Metal Shaper Monday - Heavy Hogging 

Same to you, family, and friends out west. I had to move my keyboard while watching, "Hot Chips were flying through the monitor onto the key board,,,,🤪. We are getting some of your rain here this morning, and much need here as well. See you back after the Holidays, Bear.

Dean my experience with Hot Roll Steel is that it is gummy and tears. Not only on the shaper but my old lathe also. On the lathe it is always finding the sweet spot between speed depth of cut and feed rate. I agree with Rustinox that it can handle larger DOC but no reason to spoil the soup by forcing it. Using a shaper is a matter of patients and knowledge. What may seem like a long time is actually faster than many other forms of metal removal as Rustinox has already demonstrated. Have a Merry Christmas and Happy Newyear. I will be looking forward to the next installment of Metal Shaper Monday. Thanks for bringing us along.

Little Atlas getting it done. I bet those 40 thou chips were traveling pretty good once they left the work piece.

Nice work, now you have a very useful machine! The quiet machines are the best!

All that hogging and still no pork. Thanks for the video keep on keeping on.

This was great to watch and impressive cuts

You can hear the difference after touching up the cutter.

Once again your skills and knowledge have overcome Father Time and years of use and probably abuse. I hope you get lots of use and enjoyment out of that machine. Merry Christmas and Happy New Year to you and your family. Stay safe in the shop.

Hello Dean, It's good to understand the limits of your machine but as you said you don't have to push it to the limits all the time... If we don't see you again before Christmas I hope you and your family have a Merry Christmas and Happy New Year, Take care. Paul,,

Great test Dean, I did the same test on my little Adept No.2 shaper, , from memory i think i pushed it to 0-080" cut on mild steel; amazing what such small machines can take!! merry xmas see you next time Kev uk

I have the same shaper, I was getting the same results where the beginning of the cut seemed deeper, almost like a bevel, but rounded off. My problem was a chip under the foot of the table so the table was not completely supported, as the cutter hit the work the table would 'dip' down, canting the work down giving me a lighter cut towards the end of the stroke. I hope this helps.

Looks good Dean. Big chips, small machine= impressive. 🔧🔩⚒

Gday Dean, the shaper handled the 40 thou nicely, I think you had the set over set at 2 clicks which I think is 10 thou, knock it back to the smallest set over and I think you’ll get 60 thou easy, have a very Merry Christmas mate. Cheers

Enjoyed….why is the clapper box on angle?

Very interesting, Dean. I'm pretty sure that your shaper can take even heavier cuts if the stroke length is shorter. But don't break your beautiful machine :)

I've noted the same sharkskin or "one way lint brush" effect from heavier roughing cuts on my Alba as well. I'd like to play more with the back rake behind the edges to see if perhaps there's some spring back of the surface and it's rubbing on the roughly 4° relief and galling just microscopically behind the cutting edge. Or I may be all wet and it's something totally unrelated. The dig in at the start is likely a combination of flex in all the components and the top rake angle you're using that is going to try to ramp its way into the material. It likely dives in, tensions all the stuff in the ram and head then springs back and waves a time or two and settles in at a balanced amount of flex. I get that on heavy cuts too. But not by quite as deep as you did with .004" of dive. Mine was visible but not really felt. So maybe half of what you had? I tend to run my top slide gibs a little on the stiff side. And the ram gibs are adjusted to where they drag is about where it takes me about 5 to 8 lbs of force to move it when it's warmed up and oiled. I've no idea if that is too tight or too loose. But it seems to work and stays consistent and the oil does not come out with any discoloration. Another possible contributor is your cutting tool setup. It sticks out past the ring washer by quite a ways. And the packing you're using is aluminum which may be flexing a little more than if it were steel. I'd suggest first that you make up a longer steel packing which goes in behind the cutter rather than in front. And that way the packing can also stick out along with the cutter to around just 1/4 inch behind the cutting tip. This isn't my idea either. I "borrowed" it from Rustinox from the video ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-6qedffaP7XI.html . I think it helps aid with reducing both flex and likely chatter. I've also been considering making up a much thicker and bigger ring washer to use along with Rusty's tool "holder" for the same reason. The ring washer will stick out past the edge of the clapper but it'll also be stiffer and again support the cutter holder out over a wider and more rigid base. And a very hearty Merry Christmas and Happy Holidays back at you ! ! ! ! See you in 2023 if you choose to take a little break.

I would be interesting to see how flat the surface is by taking a print on your surface plate. I think the surface finish is the material not your shaper, just have to experiment with tool grinds and depth of cut. I have never run a shaper so I might be wrong

Thank Dean. I've never pushed my Atlas that hard. Good to know it can do it. I notice on this and your other videos you seem to always stop the shaper with the power switch. I normally let the motor run and stop with the belt / brake arm. Any reason you choose to use the power switch? Thanks for the video!

Probably the chatter is because there is a up & down slop on the ram. Have you managed to figure out what is the problem?

I have just finished getting one of these machines up and running and have had very little time to play with it. So far in my experience mine would not be able to make the 0.040" depth of cut you have in your video. It has been a couple weeks since trying some cuts and I don't recall if my motor was stalling or the belts were slipping. What is the Horse Power rating of your motor? Mine is an original 1/3 HP Atlas, seems kind of weak on power. I appreciate your videos, helps me understand what should be possible. I would ask a favor, can you do a close up on the cutter so we can see the grind on the cutter better? Maybe even tell us the angles of the grind. Once again, thank you for taking the time to post this.

Ciao Dean, a very interesting video: if one you will decide to sell your shaper...give me a call please !! 😎It is so cool, and also with high dept of cut, the surface finish is good, so this means that it isi rigid because you a have a repeatable result!! Ciao Dean, see you soon!! Alberto.

Your material looks to be Flame cut so probably harder on the ends combined with some tool and clapper flex starting the cut

Oh, my Alba starts to sound like a petulent child when doing .06 DOC and an .012 feed per stroke. The motor grunts and the bull gear crank makes a bit of a slapping sound. So I only went that far one time. I rough at around .05 x .008 and it's grunting but in a tolerant manner. Parts are .... "difficult".... to find. So I'm OK with giving up a little in favor of not breaking or wearing anything out.

I THINK IT WILL DO 0.100 EASY .. WELL MAYBE DO IT TILL IT FAILS !

What was your step over when you were doing this??

Tapering g