I need a fly cutter to square up the 1.812"x2.000" block for the stirling. I could buy one, but I can also make one pretty easy. Id rather it be from tool steel, and I have a piece of 4140PH that would be perfect, but with these ball bearings in the spindle there's just no way. So aluminum it is! The first challenge is getting a piece cut off the hunk of stock I have. Since I have no bandsaw, part off is my only option. I used the part off tool down to about .6" diameter then finished it off with a hacksaw.
|You can see how close everything is. Had I not milled that one part down so I could flip the compound around I wouldnt have been able to get the travel out of it.|
|Look at the crappy fine chip. The chatter is unreal. I need to put those tapered bearings pretty soon. Why they don't already do that when they build these is the one and only serious gripe I have with this machine.|
|Finally, a piece I can work with. Now let's make it look like a fly cutter. Below is a short clip of me roughing the OD down.|
|I decided on .75" shank. First side is done!|