Lockdown Pallet Beehive by Jonathan Powell

My side interest in bees brought this booklet to my attention where the author Jonathan Powell describes how he created a beehive from a couple of scrap wooden pallets.

Beehive made from scrap wooden pallets
The beehive mounted in a tree. Length is around 1m.

The hive is intended just for the bees with no intention of humans taking honey. It provides them with a tree like cavity to inhabit in keeping with a natural hole in a tree.  We humans seem to chop down our trees at an alarming rate and the potential for ancient trees with cavities suitable for wild bees diminishes by the day.

The hive has an inner core and an outer core with an insulation layer between the two using the sawdust created in cutting the pallet material.  My engineering brain kicked in and below is a spreadsheet that helps calculate the dimensions required for a multi-sided structure having the required 40 litres volume that bees appear to prefer.

Plenty of time is available to make one of these before the spring swarming period starts.

Pallet Hive Calculator

I do not claim to be an expert on bees but my interpretation is that such hives with high levels of insulation lead to less stress in the occupants.    This in turn means they are less prone to disease.   There is also much published information about the stress induced by having high density clusters of ‘domesticated’ bees leading again to disease.   Having simple well insulated hives for the wild bees to populate in relative isolation to each other must help these problems albeit at the expense of man being less able to raid honey. 

Here is an interesting link on the interaction of wild bees and domesticated bees.

For those wanting an interesting read I recommend ‘The Honeybee Democracy’ by Thomas Seeley.   Fascinating book.

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Vacuum table update for PCB milling

I have mentioned in the past my home made vacuum plate for holding printed circuit board material flat while milling the copper trackwork.   As a technique this works really well and the results are very consistent using 5 and 10 thou miniature milling cutters from Think and Tinker.

When the artwork design needs holes drilling through the PCB material, care has to be taken not to drill through into the aluminium surface of the vacuum table.  To protect the carbide drills and the surface of the vacuum table I use a sheet of 3mm MDF underneath the PCB material to act as a sacrificial  board .  While the MDF is ‘transparent’ to the vacuum suction it does degrade the downward vacuum grip and this has always been a frustration.   If the board does not need through holes then the MDF is not required.

My wife uses an anti-slip perforated rubber sheet on the kitchen sink draining surface.   This is very flexible and looks like a weird cobweb of holes.   It struck me that this could be used as a sacrificial sheet between the PCB material and the vacuum table surface.   The rubbery material is not perfectly flat but is very easily compressed to become consistently flat over a large area.

I begged a sheet of the material from the kitchen ‘sub stores’ and mounted it on the vacuum table with the PCB on top.   I measured the overall depth of the PCB and the mat under vacuum compression to be circa 80 thou and I usually set the depth of cut for drilling to 68 thou.  This looked like it should leave a safety margin to avoid damage to the drilling tool and the vacuum table surface.

Using anti slip rubber sheet as a sacrificial spacer
The rubber mat in place on the vacuum table

The idea worked a treat.   The PCB was very rigidly clamped  in place and no damage was done to the drill bits or the vacuum plate.  Here is an image of the first board being run using this backing material technique.

Test PCB being milled using the rubber sacrificial mat
Test PCB being milled using the rubber sacrificial mat instead of MDF

This looks like a step forward in my PCB milling process and has the added advantage that the rubber sheet can be hand washed afterwards and re-used.

Anyone needing some 3mm MDF ?

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Rear Parting Tool Post on Myford Super 7

 I’ve been meaning for some time to make a rear tool post for my Myford Super 7 when parting off material.   There are various comments on the web about how a rear mounted blade is the best way to succeed for this activity.

Hemmingway Kits here in the UK offer a kit of materials and instructions based on the Geo. H Thomas design as detailed in his ‘Red Book’  (ISBN 1-85761-000-8).  This seemed like a good route to take.

The kit arrived with all the materials and documentation needed including a casting for the body of the post.  You do have to make a couple of cutting tools as part of the activity but again the material is supplied for this.  I found that having access to the Red Book in conjunction with the Hemmingway kit notes helped me better understand what was involved.

Having the Tormach CNC mill allowed me to depart slightly from the intended construction  but it all came together very well.   I had some Myford Aqua blue paint to hand from my Clough42 Electronic Leadscrew control panel enclosure and this finished off the project nicely as shown below.   However I do need to crop back the excess on the rear of the blades before blood is spilt.

Hemmingway rear tool post parting tool holder
The finished rear parting tool holder made from the Hemmingway Kit

Trial cuts have so far been excellent. I can now use the power cross feed when parting brass which is a major departure.  Overall a good addition to my workshop assets and a relaxing pleasure to make.

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How to square up a scrap piece of stock ready for machining

Can’t Remember How to Square Up Material Stock ready for CNC ?

I sometimes have to dig deep in the odds and ends heap of rough bits of materials to use on a project.  This results in having to square up the find so it can be easily programmed into Fusion CAM.   I always have to scratch my head on the process which is well documented by Tom Lipton and This Old Tony among others.  What I needed was something to pin on the wall to remind me. 

The result of this frustration is a write up and a graphic which you may find useful.  Here is a screenshot and the link below it provides both this document and the write up in a ZIP file.

Squaring Stock 

Hope that helps and if it isn’t well explained let me know and if it was useful also let me know.

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Myford Super 7 backlash solution with thrust bearings

One Job Leads to Another

I had a job for a customer that needed two M18 screws cut on the ends of a  shaft.   I have never cut anything that size before but fortunately I have installed the Clough42 Automatic Leadscrew system fitted to my Myford Super 7 Big Bore lathe.

I tried some trial cuts using the Geo Thomas ‘Red Book’ top slide method but I found there was so much backlash on both the top slide and cross slide that I was struggling for consistency.   In the end I did a hybrid cut ‘nearly there’ using the ALS using plunge cuts and then I finished with a nut die that was happy to start on the part cut thread .   This gave me a clean finish to the thread and I was relieved to get the job done.   Note that my S7 is a ‘metric’ version but the leadscrew is Imperial so screw cutting using the ALS entails keeping the half nut engaged and reversing the drive.

With the job completed my thoughts came round to giving the Super 7 some TLC to try to improve the backlash issues.   I found various discussion threads about fitting thrust bearings to the cross slide and top slide but all referred to EBay thrust bearings that were no longer listed.   After some investigation I found Simply Bearings had two suitable items in stock.   The NTA916-TRA916 is a 9/16″ core diameter bearing and washers suitable for the cross slide and the NTA815-TRA815 is a 1/2″ set for the top slide.  I ordered two of each set.

The attached PDF link below gives details of how I implemented this modification.

Myford Super 7 Thrust Bearing Mods

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