September 2, 2020
Posted By Jason

Making a 5c Adapter Plate for the HRC160

Hey. Jason McCann here from MOUNTAIN TACTICAL®, and we’re trying something new. I’ve never done a solo video where someone wasn’t manning the camera, but we’ve had tons of requests for us to keep up on video and I’ve done a really bad job of that. So I figured I just grab the camera and see how this turns out. We’ve had a lot of requests to have more manufacturing style videos to actually see stuff being made. So we have a unique situation today and have to make a one-off part. So I figured it’d be a great opportunity to kind of show you what we’re doing. So come over here by the machines, and we just made a few hundred bottom metal over here. And the next step is to make the mag catch. 

The mag catch fixture [00:01:00] went with our 5c rotary table. And that’s off at Haas being repaired right now. Some of you guys who’ve been following us know that one of our machines just had a major meltdown in the software destroyed a lot of stuff. Haas had to come out here, literally take it apart, rebuild it, and the rotary table is the last piece we’re waiting on. Well, they’ve all this bottom metal. Obviously, you guys want it in your hands. So we’re going to make an adapter. I went out and bought a 5c just standalone column and we’re going to adapt it put to make an adapter plate to go on this new rotary. 

We have, let’s even get that in the camera. There we go. There’s a new rotary that we have. So, obviously, this doesn’t match up. Let me grab this. Here’s there’s no way to attach this. [00:02:00] We have to create an intermediary place. So I figured I’d show you guys how I’m going to do this. We get these mag catches made and gets this bottom metal out and in your guys’ hands. So welcome to the journey.

All right. So everything we design we first have to design virtually. We use SolidWorks here at the shop and we design a 3D model. We’re able to do a significant amount of our engineering stress test everything actually inside the software which is really cool. But then we have to once we’ve kind of debugged it as much as we can, we get down and we machine it. And I had made a part like this before because I had to make our rails, I have a trunnion table to tilt the table, the machine table at the 20 mo ways to make our 20 mo rails.

[00:03:00] And so I had to make an adapter plate. It has keyways here. It has around the boss. It goes into the bore of the rotary the hold through. And I just took this design and adapted it for this 5c adapter. And so we have counterbores back here. So we’re going to have screws that go through the back to the front to screw into that adapter. And then on the other side, there are two grooves on the back of that 5c adapter plate, and so we’re going to hold concentricity using that. So we’re going to cut this groove here. 

The next challenge is how do we get it on and off the bigger rotary table. And so we have to cut these reliefs so we can have the bolts come through to the keyway where they’ll be T nuts holding that to the rotary. [00:04:00] But because the 5c would cover those screw holes, I need to be able to get in here with a wrench. And so cut a nice wide groove so I can actually get in there and turn the wrench. And so we’ll seem like there’s a one-off part. Never, never made it before. And hopefully, it works. So let’s get down to the machine and go cuts now.

All right. So we’re back downstairs, I saw the model upstairs [00:04:35 inaudible] goes on the back of the 5c. And we’re going to make it out of this chunk of 6061 right here. So just as we use to make a lot of our fixtures. We had a line around the shop. So this is going to come at an intermediary surface for our rotary over here on the other machine. So let’s get to the machine.

All right. So [00:05:00] we have our metal end device. Before we do anything, I go through my tool list and I touch them off before every single new run. I want to make sure, you know, things change. Things break. It allows you to inspect your tools before you actually go into the job. And make sure everything’s just dialed in perfect.

This is a great roughing tool and indexable on one inch and mill. I got from Curtis over at the tool source and we hauled some serious metal with this thing. It has three spindle coiling capabilities. And quite honestly, I don’t run it as hard as it could be run simply because there’s really no need to. As you’ll see here shortly, it removes a lot of material really fast. No sense, no sense going, you know, the one that potentially breaking an insert [00:06:00] and ruining a part. So that costs you a lot of time. So it’s measuring the outside diameter because as you cut with cutting surface wears down, and so this measures everything within ten-thousandths of an inch just to make sure everything’s just dead nuts. Perfect. So, we’re going to go in. We’re going to touch off every tool. Make sure everything’s dialed and you’re right back again. 

[00:07:00] All right. So what we’re doing is we’re getting as centered as possible on the workpiece and we’re going to let the probe dial this thing in for us. 

[00:08:00] Our x dimension is 6.5 inches. Our y dimension is 6 inches on the nose. We’re going to go down from where we’re currently three-quarters of an inch and we’ll go from there. 

[00:09:00] Nice. Now we’re centered on our stock. We’re just going to go touch off our Z-axis. We’re saying roughly 250,000 parts. Excellent. So we have our part zero. Moved the probe out of the way before we damage it. There you go. See what we can do. 

All right. Also, we’re probably going to skim our soft jaws. That’s okay. Soft jaws are just currently [00:10:00] disposable. That’s what they’re there for. But we’re making a really thick part. We are using a lot of this material. I kind of went into it expecting that. So let’s see what happens when we go. I’m going to start out slow on the rapids just to make sure all our depths are correct. And then speed it up once. I know everything’s touching off where it’s supposed to.

[00:13:18] All right, well some reason, zooming in, zoom in here. Ooh, too much area. Our finishing pass didn’t get coated on that surface. So let me go back upstairs, figure out why that didn’t get done. Other than that, it looks like it’s dead nuts. We’ll try it on the fixture. See how it turned out, but I will be right back.

Okay, back down here. So yeah, for whatever reason that finishing pass for this surface [00:14:00] didn’t make it on the last code. So we’re just going to run that and should be good to go. We’ll measure it, make sure it’s good and then flip it over to the other side.  

It is a very versatile tool. You can run it fast and hard, remove a lot of material really fast. [00:14:37 inaudible] was the cubic inches per minute that we were running earlier was, but I want to say it’s somewhere around 75 to 80, just remove a lot of material really fast. Let me come back around take more of a finishing style. I got to slow it down and we got a [00:15:00] really, really nice surface. Doesn’t do good on sidewalks, but it does really well on finishing floors. Yeah. That’s [00:15:42 inaudible] a couple of measurements. See where we are at.

All right. Well, let’s get on the calipers. Let’s on mics, [00:16:00] let’s throw it on the other rotary and just make sure it fits. I’m not sure how to film this exactly without covering up what I’m doing. But here’s what we made in that first operation, right surface finish, and then we have spindle bore here, and that’s what this boss is going to go into. And then we have these little dots here. In the second operation, we’re going to drill holes through these little T nuts that go in here. Bolts come through here. Going to walk this all together. Because we want this to go up against this face with absolutely zero put. You can see once that locks in, nothing perfect as the exact fit that we want. So I’d say it’s safe to say we can machine the other side of this. Let’s go back over the DM.

[00:17:00] All right. So I have a powerful tool in our vise. The first thing we’re going to do is we are going to grab this upper corner and we’re going to take the hat off and the hat off is that’s all the material that we used to hold the part in the first operation. So we are going to come down here, grab this corner, face this off. Make sure we have the correct thickness on the part. Doesn’t take a few passes. I speed the video up to this because it is kind of boring stuff, but [00:17:42 inaudible].

[00:18:13] All right. We’re back. Now we got that.  Got that hat off. We are going to this center. So the reason why I designed flats on this instead of going perfectly around was simply so I could just use a standard set of soft jaws and save me at a time of mega set around soft jaws. And it gives me a great on indicating points to go off of here. So there’s more than one way to skin a cat. It’s not a critical dimension. There’s no meeting surface there. So I just went with it.

[00:19:00] Excellent. I’ll pull up our programs, switch off our tools. We’ll be good to go.

All right. Here we go. I’m going to slow the rapids down, make sure we’re in the right spot. All right.

[00:20:19] Oh nice. You want to hit the finishing [00:20:22 inaudible]. 

[00:21:06] See what we got here. So we want no put. That is just dead nuts. So you know the other side is concentric to the bore on our rotary. This ring is concentric to the bore on this adapter and this ring is concentric to the bore on the other side. So we’ll get it all put together here and we put our cards right.

[00:22:00] We’ll be good to go. All right. Well, here we go. We got it all installed, how to do a design modification, made a separate part, but in the end, it’s pretty much the same thing. But we now have an adapter plate from our HRC160 to the 5c adapter. So we’ll be able to get those mag catches going. I dialed it in. We have roughly one and a half thousand run out along the face here. So anyway, so what we’re doing and once we get that fixture in there, I’ll be able to adjust that and get that going. 

So anyways guys a little different type of video today. Let me know if you like it. If you like seeing the kind of little nitty-gritty kind of stuff, the detailed stuff that we do on a day in and day out basis, let me know. I’ll shoot more of these videos.

And then just as far as you know product reviews and introductions and how-to videos, I’ll definitely do a better job doing those as well. 

[00:23:00] So, anyway, I got some mag catches to make, so we can get these final metal done. You guys have a great one. See you next time.