Build Your Own (metalworking) Lathe - Part I

Step 4 The Bed

Here's a shot of the bed pattern and resulting bed. This is actually the most recent casting I've done -- I was terrified and put it off until after most of the other castings. Why? Well, it's two feet (~61cm) long, probably 8 lbs. (3.6 kg) of molten, 750-degree (400C) metal to pour, and the dang mold is about 70 lbs (32 kg) of sand that needs to be VERY carefully carried without disturbing the mold cavity.

I almost succeeded. ;-)

The casting has a yucky spot in the middle (that's technical jargon, for you non-metalheads) - but that's not a problem -- it's easily filled with this miracle stuff called FastSteel I get at the Big Orange Home Store. I also like JB Weld, which'll fix anything duct-tape won't. Nay, the problem is that, somehow, the mold flexed slightly as I was carrying it, and the *&#%@! bed is just slightly curved up at both ends - about a millimeter or two. Sigh. Much filing/grinding to do.

Here are shots of the pattern for the bed, above the bed casting; and then the bases and bed together.

Comments

[treeman_52]

I find Quick Steel 44 harder and cures faster than J B Weid, both priced about the same. Sticks good providing you cleaned the surface,also rough up the area your repairing,try it ,you might like it.

[pineoly]

Hiya Corradini,noticed you implied "terrified at thought of pouring Bed Casting".And rightly so for its a hit or miss situation and most are misses.If you steered away from this guy Ginger for awhile and used your own head you could have substituted a 2x2 channel and filled it with two re-bar and footing cement.I did and result was very flat,square and strong bed. Also made mine the length I had (33in)on hand.Very little scraping was req'd just to clean it up.Didn't have to pour any bed nor base pads either.An hour or so to fill channel with cement and a day or so lettin it set up and I was ready to go.Made entire lathe(minus cross slide,all steel and dovetailed) in less then 5 days and didn't pour one Alum casting.I have piks to show if anyone wants to see them.Just E-Mail Me at [e-mail] try Bondo some time on those dips and crannies.Try it,you'll like it! All kidding aside your doin a fine job and would like to see it complete

[corradini]

Sounds terrific. If I were continuing with the project, I'd look VERY seriously as that as an idea - I like especially the rebar/cement fill, for stiffness.

It seems you would need some kind of feet or mounting - maybe not base pads per se, but you'd want to raise the bed from, and mount it to, whatever the supporting pad or infrastructure is. Which you could easily cast into the cement, drill-thread-mount into the 2x2, or some combo.

I'm curious as to how you made the other pieces (slides, cranks, etc.) w/o casting or machining - I'd love to see your pix, and sure others would too. Why not post 'em here?