My Stupid Idiotic Bonehead Mistake....

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Whats up boys and girls?Boy was I "off my game" today..Heres the deal..The Compound Clutch in the lathe I run does not stop feeding when you flip the handle down when its out of oil..So it ran out...And the "plunge cut" I was doing continued on its merry way.. So now i have a groove thats .130 too deep.. And to make matters worse it ended up too wide too.. Heres the piece..3" dia solid 6061 T-651 aluminum..89" long..They need 157 grooves in them..+-.000 on the spacing..+-.002 on the O.D. of the groove.. The groove in the middle (of the pic) is the "trouble spot.."So its the "electric eraser" to the rescue!!After machining........."what oops??"These are getting sent out after for Hard coat annodizing..5356 is the filler of choice because of that reason..Heres a little hint..Annodizing  builds up the surface..So if you finish the journals "right on"..when they come back your bearings will not fit..So these journals will be finished .004 undersize..The annodizing is going to be .0015" thick for a total of .003...That will leave the journals .001 under so the bearings will slide on nicely..All that must be put into the equasion before you say "its done!!!"I have 4 of these made.. I get all the fun jobs.....zap!Last edited by zapster; 01-23-2007 at 05:21 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Nice job zap!!...but wouldn't some of these jobs be more efficient in a CNC?I think the maching that you do is incredible and I'm all for making things by hand but from a business perspective, I think it would make sense to go automated.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Originally Posted by ZTFabNice job zap!!...but wouldn't some of these jobs be more efficient in a CNC?I think the maching that you do is incredible and I'm all for making things by hand but from a business perspective, I think it would make sense to go automated.- Paul
Reply:Originally Posted by ZTFabNice job zap!!...but wouldn't some of these jobs be more efficient in a CNC?I think the maching that you do is incredible and I'm all for making things by hand but from a business perspective, I think it would make sense to go automated.- Paul
Reply:nice work zap , and i lould rather see parts made old school than on a cncold school machining takes more skillbut if you need to make 10 or more then cncChuckASME Pressure Vessel welder
Reply:Originally Posted by chopper5old school machining takes more skill
Reply:but if you need to make 10 or more then cnc
Reply:We all make mistakes, damn you're hard on yourself!  Yepper, I had trouble talking to these CNC shops, they want you to order 50+ items and still pay up front for the programming. I use a local place called APEX machining to do my one-off stuff.  All my stuff comes within budget and I still have a little room for profit.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:We all make mistakes, damn you're hard on yourself!
Reply:I have to agree that you did a great job fixing it. Now the big question, What is IT?
Reply:A mistake forum would be cool...and we can all learn from mistakes. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by MJDamianiI have to agree that you did a great job fixing it. Now the big question, What is IT?
Reply:Originally Posted by MicroZoneA mistake forum would be cool...and we can all learn from mistakes.
Reply:I use to work at Tilton engineering (super starters) and they had cnc mills and lathes and with all the programming and set up you would have to make it worth your while, good save though Zap.
Reply:Looks real nice, Zap! You must have been running pretty hot to put that weld in there. Have any trouble with balling tungsten? What did you use?Bill
Reply:Originally Posted by WHughesLooks real nice, Zap! You must have been running pretty hot to put that weld in there. Have any trouble with balling tungsten? What did you use?Bill
Reply:hey Zap nice save old school is the best school you got love the electric eraser saved many of us remember a fu&k up is some thing you can't fix  that was a tactical error Creative metal Creative metal Facebook
Reply:i think he was just bored with cutting all thouse groves and wanted to play with the TIG to break the bordum.great looking save.i think the mistake room should be called "spilt milk" but "Boo Boo room" is nice toothere is a lot to be lerned from our mistakes thats for shore.some of the best lessons are lerned that way, and most are not easily forgotten. summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:beauty eh?***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy
Reply:I hope the specification didn't call for the T651 heat treat.
Reply:Originally Posted by 76GMC1500I hope the specification didn't call for the T651 heat treat.
Reply:It Looks Real Nice But What The Heck Is ItKISS...KEEP IT SAFE STUPID
Reply:Originally Posted by TIGBOYIt Looks Real Nice But What The Heck Is It
Reply:could the dissimiler aloys in the weld efect the heat treat?? or be efected by it ? summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:Originally Posted by fun4now.could the dissimiler aloys in the weld efect the heat treat?? or be efected by it ?I was just wondering because you said T651 so I thought there might have been a heat treat specified.  Welding would have changed this.
Reply:Originally Posted by 76GMC1500I was just wondering because you said T651 so I thought there might have been a heat treat specified.  Welding would have changed this.