Engineering Video Favourites Updated List

As the months (and years !) have passed while authoring this site, my favourite YouTube sites have morphed and changed as my skill level and interests have become more focussed.   The other aspect is that many of my early favourites have just faded away and now rarely post if at all.  I guess it takes a great deal of commitment to create regular footage over a long period of time so it is understandable that people come and go.

At the risk of everyone clicking and leaving, here is a share of the sites I now look forward to visiting and viewing : –

Top of the list is Clough42 for his highly professional, regular posts on home workshop activity but key for me is his use of Fusion 360 for all his engineering modelling.

I met Jimmy Diresta at NYC CNC in 2016 and I love to watch his almost ‘off the cuff’ creations in metal and wood.

For TIG welding I have watched many sources but Pacific Arc TIG Welding is my current favourite and Dusty does some amazing stainless TIG welding artworks.

I need to mention This Old Tony even though he has been absent from the scene for a long period.  He is now back and on top form.

Then of course for serious CNC activity there is John Saunders and John Grimsmo.  Both these guys have done incredibly well as they have emerged from their garages and blossomed into YouTube stars.

Finally a less well know site for Fusion 360 is Mechanical Advantage hosted by Kevin who was my instructor on the NYC CNC Fusion 360 course.  Really nice guy and always helpful if you have a problem.

So that is my current short list of ‘ones to watch’.   If you haven’t discovered any of them then check them out.   But don’t forget to come back here every now and then just in case I get up to something interesting.

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Burgess BK3 replacement lower blade guide

Burgess BK3 Final Modification – Lower Blade Guide

This is the final piece in my Burgess BK3 bandsaw upgrade jigsaw.   Having successfully replaced the top guide with a double bearing assembly my attention turned to the lower guide.  Using the same principle as the upper guide I came up with the following assembly.

Burgess BK3 bandsaw replacement lower guide assembly
Stylised Fusion 360 image of the replacement lower guide assembly on my Burgess BK3 bandsaw

This seems to work well and is straightforward to implement.   The bearings are standard 1/2″ size parts from Bearing Boys.   These need a small brass bush to mount them on the sliding brass blocks.  The blocks need a single M3 washer to space the bearing from the block and the body.

The blade pressure roller is made from silver steel and can be heat treated to improve wear from the blade edge.

The mounting bracket arm picks up on the original M5 mounting screw concept.  The bracket could be milled onto the main body as a CNC operation but the two part assembly works fine and is very rigid in operation.

Here is a set of drawings for my BK3 lower guide assembly

The link below is a complete set of notes and drawings pulled into one ZIP file to cover all the modifications I have done and separately document in my blog and other author’s notes that I have come across.  I hope that helps.

Updated file link to BK3 Modifications v2

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Enclosure finally added to my Tormach PCNC440

Reduction in Sparkly Bits around the House

When I bought my Tormach PCNC440 in 2016 I included the enclosure kit in my order.   On receipt I thought that fitting the enclosure would dominate the size of the workshop so I never got round to fitting it.   It has sat in its shipping box since then.  I have consequently shared quite a bit of my swarf (chips) with long suffering family.

After a recent (particularly heavy) CNC run I had a serious covering of swarf in the machine tray and because I had no enclosure round the mill, I had quite a lot distributed further afield (i.e. into the house).   Domestic peace was becoming an issue. Time to do something about it. 

Out came the enclosure kit, cobwebs dusted off and around three hours later I had the enclosure fitted.  I have to say it looks good and does not overpower the workshop as I thought it would.   My wife is impressed and says it looks a more professional machine and ‘if you had it why didn’t you fit it before now’ ? 

My Tormach PCNC440 with its enclosure fitted
The picture above shows the enclosure mounted on my PCNC440 with the monitor in the original position before fitting the extension arm to the ISO bracket. The keyboard tray uses a domestic drawer rail mounted on the top of the standard Tormach cabinet. My recently fitted dual fogbuster system and my Hall Effect based tool height setter (yellow top) are visible.

The fitting did however create some follow up problems.   

My control monitor had up to now been mounted on the side of the 440 on a standard ISO TV mount.  With the enclosure fitted this meant it was ’round the side’ and difficult to get to.   I debated a new long reach ISO but they are expensive.  Plan B was to make something. I rummaged around in my aluminium stock and with the help of Fusion 360 came up with a seriously overengineered extension arm to add to the existing ISO mount. This would allow the monitor to move forward to be in reach at the front of the mill. 

ISO bracket extension on Tormach PCNC440
My seriously over engineered extension bracket to move the ISO mounting of the monitor more to the front of the 440

This bracket became the first CNC job to run after fitting the enclosure.   I am pleased to say it was the cleanest my workshop floor had ever been after running a job.

Having fitted the new bracket and mounted the monitor, all the cables needed extending.  Fortunately I had had the foresight on my original order to include the extension cable kit.   As a result I only had to extend the power supply lead from the monitor 12V ‘brick’ supply.

The second issue was where to mount my ITTP probe as this had formerly mounted on the side of the 440.   With help of some more Fusion design I modelled a corner mount that picked up on the enclosure fastenings.

After that first heavy machining run I noticed for the first time the slight smell of the mist coolant when opening the enclosure doors.   Before the enclosure was fitted the smell must have dispersed into the general workshop air.   With the enclosure fitted the air was concentrated inside the mill and I only got the smell when sticking my head inside.  While it had never been a problem (as far as I can tell …) I thought I should do something about it.

Sometime ago I installed a ceiling extract duct in the workshop.   This vents to the outside world via a custom roof tile. Normally the system sits with a flared cowling (made from a cut down flower pot) on the ceiling entry duct.  The system normally acts as a background trickle extract.   The cunning plan in the design was to use various pipe components to provide bayonet style connection pins (Nylon screws) to allow extension trunking to be used.   A bit like a BNC RF connector if this is familiar to you.   This would allow me to use an add-on length of expanding flexi trunking to bring the extract nearer to any heavy fumy activity such as welding or oil bath hardening.

With the use of further scrap odds and ends of aluminium, I mounted a pair of support bars across the top of the new 440 enclosure. These would fix the ducting over the enclosure during heaving CNC sessions.   Not a total solution but certainly one that will reduce the general smell of XtremeCut 250C when I stick my head in the enclosure.

Workshop extract system
Extract system showing ceiling mounting intake, trunking adapter and mounting on my Tormach PCNC440.  Note the two Nylon screw protrusions are for a bench mounting clamp when used for welding extraction etc and now used on this new use of the system on the mill.

A good day’s activity with all the issues addressed and domestic bliss hopefully restored.

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Update on CNC milling printed circuit boards on a homemade vacuum table

Update to the use of FlatCAM to mill PCBs

There are quite a few entries on my blog regarding using FlatCAM to convert PCB design software manufacturing files into CNC code.   I also have mentioned my small home made vacuum table and a floating foot compression device both for holding the PCB blank flat while the milling takes place.

I have revised my original write up to focus on FlatCAM version 8.991 and also pulled together notes on these other techniques.   If you like it let me know.  If there are mistakes also let me know.

FlatCAM and milling pcbs updated notes 2021

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Making a Brocot Escape Wheel using Fusion 360 and Tormach PCNC440 CNC milling machine

A Steep Learning Curve

My wife has presented me with a sign that has just got JSN written on it.  It is to remind me when I answer the phone to a ‘can you just do’ enquiry…… to Just Say No.

I try my best to live up to her expectations but sometimes something comes along that should really be a JSN job but which scratches an itch.   You know what I mean.   You think about it and you do all the right mental arithmetic in your head and the answer keeps coming back to the same – don’t even think about it.  But the the other side of my brain is screaming at me … what a challenge, what a learning experience, what fun to have a go at it.   Providing the asking party is aware of your thought process or lack of it and accepts that it might just go belly up and never come to fruition then why not ?

Back to the story – 10 days or so ago I had a call from David Pawley who is a turret clock expert extraordinaire to say someone he knew was after an escape wheel for a turret clock and was desperate.   David passed on the details and a couple of days later the potential customer arrived on our driveway.  After a suitably socially distant conversation and a rubber gloves inspection of the old damaged wheel …. I got sucked in and turned the JSN sign over to face the wall.

Brocot 30 tooth escape wheel
The original Brocot 30 tooth escape wheel that needed a new one making

As you can see it is not an ordinary escape wheel and I had to delve into one of my favourite books ‘Wheel and Pinion Cutting in Horology’ by J Malcolm Wild FBHI in order to learn about Brocot Escape wheels.   Malcolm is a great guy and his book should be on any clock experimenters bookcase.

The Brocot is no ordinary escape wheel.   In fact it is a real challenge.   Not a simple fly cutter job.  Traditionally it would be cut in an indexing device such as a lathe with two different cutters, one for the curve and one for the notch.  I didn’t have these so I thought I would probably upset the traditionalists and try to use CNC.

Read all about the adventure and see the result in this pdf download …….

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