precise. It doesn’t matter with a roughing mill, but other end mills have the same issue.

On top of that, I’m almost sure the ATI videos I watched endorsed carbide end mills. Carbide is really hard, and it’s expensive. The benefits are that it lasts a long time and performs well and cuts faster. Now I’m being told it should not be used on manual mills, because you’re supposed to climb-cut when you use it, and that will make a manual mill flex. I hope I have this right. I believe I was told that if you cut conventionally with carbide, it breaks up over time, and you get bad finishes.

The upshot seems to be that edge finders are worthless for some of the uses I hoped to use them for, and I was dumb to buy carbide. Apparently cobalt is a better choice for me. A lot of people tell me not to get cobalt, because it costs a little more, but it seems to work way better than HSS. At least in drill bits.

I guess I won’t regret spending $10 each on two carbide cutters, since they’ll definitely work long enough to be worth the money.

If you can’t use an edge finder to locate a cutter precisely, you have to do it some other way. I believe that sends you back to the rolling-paper method. You embarrass yourself by buying rolling papers like a depraved stoner, and then you find edges by holding them between the work and the cutter. The edge finder will tell you where the spindle is, relative to the work, but that’s not the same as telling you where the edge of the cutter will be.

I’ve been trying to find a good used rotary table, but it’s not that easy. You also need indexing plates and a tailstock, and by the time you get done looking for this stuff, you’ve been shopping for six months. It may be time to bite the Enco bullet and go Taiwanese again. You can often save three figures by getting old American tooling, but what does that savings cost you in lost time you could have been spending machining? It amazes me that people brag about shopping a year for a taper attachment or a steady rest. How long do they expect to live? These are usually middle-aged or older guys. A year can easily be five or ten percent of their remaining time on earth. When you decide to dedicate a lot of time to something, you need to ask yourself how much time you have left. I find life so interesting, I want to live a thousand years. That seems unlikely, however.

A few months back, my dad was talking about getting a travel trailer. I’m very, very glad he still has enthusiasm for things like that. But my mother has been gone for 12 years, and he’s 77. A lot of the people we could have visited 35 years ago are dead or elderly. It’s late.

My grandfather once leased a house to a 67-year-old man, tying it up for a number of years. Someone in the family complained, and my grandfather said, “He’s an old man. He won’t live long.” When he said that, I believe he was 72.

He was right, but you can still see my point.

I guess it will sound funny, but one reason I bought a convertible is that we didn’t do anything fun when I was a kid. My uncle Jim had a couple of convertibles in the Sixties, and some family members talked like he had gone insane. That’s how boring most of us were. My dad, my mother, my sister and I were pretty dull. We rarely went on real vacations. We never toured the US. We didn’t have a boat or an RV. We had no regular activities, like shooting or bowling. We belonged to no clubs or organizations, apart from the country club. We didn’t go to church regularly. We never belonged to a church. Golf was the only sport, apart from games my friends and I played in the yard, and my dad was the only one who golfed. We watched TV; that was our main activity. Isn’t that awful? I hate to admit it. That was our life. I went to school, and then I came home and watched TV, and I refrained from doing homework unless I had absolutely no choice, and after that I went to bed. My mother was the only one who wasn’t a TV addict, but she didn’t really do anything with the time she saved. My sister and I didn’t have many toys, which is weird, since we were well off. Mike says the other kids felt sorry for us. I had no idea back then. My mother bought me a banjo when I was 15; that was nice.

I guess I wasn’t as bad as the others. I enjoyed shooting BB guns, fishing for inedible fish, breaking things, and fireworks. Mike and I used to get together and do the kind of stupid, aimless things kids do when they’re on their own. Like Beavis and Butt-head, I guess, except we weren’t that mean or stupid. We tended to do strange, creative things. I had another friend nearby, but he wasn’t bright enough to come up with things like that. We also had CB radios and other passing interests. My sister didn’t do much of anything, but that’s normal for girls.

I remember Mike somehow got ahold of a surplus parachute. We put it in his yard, on a busy corner, and we weighted the perimeter. Then we put a fan under it and put some lights inside. It blew up into a big, quivering white dome, and we went inside and hung out. Cars slowed down so people could see this glowing object and wonder why these two abnormal kids were doing something that wasn’t ordinary.

I got my first convertible in 1980, and Jim was part of the inspiration. His branch of the family had more fun than the others. I’m sure my mother told me the car would flip and burn immediately, and I would be trapped underneath it like a chicken in a roasting pan. Oh, Lord. A convertible. Please, don’t let this happen to my child. Next he’ll be base-jumping. My mother didn’t like electric windows, because she thought any car with electric windows would plunge into a canal at the earliest opportunity, and there she would be, unable to roll down the window and escape. Meanwhile, she smoked at least two packs of cigarettes a day. I was crazy about my mom, but I knew there her logic had its weak points. I’m ancient. So far, I’ve know ONE person who was in a convertible that flipped, and he didn’t roast. I don’t know anyone who has driven into a canal. You can keep a punch in your car to break your windows, if that kind of thing worries you. I think my Glock will also do the job.

Once in a while, you have to do something. Just spend the money and do it. It isn’t going to do itself. I’m really glad I’ve had two convertibles and two motorcycles. I’m glad I lived in Israel for four months. I’m glad I published three books and got a bunch of tools and guns and learned to make beer. I can’t even guess how boring life would be if I didn’t do things like this. By and large, the strange and challenging things you do will be the things you remember with the most pleasure. That’s an extremely important lesson young people should learn. You shouldn’t be a sensation junkie or a hedonistic wastrel, but you should embrace opportunities to shake up your life. You should be conscious of their value and jump on them instead of avoiding them. You don’t want to leave your kids a diary that has entries like, “July 17: I celebrate 63 victorious years of resisting buying a motorcycle. I will celebrate by putting a small amount of real sugar in my oatmeal.”

I think a rotary table will be a real asset. Right now, I can drill holes and make straight cuts, and that’s about it. Not much utility for what I paid. A rotary table will let me cut arcs, and it will allow me to do tasks that require breaking circles up accurately into sections. Circles of bolt holes, for example.

I should take one of the bikes out today. I hope my mom will be too busy in paradise to notice.