Cutting a Huge 1 Inch by 10.5 Inch Internal Keyway - Vertical Shaper - Manual Machine Shop
The Morey Vertical Shaper is by far my favorite machine here at Topper Machine LLC. There are many other options for cutting keyways, but they all are very inaccurate. This machine will cut them perfectly, with the right machinist at the controls.
This particular job is for a 1.000" wide (+/- .001) by 10.5" Long with a center tolerance of +/- 0.004". The shop who was doing these has been struggling and causing all kinds of delays and scrap parts. Now, I get the chance to prove myself again.
The final outcome of the inspection of my part was nearly perfect. The width of the keyway was 1.0005, and the center was only off by .0017". All within tolerance, but I intend to do better on the next one. The keyway cut by the former shop was 1.0055" wide, and 0.045" off center. The future jobs were awarded to Topper Machine LLC, and this is just one of several similar parts I will be doing for this customer.
Topper Machine LLC is an entirely manual machine shop located in Spooner, WI. Our videos will highlight some of our shop work.
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*UPDATE* The results of the inspection are in the video description. Yes, I got the job! *UPDATE*
Great news. I knew your workmanship would get you the job. You take the time to do the job right the first time!
Great job, no doubt!
Thoroughly deserved. Really enjoying your channel and looking forward to the fixture build
Looks like a great machine JT but as we all know a machine is only as good as its operator. I know you have proven to your customers that you are the man for the job. Congratulations on getting this work.
Josh I'm watching your videos backwards from the newest to catch up glad to see you pick up another customer based on some one who can't do it right. Back in the day In the Fox valley the job shop owners I worked for would scream day after day we can't f**k that up or we could lose that customer. glad to see your workmanship and skill rule the day. I Had the opportunity during my apprenticeship to run a Morey horizontal planner that was converted off the line shaft but was still leather belt drive I will never as long as i live forget the sound of the belt sequel at the table directional change or the smell of the belt dressing or the big chips. Clapper Box !!! If was not for KZhead and a few hard core KZhead channels that nomenclature would be extinct just like the guys who learned how to use them on their apprenticeship will soon be. Oh how your channel bring back the old memories that have been long been forgotten. Hopefully when I am in the old age home i can spend all day going back and watching your KZhead videos and the videos from others like this old tony, and Adam from Abom79 and many others to fill my days. Keep up the great content.
Great to see a man who really enjoys what he does. I know nothing about machining but derive immense pleasure watching the way you go about your work.
This warms my heart to see a skilled machinist still making a living in the US and to see US made antique machine tools still being used. The only modern machine that could cut the keyway would be a wire EDM. I worked as a machinist in three different shops. Two were tool and die shops. None of them had a vertical shaper but I did occasionally run a horizontal shaper and that was one of my favorite machines. It was a Gould & Eberhardt. Right next to that one was a Steptoe shaper. I miss working as a machinist but have a small vertical milling machine and a Southbend 9 in lathe in my home garage for personal projects.
I would make the room if one ever came my way ! 👍
You wouldn't regret it. Its a workhorse for sure
A hungry monster that is fun to watch. Great job. I appreciate keyways much more now.
You sure have a lot of these old machines, which were built to last and still work well after decades. I have a few power tools that are around 50 years old now and still working well with routine maintenance. More modern equipment often has a shorter life, so it pays to look after this old gear and keep it working for the future.
Nice swarf. I was working with Allen screws today, yes crap in the hole can make for big problems. Thanks for the upload. Pats for Rocky.
Nice friggin job Josh! That customer is coming back, no doubt.
Great job Josh....you "got it right the first time" I cant understand why you love this machine, I used to hate using a similar machine when I was an apprentice (in Australia 50 years ago!) We didn't call it a vertical shaper, we called it a "slotting machine" Keep the videos coming Josh, I love your work.
I am not a machinist and I know nothing about this machine but your excitement over it is something else. It looks like this job has taken your machine to the limits. It is also cool how you are willing to go where someone else has failed. I do not know how much load this part has to handle but it looks like the wall thickness at the corners of the keyway are thin. I also like how you are thinking about how you can do it better the next time. As you get older you will appreciate a clean crap hole more and more. Thanks for the great video and it is always good to see you.
Thanks Josh, glad to see machining videos again. Maybe can you give us approximate times it takes for the different processes you have to go through to make/machine the parts. I know it takes a lot of time for set up and the actual machining and clean-up after the machining is completed but I don't think others realize just how much time is involved. I love the machining videos from you. Thank you! Bill
This job took a while to figure out and set up. the actual cutting wasn't much over 30 minutes. Then add in setting up the camera and planning the shots. This job took 6 hours. I could cut that significantly without the filming.
Congratulations on a new customer. I love old fashioned shapers and planers and slotters. It's soothing and hypnotic. Very peaceful and calming.
Josh, that Morey Slotter is in very nice condition, glad to see you got the contract; you deserve it. It looks like the other shop tried to broach the keyway and they failed miserably. Look forward to more Morey Slotter videos!
...the "other shop" doesn't have one of these machines-(?)
Love the crisp sound of a sharp tool making chips.
Nice bit of slotting Josh, tool holder looks great. Thanks for sharing.
Great job. It always comes down to the right tool or machine for the job.
Great work. Good luck with your customer. Thanks for sharing.
Congrats on the job. I notice you really love what you do.
Great video Josh, I really like that machine to, love all old machinery.
Great video. That was fun. Hope you get the job.
Nice job Topper. I have never machined a keyway as big as that.
Definitely putting one on my list of must haves. Awesome job Josh, as always!
I wish I would have had this thing years sooner. It has been a great asset.
Thanks for the video. I had no idea about how any of those internal keyways were cut other than broaches. Vertical Shaper! YES!
Beautiful vertical shaper Josh. Nice work. Very impressive. That's a nice tool holder you made. Thanks for sharing. Take care, Ed.
G’day mate. New customer, fixing other companies stuff up.. Could be slightly nerve inducing. Great filming. Thank you for showing the entire process. Looking forward to hearing the customers feedback. Have a good one 👍🇦🇺
Feedback on this is in the video description. I shot this a few weeks back, takes time to edit and almost a day to upload. UGH.
Thank you
@@TopperMachineLLC You should try our internet. A video this size would be lucky to upload in a week.
@@BrucePierson mine is bad enough, I wouldn't want to try worse. Lol
cutting like a butter,i love the sound
bravo Josh, I got to run a vertical shaper one time in the shop I worked ......and like you said, it is fun to run.....cheers from Florida, Paul
Awesome machine Good luck on the contract
Good job! I've never seen a vertical shaper before and it sure looks interesting and useful. Thanks for letting us take a look.
Those old machines look so cool. It's hard to describe but the new stuff just doesn't have that steampunk/bladerunner/mechwarrior vibe I get from that old vertical shaper.
Wow Josh. That was awesome mate. How cool is that Morey vertical shaper. Thanks for sharing with us mate. Cheers Aaron 👍🍻
That slotter is sweet , looks like you got it all worked out in the last video and seems to have paid off .
What a beautiful machine..
That shaper is slick!
Never seen one of these. Looks like fun to operate!
awesome machine. great vid. thx
I've never worked with slotter, but I guess I felt in love of your machine. Keep going recording these awesome videos man. Best wishes
Love seing how they dew stuff like this .that machean is awsome
That is a really cool machine, I love the stroke position indicator on the side of the head, its just old school novel to say the least.
Very nice machine!!!
Nice work.
I can totally understand that this is your favorite machine in the shop. It's a cool toy :)
Way to go Josh buddy, thanks for sharing buddy 👍
This is the first You Tube video I'v seen of a shaper doing something a milling macine can't do.
An interesting job, Josh. I have a vertical slotter for my Bridgeport, I didn't think I would ever use it but now I think I will restore it and set it slotting. Regards from Scotland.
The slotting head is worth more than the rest of the machine.
Nice to hear those chips roll up Josh, Greetings from Chris in France.
What a cool machine. My 1st time ever seeing a vertical shaper. I’ve seen a couple horizontal machines but not this one. Seemed like it took a good bit of time to get it set up properly……But that thing is awesome to see workIng👍🙂
Very nice and what an awesome machine to look at as to how things were once made! Hello from San Antonio, TEXAS!
There is no better way currently to do this kind of job. There are still a lot of these machines hiding out there, still making parts.
my word Josh you get all the good jobs! Well someone has to get this stuff done, I've done my share of them, so now it's your turn hahahaha! Love your channel and approach to your work keep at it sir
Thank you, I like this kind of stuff. Thanks for watching.
hi there always interesting watching , thanks john
Cool machine been waiting for this video.
Wow what a machine! It's Jurassic! 👍😁
The job is yours!
NICE! That's a great machine. I don't think the previous shop used a shaper to make that inferior keyway. Definitely the right machine for such a tight tolerance. I'm glad this machine is being used and didn't wind up at the scrap yard like so many others.
That's some beast of a sewing machine you've got there 😄
Pretty dang cool,👍
Nice chips love it ...very rigid slotter love it too 💕💕💕
Nice job, very cool machine
That is one cool machine.
You remind me of David Richardson at times. He also was enthusiastic about his machines. Like you he did meticulous prep and set up. He could do wonders with his one hundred year old machines. ( this old steam powered machine shop). I enjoy watching you work. You enjoy your work. It shows in your finished product. May the Lord bless you.
I watch Dave. Love his channel. He is a regular viewer here as well.
A fascinating video Josh, thank you for taking the time to make it. I notice the otherwise excellent audio quality is not as good during the voice-over as it is when you speak directly to the camera.
You should make a magnetic holder for the camera to mount above the cutter. So it will follow the stroke. Good job on the video.
Good job. For shops which have floor space and expertise to run such machine, BIG vertical slotter can bring in jobs which are hard to make accurately enough with other methods. What that beast weigh?
Great machine. Recently a very nice smaller vertical shaper was up for sale here in Holland but unfortunately I do not have the space for it right now. Also there are a few as big as this one. Will have to sell a couple of machines and maybe this year we'll get one.
I bet you get the job hoping so anyway. Thanks for the video keep on keeping on.
I sure did. This was shot about a month ago. Passed inspection with no problems
Thanks for another interesting educational video. I wonder if the HSS cutter would cut more efficiently if the cutting edge was ground slightly curled similar to broach teeth?
I already worked on a vertical shaper as an apprentice (in the GDR). I didn't need it very often. Mostly I had to do with lathes, milling machines and boring mills. But a good vertical shaper is very useful! Also for internal gearings for example. Greetings from Dresden! 👏👏👏🛠❤🇩🇪❤🇺🇸😎 PS.: I hope my English is somewhat understandable. 😉
They are a great machine. Your English was great. Thanks for watching.
Greetings from America Your English is perfect. I would never have known you were German.
@@ellieprice363 Thank you! My great-grandparents and grandparents (on my mother's side) were Americans of German descent.
@@michaelkoch2109 Thanks for the update. Sorry about what happened to Dresden in WW 2.
i hope it works out well
This is a very cool machine and a great project. I hope you get the contract
I did, they are sending me all of the future work.
I really miss vertical stroking keys. Something so relaxing about it. Oddly I never cared for horizontal.
You did prompt me to look into the table oiling on my G&l the other day because I felt like it wasn't putting out the right amounts. I think I need to look into changing the bijur oiler numbers as the screw is getting more oil than the ways and I feel like it should be the other way.
I'm glad I could help. Hopefully you get it all sorted out. You should do a video on it. I would watch!
If you have many of these to do, on your tool holder, machine a locator hole above your cutter on centerline and make a pin to go through the hole in the part and into your tool holder to align the center of the part. 😎
Awseome machine .. Much better than the small lathe BcBloc02 has got. This is big. And bigger than Aboms Gear. SIZE Matters. IM A FAN
Great work! Amazing that machinery of this vintage is still earning its keep, glad to see fellas like yourself keeping it alive! Daydreaming about the amazing machinery that processes like that have help make, no computers, just skilled workers making it happen…
I've an antique slotter that needs restoring.. Runs off flat belts... It has a rotary table....and you can take the ram out of square with the table too... Cunliffe & Croom Manchester England 1900-1910
I have a horizontal shaper and the clapper box doesnt work on there for keyways. At least in my experience anyhow. I have to bolt it tight on order to cut internal keyways. Problem i had was in such a light cut it tends to float over for the first strokes then dig in and bog down or snap cutters of mess up the fixture. When its bolted you can take .001 cuts without any issues. Great machines!! Also great vids. Keep up the good work!
I have a job going right now that I tried the clapper on. Same result you saw. Rigid is best in this instance.
Boy, sure would love one of those... I periodically do a 1 1/4" keyway in an 8" bore, 10" long, in STAINLESS... 😩 I have done them on my 16" shaper but it sure is a task... Takes all day to do one... In fact, I have a PO in my email right now for another pair. But I think I'm going to look into wire EDM to do the keyway. It's just too rough on a 120 year old shaper...
I just did the second part for these guys. A little smaller bore, 9.5" long,, in ductile iron. That was a learning experience. I couldn't imagine stainless. I feel for you. EDM can be a good avenue, but in my experience won't be perfect like a shaper can cut.
18:25 Till next time......Remember I love this machine........
Josh, Knowing you’re a machinist and solo videographer, this was great; what a wonderful old beast she is ! Did you stone the shoulders of the internal key way or leave them “as cut” ? Thank you
The only thing I did was break any burrs. Came out perfect.
...well, if ya LOVE IT so much- then why don't ya MARRY IT?!!
It insure accuracy, you should start with a thin tool and cut either side of the slot and then the center. This will result in less wandering which may be due to changes in density of the material. However, I would be interested to know if the shop before you used a shaper or tried to broach the slot.
Thanks for showing how you setup the part think I might try that next time on my sloter how much does it feed at a time in auto feed?
Best I can get is .003 consistently. There was a lot of wear in the feedbox. Definitely something I will need to address coming up.
earlier i picked up a 1x1x12 inch key. get home and look what we have.
How did you orient the keyway centered on the hole? I could see the other one off center of their hole, but you didn’t show how you lined up yours on center. For me (about a year into machining) the setup is the most interesting part of watching these videos.
I can't give away all of my secrets. If I did, everyone would be buying these machines and trying to compete.
going by scribe marks and centered the cutter on them. with a square off the table on each side of the hole and then scribed to the top and then using centerline of cutting bit
We did a part like that with a 1" push broach using a shop made hydraulic press with insufficient stroke. Every "push" required resetting the table up then down. We stepped .030 per push, not .060 like Dumore says. I think it was 12 or more pushes. It took 2 hours. Plus we made a full length bushing. Aluminum. It worked ok. All for one part. And the fork lift is driving right behind you back and forth the whole time. The job is dangerous as hell. I tried to get the owners to get us a shaper. We broach plenty of other parts. They won't get me one. Commies.
nice indicating in. didint se this metod but shure is the best one yet. The machine hase claper box, but is spring loded, if you pus the tool in it wil "clap" a little bit, try it buy hand . i have put a 2 axis dro on mine so be nicer to use
I've tried many indicating methods, but this was the most accurate. No clapper box. Very rare to have one in a vertical shaper/slotter.
I advise you to harden the cutter mandrel itself, it will be better to stiffen and maintain the size.
Nice work sir. I know what you mean about broaching/key seating. I enjoy it too. The company i work for has a Ravensbruck slotter just a bit smaller than yours. Could you mention again the name of the company you bought your cutters from please. I'm really tired of grinding my own tools. Thanks.
Sharp-Rite Tool, keyseater. com
@@TopperMachineLLC thank you.
You sure you haven't got a clapper box? I've seen a few slotters with spring loaded clappers, pretty heavy springs to hold the bar up.
Clapper boxes are very rare on these and not reliable. Rigidity is the key on these machines.
Your teasing me! ............................Robbie
I missed it. How did your get the slot centered to that hole? You just eyeball it?
Would that machine be a WW2 era ? It runs nice. I don't think I would run it any faster because I'd be scared of what would happen if it crashed lol. AL B.
Yeah Josh, Keith, until now, I haven't seen a Vertical Shaper. Does this also operates, with the table run into an auto rotation. Or basically the table gets only locked down, then manually, you rotate it???
The table can be powered also.
Technical question, is the cup holding your oil dabber brush a break caliper piston?
It's a piece of DOM with a plate welded to the bottom. Nice and heavy.
The cutting tool for this job is what material? Thx
Has this machine earned it's keep? Are you in the black once purchase price, rigging, tooling, etc. costs are figured in?
It paid for itself very quickly. Every machine in the shop had paid for itself with the first few jobs, with exception of the Lion Lathe. But, the Lion will have broke even after another few weeks. I don't buy equipment for fun, they all have to have a purpose and a way to pay for themselves quickly.
Josh, what other tool could be used to make a key seat of that size?
A tool holder with just a HSS bit would work. If you're talking machinery, a broach could work, but never be this accurate. Keyseaters may go big enough, but I am not sure.
I think you should pin stripe it and give it a fresh paint job!
The discussion is currently happening about painting it.
do you have a formula to price jobs such as that? i would charge hourly rate for me and another rate for the machine
The customer and I have came up with a price that is good for both of us.
That material around the hole is pretty thin- I would worry about distorting the hole- maybe turn a round plug to keep the hole supported during the cut.
It wasn't really that thin. Probably an optical delusion from the camera. It went through a rigorous inspection process, and passed with flying colors. There are about 20 variants of this job, and this particular part is 1-2 per year. Definitely looking forward to the next one.