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I made smoke box saddle. This was made from sheet metal work according to the textbook, but I had no confidence to silver solder the sheet metal parts. So I made upper part from sheet metal and lower part from block cut out to the shape. The upper part was cut and drilled from 1.6mm copper sheet.
煙室サドルを作ります。教科書では板金工作になってますが、板金を組み合わせて銀ロウ付けなどうまくできそうにないので上部だけ板金、下部はムク材の削りだしとします。まずは、上部を1.6mmの銅板から切り出し必要な穴を開けます。
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The copper sheet was annealed and fixed the failed smoke box.
この銅板を焼きなまし、失敗した煙室にねじ止め。
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I bent the copper sheet hitting by a plastic hammer. Obviously both ends could not be bent perfectly, but this would be machine cut later to the shape.
プラハンでたたけばそこそこうまく曲がります。当然端はちゃんと曲がってませんが、後で機械加工をするのでかまいません。
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The lower part was from 6mm thick 30X30mm brass square rod. Necessary holes were drilled and the centre line was marked with spotting drill.
下部は30X30mmの真鍮角材を6mm厚に切り出して、必要な穴を開けます。中心線をけがく必要がありますが、穴あけと同時にフライス盤でスポッティング・ドリルを使って浅い溝を掘りました。
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I made a fixture to cut a concave on the block.
曲面切削用のヤトイを作りました。材料を取り付け中繰りバイトで削ります。
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The work was lightly cut by hand turning the lathe spindle. The fixture was adjusted to obtained equal cut on both side of the centre line.
手で主軸を回しながら軽く削り、削り跡が中心線に対して均等になるようにヤトイを調整します。
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After cutting a bit, the cut was found not parallel. The fixture was not perpendicular to the spindle.
ちょっと切削したところ削り跡がテーパーになっちょる。ヤトイの平行が出てないみたいですね。
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I adjusted the fixture by adding 0.01mm thick shim.
ヤトイの組立部に0.01mmの銅箔のシムを入れて調整。
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After the adjustment the cut was parallel.
削り跡が平行になりました。OKでしょう。
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Cutting was about finishing. The uncut parts (blue coloured) were parallel and equal. I thought the enough accuracy was obtained.
もう少しで切削完了。両端の削れてない部分(青色)が平行で均等です。精度は十分出ていると思います。
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Finished lower part.
出来上がった下部部品。
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Both parts were silver soldered.
上下部品を銀ロウ付け。
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After silver soldering the saddle was attached to the fixture again and the upper part was thinned to 1mm.
銀ロウ付けしたものを先のヤトイに取り付けて上部を1mm厚まで切削。
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Both sides of the saddle were milled vertical.
両サイドをエンドミルで直角に仕上げます。
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Finished saddle.
完成したサドル。
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