Shop built bushing machine

[jhe.1973]

Hi Everyone,

I made this bushing machine over 35 years ago. I was learning clock repair from a repairman & there were so many things I didn't like about his Bergeon machine. Right away I wanted something heavier & deep enough for some of the large hall clock chiming movements that I had seen.



This is mostly built from O1 ground tool steel that I used as purchased. The column is Stressproof steel that my brother-in-law gave to me. It was leftover from a job his shop had run. The spindle runs in a hardened drill bushing so it can be replaced if it ever wears out - as if that's going to happen.

This machine has a 7.4 inch deep throat so I can just about reach to the center of a 15 inch wide plate. While making it I realized I could make the slide way for the clamps as one piece that swivels around the lower anvil. This assembly is tightened with the knurled nut from below. This allows a plate of infinite length - if I should ever run into an infinitely long plate.



I also made the clamps to swivel on their base and overlap at the center so I can hold short & irregular pieces if necessary. I just used some hardware store key stock for the clamps and never got around to polishing all the cad plating off of them.



Because I didn't care to have lock nuts under the slide way for the clamps, I have flanged studs that come up to the knurled nuts just below the clamps. This keeps my hands right around the same level as the plate I am centering. I feel that this is more comfortable and goes quicker than having to reach under to lock the clamps down.

While I was at it I copied all the Bergeon cutters in HS steel starting with hardened drill blanks and grinding them to size. I don't think they will ever wear out either.



You may notice that I turned off the end of a KWM style hand bushing tool so I can use their cutters & bushings if I should ever want to.

I actually made two of these machines, giving the other to my clock repair friend that I had learned the craft from.

He was happy.

 

[Dean Williams]

Excellent work, Jim. I can see why your friend was happy! It's a beauty.

 

[John P]

Now thats a nice piece of work. Jim, you gots some hours in that. I made one myself but I see some improvements I can make.
Good work Jim


John

 

[Max Phillips]

Very nice work Jim! Seeing fabrication like this is what keeps me motivated.

 

[jhe.1973]

Hi Everyone,

Dean, John & Max:

Thank you for your compliments and interest.

I realized that I should add another photo to show a detail that isn't obvious from the other photos. This is the method I used to locate the clamps and also to keep the clamping flanges from turning:



The stub on the bottom of the clamp is the same size as the head of the socket head screw. They have just a slight clearance in the slot. I also slightly dished the bottom of the clamp, near the stub, so as to provide a radius corner for the stub.

 

[Max Phillips]

Jim, did you make those milling marks look like art on purpose? I hope you made an extra to hang on the wall.

 

[jhe.1973]

Max:

Nope on the milling marks being intentional. They are actually the result of the flycutter picking up small bits of metal on the cutting edge and scoring the finish in a random manner. Most likely the result of the tool getting dull.

I still intend to polish out these marks someday but now I guess I should frame a good photo of them to hang on the wall when I do.

 

[R. Croswell]

I found a Bergeon tool at a reasonable price so that was my choice. I usually use a smaller size Bergeon bushing and broach it out to fit. Biggest problem with the Bergeon machine is that the clamps are not adjustable and won’t move in close to grip small parts (previously mentioned) and the height of the stumps is not tall enough for my liking. www.merritts.com does sell a set of replacement jaws and while they are not especially well made they are a lot more versatile.

As for bronze or brass, I’ve used both and can’t say that I’ve ever had a problem with either that could be attributed to the metal. Generally I now use brass bushings unless it looks like bronze was used originally.

RC

 

[jhe.1973]

Hi Everyone,

The last few weeks have been quite busy – even for me!

I set aside three weeks to get my depth tool & bushing machine ready for the craft competition at the 2012 NAWCC National in Pasadena. Then the spout on the upper plastic tank of my car’s radiator snapped off just after getting on the Interstate.

There went one week before I got it up and running again. I had to make a special hole saw to machine out one of the spark plug wires that would not budge …………… but that’s another story!

So even though I scaled back plans of how I was going to display the tools I was REALLY busy trying to make it. Even thought of dropping out!

The bushing machine was an afterthought and when I started taking a close/critical look at it I didn’t know if I had enough time to ‘clean’ it up ‘cuz my surface grinder hadn’t been hooked back up since a floor plan change.

It had some light surface rust and in a few places, where there was steel to steel it was rather deep.



Notice the column was just turned, not ground. Here is a detail showing how the column and arms are located. Also the base has been finished here:



I started finishing the top arm using a cast iron fixture plate as a lapping plate w/150 grit grinding powder and oil. Then went to 240 grit emery cloth followed by 500 grit wet/dry finishing paper;




After two days, this was the finish on the top arm:



The reflection is the security door to my shop and is about 10 feet from this upper arm.

Then I hooked up my grinder but I still had to finish lap everything ‘cuz my grinder has a bad coupling driving the spindle so the finish isn’t as good as could be.

I’m showing this ‘cuz I have said elsewhere on this forum that a person doesn’t need fancy tools for everything.

Right Jay?

More in the next post..................

 

[jhe.1973]

When assembling everything, I made brass shims for between the top and bottom surfaces the guide bar so the clamps will not create rust rings again if the machine isn’t used for a prolonged time.



The only time this area rusted was back East where the humidity was a lot higher, but I figured why chance it again?

Here is a photo I took for the show to illustrate how easily this machine accommodates a big hall clock plate. This is from a Winterhalder 9-tube retirement project of mine. The standard 8 day movement is for a size comparison.



Drum roll please......

Ta Da!

 

[harold bain]

Congratulations, Jim, a well deserved award for your efforts.

 

[jhe.1973]

Congratulations, Jim, a well deserved award for your efforts.

Hi Harold, thanks so much for posting this, it does mean a lot.

 

[cazboy]

Jim, your bushing machine is fabulous, it appears to be extremely well-made. But more than that, it seems extremely functional! Thanks for sharing it.

One thing your machine brings to mind pertains to me - a dabbler who is currently preparing to purchase some hand tools for bushing. As I read various threads here, I see that the KWM and Bergeon machines are deadly expensive and still have huge deficiencies!

 

[jhe.1973]

Jim, your bushing machine is fabulous, it appears to be extremely well-made. But more than that, it seems extremely functional! Thanks for sharing it.

One thing your machine brings to mind pertains to me - a dabbler who is currently preparing to purchase some hand tools for bushing. As I read various threads here, I see that the KWM and Bergeon machines are deadly expensive and still have huge deficiencies!

Hi Doug,

Thank you for you interest and the kind words. It is my pleasure to share it.

At the craft competition someone suggested that I market these machines. I've kicked the idea around before and I think that it might be possible as a semi-finished kit. Things like the line bore of the spindle and anvil holes, all milling and turning etc. The final assembly and finish desired would be up to the owner.

After all, I used this one for 30+ years as machined and entered it as an afterthought. The clock repair instructor that I gave the other machine to painted his a light green.

To each his own.

 

[cazboy]

Jim, I just sent you a private message.

 

[Kevin W.]

Nice job Jim.Often times engineers design a tool they never use.Its nice to see someone with your machining experience and talents making a machine a clock repair person would love to own.Well thought out and made to how we would like it to be.

 

[jhe.1973]

Thanks Kevin for your comments and interest.

I know just what you mean about engineers designing what they don't use and I agree with you completely. However, I often see where the accountant mentality running a company restricts the engineers/designers from utilizing their skills so they end up with what the bean counter wants and not what the engineer knows is needed.

Classic Dilbert! Can you guess it's my favorite comic strip?