Chamfering Machine

I guess I could call this Version-2. My first attempt was a V base I adapted onto a Makita variable speed trimmer router where the cutting occurred on the end of the cutter, which was my preference. It worked OK but it had a few issues. It was kind of gangly to mount & also not super safe to hold with one hand & push the work through with the other. The depth control used the ratchet wheel & clamp, but it was kind coarse & fiddly to adjust. The bigger concern was metal shavings could dropping through the cutter clearance hole & ultimately into the motor windings.

So this assembly uses my Bosch die grinder in lay down mode. Unfortunately this grinder is not variable speed but seems to work OK. This has the cutting action on the side of the end mill. Die grinder motor vents are more protected than routers by design. But the firewall, base & 2 side members kind of make a natural confined box so 90% the chips drop down safely into that natural cavity, nothing back to the motor.

To adjust the chamfer depth, I loosen the clamp handles, turn the knurled knob which jacks up the V frame up or down. The frame movement is confined by the UHMW slide rails. The base is 1/2" MDF. My original plan was to mount the MDF base to a bench top, but I decided to add a keel from same material & hold it the bench vise. A lot more convenient to quickly set up & store away.

The test cuts look pretty good. Quite smooth & consistent. The aluminum tester is about .070", the steel is about .020". You can zip through the edges pretty quick & there is no kick back tendency, it’s quite controlled.

The V rails were designed around 3/16" thickness but I realized what I had in my scrap box was under that thickness & kind of garbage mystery material from sheet metal stamping. After filing & straightening it still looked like crap so I gave it the Tremclad spray bomb treatment to prevent rust. In hind sight it’s probably going to just scratch off so maybe I’ll find some nicer material one day. Anyway, the machine turned out ok.

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Some construction pics
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Few more.

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What I forgot to mention is my home brew creation is intended as a lighter duty, cheap mans version of an industrial tool like this. I haven't used one myself to compare. Because of the price & space required, I doubt I'll ever own one. But if any of you have experience on them I'd be interested in your comments. Looks like they use carbide inserts?

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petertha,

Wow, that is amazing design and so useful using your previously purchased Bosch die grinder. A quick release and the Bosch die grinder is not totally dedicated to this tool. You have shown us a very useful tool design. I have always wanted some sort of chamfering machine and now have some direction on where to start because I too have the Bosch die grinder. Also, don't forget to use ear protection - it may seem like no big noise deal but it will eventually catch up to you - trust me I know and regret not having used ear protection years ago.

Regards,

Paul

Regards,

Paul

Thank you.

Just for topical interest, here is the base I made for my Makita mini router. Hopefully you can see what I was referring to about the proximity motor vents. Not good for swarf ingestion IMO.

And here is a link to Stefan's chamfering machine setup.
Chamfering machine


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Thanks petertha! We've added your Chamfering Fixture to our Metalworking category,
as well as to your builder page: petertha's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="http://www.homemadetools.net/homemade-chamfering-fixture"> <img src="/uploads/211055/homemade-chamfering-fixture.jpeg"/> </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="http://www.homemadetools.net/homemade-chamfering-fixture">Chamfering Fixture</a> <span> by <a href="http://www.homemadetools.net/builder/petertha_2">petertha</a></span> </div> <div class="tags">tags: <a href='http://www.homemadetools.net/tag/grinder'>grinder</a>, <a href='http://www.homemadetools.net/tag/fixture'>fixture</a>, <a href='http://www.homemadetools.net/tag/chamfer'>chamfer</a> </div> </div> </div> </div>
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Petertha
Very nice build and quite functional and desired. I thought of one but another project bumped it.
To say it enough there is no such thing, HEARING PROTECTION I'm 60 years old and my hearing is almost gone, just because of loud noises all my life. Put ear plugs in and walk around all day and see what not hearing is like. AND don't worry about the cricket chirping or the frogs croaking, you might not hear them at 60.
Nelson

Nelson,

I am with you 100% on using ear protection devices for protection against exposure to excessive shop noise. We naturally take for granted our hearing until it is significantly diminished because we thought it was okay to go without the ear protection. Today, it is cool and absolutely necessary to use ear protection plugs or headphones because the alternative is forever diminished hearing by the time you reach sixty and it gets even worst there after. That is my situation and I regret not being more careful with my hearing. The same is true for eye protection. Use your safety protection gear no matter how minor or simple the operation being preformed because what can go wrong, will go wrong and in an instant you will damage your eyes without using the proper protection.

Thank you for speaking up on this important safety advice,

Sincerely, Paul Jones

Paul
I guess I can say I have been bless with failing sight for many years and have worn glasses for over 40 of mine. After starting to work on metal I questioned my eye doctor about safety glasses. Well I have been sold on them since. I do not know it may have been a curse, but my eyes are protected the same.
Nelson

I agree wholeheartedly about hearing protection. I have tinnitus from too much unprotected youthful shooting and rivet hammering.
It's really annoying - especially at the symphony.

What I don't understand is why we don't have earlids. Internal flappers in the ear canal that work similar to eyelids with the exception that the default state when sleeping would be open rather than closed; must listen for those wolves outside the cave.
Beyond the aspect of hearing protection, just imagine the benefits of being able to unobtrusively shut down your hearing when the kids arrive with all the undisciplined grandkids in tow.

Actually, I think there's a real market for soft plastic fake hearing aids that could be worn in such a situation.

I have several 7 and 9: rt angle grinders laying around with bad gears. Years ago I made a straight grinder out of a 5 " angle grinder which made a perfect pencil grinder with a 5/8'11 arbor it was great with the 2 and 3" diameter cob stones as long as they had a 30000 RPM rating Seeing this chamfering rig it has started me to thinking about making another straight grinder out of one of the heavier duty 6000 RPM machines without the 3 to 1 reduction gears it would have 18000 RPM More than high enough for cutter speed and heavy duty enough to stand up to my punishment.
For hearing protection since I already have a 60 &30% loss I wear a pair of tactical shooters ear muffs now when using the chain saw or cutting sheet metal with a circular saw and other things that make loud or high impact sounds safety glasses are fine but I can't see through even new high dollar ones for critical measurements. using a chain saw is fine don't need to see much cutting trees any way I mostly wear a clear face shield when grinding though and I couldn't hit a nail to save my life wearing any kind of glasses, prescription or plain or a face shield

Soft plastic faux hearing aids? Humm you may have something there need help in creating a start up company?

There is a great big market for hearing aids and sport related injures. If it's not using our head it's doing totally stupid things. And I have done some very stupid things in my life.
Nelson

Nelson what Marv and I were referring to is creating a phony plastic hearing aid which would actually be sound suppressing ear plugs, we can pretend is not working so we won't have to pay attention to or even hear the grand kids.

I tried to read carefully. But didn't find info about blade you used?
Tungsten carbide cutter?

I got it now, the only problem is I do not hear them most of the time.
Nelson

petertha,

That is a very nice concept and I sure it serves you well. Have you thought of adding a dust/chip pick up adapter for a shop vac?
I have a small Elu router and router table set up in a for my chamfering needs. I have added a dust pickup for mine and it makes all those sharp ugly chips vanish. I use a piloted 45 degree carbide bit and it can sling a lot of chips. As for noise I second what has been said here. I now sport a pair of new hearing aids as a result of not using hearing protection for most of my 50 plus years of machining around loud equipment.

Quote:

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Originally Posted by ncollar

... And I have done some very stupid things in my life.
Nelson

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Haven't we all! I damaged hearing in my left ear with a single gun shot without hearing protection. Lets not get into snowmobile and biking accidents, as you say doing stupid things.

This chamfering tool has me interested and has already given me ideas. My only concerns are finding a cheap grinder to repurpose and the amount of hangout required to clear the collet nose. I looks like a great place to use a set screw holder or even a shrink fit solution. Of course a set screw holder implies building your own spindle.

All this has me wondering if adding a flinger to the vertically mounted arrangement would do enough to keep the swarf away from the open windings. These tool posts have me thinking and distracted from completing my shop area in the basement.

Quote:

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Originally Posted by Tuomas

I tried to read carefully. But didn't find info about blade you used?
Tungsten carbide cutter?

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Yes, 0.250" shank & (constant body) 0.250" diameter 2-flute carbide end mill.

Quote:

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Originally Posted by wizard69

All this has me wondering if adding a flinger to the vertically mounted arrangement would do enough to keep the swarf away from the open windings.

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I'm not sure if you clicked on the link I provided in earlier post but there is an example of Stefan's chamfering machine setup, a die grinder in vertical mode. Here it is again
Chamfering machine

He milled a port in the side of the body & that's where chips stream out. I think I recall in one of his YouTube videos showing it in action & he may have it manifolded to a vacuum, I cant recall. Its a torrent of chips.

Just to be clear, I don't think die grinders are 'as' susceptible to chips in the motor windings. The vents are well back & smaller & its (somewhat) made for duty like this. Anyway on my tool, its very well protected & chips drop into a natural made cavity. The reference I was making was my first attempt - an inverted router. Routers breath differently to die grinders because a) they are intended for wood so sawdust isn't as problematic and b) mostly cut bit down & cooling fan blows out. Basically a good portion of the motor is open vents. Even when the bit points up like in a router table setup, there is usually a collet or similar closure. Anyway I viewed a metal shaving environment as more hostile to motor windings to a router.

petertha, Ok I am hooked I am going to make one this month after I get the solid rod aluminum.
My congrats for a well thought out build, many a time when I am using my belt sander to do the edges,
I wish I had a device as you have built good job...Cap..

petertha,

This is a very nice concept for a chamfering machine. It is similar to a machine (Burr Beaver) we had years ago in the shop. We used it to chamfer steel mold plates. Your version is well designed and executed and it is portable.

I'm with you Paul & Nelson, for the use of quality PPE. During the late 80's I subcontracted in Parks maintenance and the contracter hired an experienced chap who had no bridge on his nose and would not wear safety glasses. I told him HE HAD TO! He refused stating he didn't during the 8 1/2 years with his previous employer for whom the contractor was working. I presumed they let him go because of this as he was very good at his work. I compromised with him and stated that he could wear my "racing goggles" if he wanted to work. He couldn't believe how well they fitted his face and the "spongy material filled the void where he had no nose bridge. win win win!(except my financial cost but I had peace of mind about my work colleague's eyes). I knew a safety officer supervising over 600 staff safety and he lost an eye on his own yard . He missed one blade of grass and picked up the line trimmer & cut that one blade taking out his eye: he had forgotten he had removed his PPE.
Interestingly, in 1999 I found employment with a local goverment and had to sign an agreement(after passing the medical including eyes & hearing) that stated Ithey would own any invention I made while working there=very ambiguous relative as to what invention. I continually complained about the quality of the ear plugs they allocated and eventually used my own quality muffs for protection. After others complained also, the ear tests were done again and mine had deteriated in the four years. They brushed off the matter suggesting my out of work hours work may have caused the decline or my muffs may have been faulty.

The best protection is the minimum in my humble opinion so don't settle for second best.

Regards,
Ranald