Flycutting a Saddle

[editor@glue-it.com]

In particular this is flycutting a saddle on a manual milling machine with a simple flycutter. This is my technique for getting an accurate radius and how to measure and then adjust.

[Toolmaker51]

That method works correctly, there is a preset to streamline the setup.

Measure shank diameter. Lay the cutter shank horizontally in a Vee block, lay on side to get cutter slot parallel, and clamp. Re-erect Vee block.
With height gauge, touch off shank diameter, to realize centerline.
Adding desired radius, set height gauge to that dimension. Raise cutter in contact to gauge foot, viola'!

Granted, it works best to have two cutters, one a rougher. We saddle weldments this way frequently, especially square/ rectangular tubing for round stock.

[hemmjo]

Interesting process. I like that he is using "1 3/4" diameter tubing, and measuring it in mm.

[editor@glue-it.com]

Interesting process. I like that he is using "1 3/4" diameter tubing, and measuring it in mm.

The larger copper tube sizes tend to be in the old imperial system of measurements......but overall working in mm is so much easier (I know lots will not agree...)

[hemmjo]

Understood, was not meant to be critical, just that we need to be able to work in both.

The funny thing is, Copper Tube Size (CTS) is typically expressed as the ID, which for that tube would be 1 1/2" CTS. Even crazier is that 1 1/2" CTS is not really 1 1/2". It is close but the ID varies, while the OD of CTS tubing remains constant so the fittings will work with all types. The wall thickness varies according to according to type. J, K, L, M.

It is just how things evolve.

[DIYer]

Thanks editor@glue-it.com! We've added your Saddle Cutting Method to our Milling category,
as well as to your builder page: editor@glue-it.com's Homemade Tools. Your receipt:

Saddle Cutting Method by editor@glue-it.com

tags: fly cutter