Bob Fritz knows his way around a home machine shop.

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1 Bob Fritz knows his way around a home machine shop. Why you need your own machine shop, and how to afford it. BY BOB FRITZ I m not a machinist, and I don t play one on TV. What I am, however, is a home machinist; I m the guy who wants to cut a square hole through a pipe, or a long slot in a bit of flat steel you know, the sort of job that would take a week and could cost the same as that new GPS you ve been drooling over if you took it to the local machine shop. It s the sort of job you could do if you just had a bit of skill and the right tools. What we re going to cover is just that: a discussion of the tools (no, you don t have to spend a fortune) and the skills (yes, even you, who sneered at the guys who took Industrial Arts classes in high school, can do this) that you ll need to tackle these sorts of projects. So why go to all this trouble? For instance, why cut a square hole through a pipe? I recently found that the tubes that accept the gear legs on my Van s RV-6 kit had been distorted by welding. To round them out I needed to run a ream through them. I called a couple of professional shops that I know and they said, No, can t set that up don t have a milling machine that big. Have to do it by hand. Hmmm, that would be expensive! Well, first off, it s a tube that should be inch inside diameter. Yes, a ream that big is available and, no, it s not expensive, only about $30. But what to turn it with? A big wrench won t work; too much torque all applied to one side cocks the ream over and jams it. What s needed is a tee handle! The ream has a round shank terminated by a square end, so I took a piece of pipe lying around the shop, set it up in the milling machine, drilled a round hole though one side Fitting a round peg into a square hole. and then, using a small endmill, cut a square hole opposite the round. Voila, a tee handle. It worked too. That probably would have cost a couple hundred bucks Photos: Courtesy the Manufacturers, Bob Fritz KITPLANES April

2 Home Machinist, Part 1 continued to have the experts do it, and it took less time for me to do it than to run it down to a shop. Don t You Just Love Justifying Toys? You re still with me, so that must mean you re thinking, Hey, I needed to do something very much like that! The question is where to start. First off, have some idea of how to use the equipment. This is supposed to be fun, and there s nothing like fast progress to get you grinning. There are two ways of doing this: 1) Check if there s a local high school or junior college that runs adult education classes in the evening. If they still have an Industrial Arts department you might find that you can go down there in the evenings with your projects and get both instructions and the machine tools; 2) Check out the web sites for howto. (A sampling of good sites is listed at the end of the story; direct links can be found at Yes, it s slower, but the longest journey begins with a single step, Grasshopper, and you d be amazed how fast you ll figure it out to the level you need. A community workshop would also be a great place to get your hands on the hardware. Or some of the manufacturers have videos and web pages with a lot of good information about how to get started. I d like to hear from readers who have suggestions about other sources of training. (Send them to editorial@kitplanes. com, and I ll include them in future articles.) Just don t be put off if you have zero experience; you didn t have any experience in building an airplane and you took that on, right? What About the Cost? Too expensive, you say? Well, let s look at it this way: Your neighbor likes to fish, so he just bought a nice bass boat that needs a trailer and a new truck to pull it. The boat needs a new fish-finder/depth sonar, CD player, etc. Does $30-60,000 sound about right? That buys a lot of fish, and the boat depreciates about 30% a year! (The fish depreciate even faster.) But a nice machine shop can be set up for about 5% of the cost of the first year s depreciation of this fishing rig. Perspective is everything. Not only is a shop a lot less money, that airplane you re building gains in value The Midas 1220LTD is an excellent choice. when it gets the FAA sign-off. Anything you buy to aid that process is, in a very real financial sense, an investment. (Yes, I m married. And, yes, she thinks this is a reasonable idea.) The really neat thing about owning your own machine shop is that it s eminently useful after your Bugsmasher 8 is done. Next up is what to buy. You already are, or are thinking of, building an airplane, so presumably you have a pretty good toolbox with a dial-indicating caliper, maybe a nice little bandsaw, and you know the difference between a #2 and #3 Phillips screwdriver. If so, you re a good candidate for a milling machine and/or a lathe. What s the difference? Well, a mill holds the part (clamped down on a table or in a vise) and moves it in the horizontal axis while a spinning cutting tool is moved in the vertical axis. A lathe, on the other hand, usually spins the material about its own horizontal axis while moving the cutting tool in the two horizontal axes. That means a mill can cut You get Timkin bearings and computer control for $13, KITPLANES April

3 a flat spot on the side of the material or knock a square hole through it, while a lathe can cut circumferential rings around a cylinder or drill a hole exactly on the material centerline. Mill or Lathe, Then? Which is better? Experts can use a mill to do almost any job that can be done on a lathe, but not the other way around. The operative word here is experts. The other implied operative is convenience; if the operation is complex or requires an overly clever setup, then it s not for you. If you know how to do it, then you re already way beyond the scope of this article. You have a choice: Buy a lathe and then a mill, or buy a mill and then a lathe. Deciding comes down to an issue of floor space in the shop, beyond the fact that this is an investment. Each machine will take up about 15 square feet. In a two-car garage, that eats up open work area fast, but if you ve got it, go for it. There s a third option. If you don t have the space, and assuming you can t sell the spouse on converting the living room, then a combination machine might fill the bill. I started in a one-car garage with parts going to storage, so I was severely limited and could only consider a combination machine. It s not capable of taking the bigger bits of raw material and, being lower cost, doesn t have the precision of the machines at the local professional shop, but it uses only 9 square feet of floor space. Think of it this way. A 10-ton dump truck carries more than your car, but do you need that capacity? The biggest load you d ever see is a couple of bags of cement. I ve had times where I wanted bigger, faster, computer controlled, more accurate, etc., but for the sort of work I want to do, the combination machine is fine. Anything larger I take to the pros, and so far that hasn t happened. The Independent Voice for Homebuilt Aviation Price of Admission For a combination machine, prices range from $500 to $13,000, and you get what you pay for. The low end is barely useful; the high end has every option includ- KITPLANES April

4 Home Machinist, Part 1 continued ing numeric control. You can target the $2500-$3500 range, however, and get a machine that is more than adequate for the typical home user. Now that you ve decided it s monetarily justified and you don t have the space for separates (lucky you if you do), what to buy? There are several nice hobby machines out there, but what should you look for? Well, like the dump truck analogy, you could look at how you ll use the This tool post is inexpensive, but it is the best upgrade for the lathe. This works, but it isn t convenient when it comes time to change the lathe tool. machine. But if you re like me, you probably won t have a crystal-clear set of jobs, so let s run a check list of what to look for in a combination machine. Thread cutting. Most of the machines will advertise that they can cut threads, but in the four years I ve had mine, I ve yet to do any. Ease of transfer. What you will want to do is switch from milling to lathe work with a minimum of fuss. If you have to switch belts or bolt/unbolt something other than a vise, then look elsewhere; it has to be convenient or it won t get used. Ease of speed change. If it takes 10 minutes to change the tool speed, keep on looking for the same reason noted above. Size of raw stock. Here s where you have to look at what you want to do versus what the machine will do. I ll cover this in some detail next month, but bigger is better. All of the manufacturers advertise accessories, but are they any good? Do you need them, and if so, which ones? This can be confusing as well as tempting; after all, more is better, right? Not always. Don t buy your machine based on the accessories, because once you start working you ll find that what s included ranges from useful to never used. Just take the package and plan on a few upgrades, most notably the vise and the tool post. Fortunately, the upgrades usually cost less than $100 and they re well worth it. The single most important upgrade to the milling section is a good vise. 50 KITPLANES April

5 THE RIGHT STUFF THE RIGHT PRICE Everything you need to build and fly your homebuilt aircraft. PERFORMANCE REVIEWS BUILDER'S TIPS SHOWS & RACES DESIGN YOUR DREAM MACHINE ADD THE ULTIMATE IN AVIONICS AND ENGINES For faster service and the lowest subscription rate or call

6 Single-place Ultralight Two-place Special Single-place, clipped-wing Home Machinist, Part 1 continued Well, that s a lot. We ve touched on the cost, justification, use and a few of the basics to look for. In future articles we ll evaluate combination machines and compare their capabilities. We ll take you to bargain sources of accessories and make some recommendations. Later, we ll talk about some projects specific to kit aircraft such as cutting a panel and some dandy little customizations to make your plane say mine not just another kit. As a home machinist, I d like to hear from you pros out there. Send a note to our editorial with the subject of Home Machinist if you have tips, updates, corrections or just want to point out a gaff. After all, it s the journey not the destination that makes flying interesting. Editor s note: This is the first of a monthly multi-part series on machining for the masses. If you have specific questions for author Bob Fritz, or if you have certain projects you d like us to cover, us at editorial@kitplanes.com with Home Machinist in the subject line. RESOURCES Department of Mechanical Engineering, Massachusetts Institute of Technology machinetools/lathe/intro.html Tech Shop Although it repositions, this model won t stay in position. Special Two-place, clipped-wing QUALIFIES FOR SPORT PILOT LICENSE Action-packed video (VHS) and Information Package $10 Celebrating 22 years building Challengers! P.O. Box 370, Moline, IL (309) Fax: (309) A piece of pipe became a ream handle and saved several hundred dollars. 52 KITPLANES April

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