Drive Adapter for HF Elec Pipe Threader

Doing the SWAG mod to my Harbor Freight tubing roller. They say to just mash the 1/2" threading die onto the 3/4" drive shaft for the roller. I want to keep the 1/2" die usable so I designed an adapter to fit the octagon drive bore in the threader. This is an 8 sided bore. It would have been to easy to make a 6 sided one.
The HF Pipe Threader.
http://images116.fotki.com/v693/phot...MVC018F-vi.jpg
This is one of the original dies... 8 sides, not 6... Is this a "metric" hexagon?
http://images9.fotki.com/v120/photos...MVC019F-vi.jpg
I designed the adapter in 3D CAD so it was easy to get good dimensions. I first designed it by cutting 8 chunks of 3/8th's plate but thought it would be easier to assemble if they were all one piece.
We laid out all of the cut lines and clamped the plate to a small angle block.
Doing all of the cutting on VBS was pretty quick with the layout lines and block clamped on to guide the initial cut.
http://images19.fotki.com/v285/photo...MVC005F-vi.jpg
The spacing was .526 inches between the centers of the cut. With all of the cuts made.
http://images41.fotki.com/v305/photo...MVC001F-vi.jpg
See next post.

We left about .030 at the bottom of the cut to hold all of the pieces together.
http://images116.fotki.com/v695/phot...MVC002F-vi.jpg
This is the "spindle" for the adapter. I cut a chunk of 1 1/4" dia. steel, cleaned it up in the lathe and bored a .75 hole thru the middle.
http://images107.fotki.com/v780/phot...MVC005F-vi.jpg
http://images114.fotki.com/v145/phot...MVC001F-vi.jpg
Drilled and tapped two holes on one end, 90 degrees apart, to clamp the adapter to the shaft.
http://images9.fotki.com/v1542/photo...MVC004F-vi.jpg
See next post

Used the spindle to form the 3/8th's plate. This wasn't that easy. It took two sets of pliers to do the bending.
http://images53.fotki.com/v1502/phot...MVC006F-vi.jpg
Getting it there...
http://images53.fotki.com/v1465/phot...MVC008F-vi.jpg
The hose clamp pulled it down pretty close but we ended up using a hammer to get it the rest of the way.
http://images9.fotki.com/v1542/photo...MVC017F-vi.jpg
Adjusting the fit. It fit real well on the first try.
http://images116.fotki.com/v694/phot...MVC010F-vi.jpg
See next Post

I welded everything up and checked the fit. Did a little clean up grinding and it was good to go.
http://images53.fotki.com/v1519/phot...MVC008F-vi.jpg
This thing got very hot during the welding but it still fit the shaft and the drive bore with no problems after it cooled.
http://images114.fotki.com/v74/photo...MVC013F-vi.jpg
I'll end up painting it black but this will do the job and I don't have to destroy the pipe tap from the kit.
http://images19.fotki.com/v1612/phot...MVC014F-vi.jpg
Thanks for looking.
Mark

Thanks astroracer! I've added your Drive Adaptor for Pipe Threader to our Metalworking category, as well as to your builder page: astroracer's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="/drive-adaptor-for-pipe-threader"><img src="/uploads/71060/drive-adaptor-for-pipe-threader.jpeg" alt="Drive Adaptor for Pipe Threader" /></a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="/drive-adaptor-for-pipe-threader">Drive Adaptor for Pipe Threader</a> <span> by <a href="/builder/astroracer_2">astroracer</a></span> </div> <div class="tags"> tags: <a href="/tag/pipe">pipe</a>, <a href="/tag/welding">welding</a>, <a href="/tag/threading">threading</a>, <a href="/tag/adaptor">adaptor</a> </div> </div> </div> </div>

did you make the 7 cuts on a band saw?

Yes we did. You don't have to jump through all these hoops though, Swag Offroad makes a machined piece that does the job now. :)
https://www.swagoffroad.com/SWAG-Mac...ub-_p_113.html
Well worth the 35 dollar price tag.
Mark