Square Holes - 5 Methods To Make Them in Metal

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G'day everyone,
In this video I will be going through a few methods of creating square holes. I will be needing to machine a few of them in the future in order to repair my broken 4 jaw chuck, and after looking into some of the methods, I thought that it might be an interesting video topic.
In this video we will also be revisiting the old die filer that I used make last year. I will use it to file a hole square. I will also look at shaping a hole square and make a cutter from silver steel. I will also revisit the rotary broach tool I made earlier this year.
How does rotary broaching work?: • How does rotary broach...
Joe Pie's Video: • Can You Grind Tools on...
Timestamps
0:00 - Intro
1:36 - Hand Filing Holes Square
3:04 - Using A Die Filer To Make A Square Hole
5:01 - Using The Milling Machine To Make A Square hole
6:08 - Shaping/Broaching - making the Cutter From Silver Steel (Heat Treatment)
9:58- Shaping/Broaching The Hole
11:37 - Rotary Broaching A Square Hole
#machining #diy
Making Square Holes
Machining Square Holes

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11 июн 2024

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Комментарии : 454

@maurorivarola2704 Год назад

For a moment thought I was watching this old tony channel haha

@tootaashraf1 Год назад

yeah lol

@noahstephens7622 Год назад

I wish.

@zaq405 Год назад

I got the same vibe. TOT has been MIA for a while. I hope he's okay. I miss his humour.

@tune3garage Год назад

Seems Tony has been playing with the time machine again.

@TheMrSepe Год назад

Same here, is this the new old tony🤔😅

@wizrom3046 Год назад

You can make "reverse" files for your die filer machine. It is easy if you dont mind losing a bit of length. Use a blowtorch to heat the end of the file to anneal it (so it is no longer brittle) then just grind that new "handle end" to a round shape or whatever shape fits your machine mount. Then mount the file upside down. Obviously you can cut off the original handle end. 👍

@tim_sees Месяц назад

I was thinking something similar. Logic ;)

@makerunderground Год назад

We sometimes use the same method as Joe in CNC machines to make hexes in implant screws, except in CNC it's easier to use a one cornered tool and index between corners. It's considered a form of skive broaching. Great intro, btw.

@steveocvirek6671 Год назад

Love the home made square bit at the start - funny! Great informative video. Thank you.

@CharlySardo Год назад

Best part about machining (at least for me) is that there is so much I don't know and so many people to show me stuff. Thanks for the video.

@skunkjobb Год назад

Holding a rotary broach that way without a specially made tilted holder for the tail stock was a nice idea. I have been thinking about a rotary broach but thought it was too much work for something I would use so seldom but a chuck in the regular tool holder can be used for so much more.

@philsmeanderings7991 Год назад

Good watch , something cool about making a perfect square hole in steel. Yes that Joe Pie has some really good knowledge both old and new school.

@JohnBrown-hx5oy 2 месяца назад

I subscribed a while back and continue to watch your videos. This has become my favorite channel, and after watching your shop tour, I am amazed what you are able to do in such a small space! I really hope you continue making these videos. You are an inspiration!

@jimsvideos7201 Год назад

You can drill holes slightly outside the shape of a square hole so that it will accept a square plug, and get a more fatigue-resistant structure for it.

@greenetolstoy 2 месяца назад

It's almost 02h00, could not sleep and so turned on RU-vid. This was the perfect video for the hour. Great skills!

@violettownmicroenterprises1528 10 месяцев назад

Thank you.... that was so good, learning is joy.

@kevkev5935 Год назад

This is such an awesome video. Making that cutter from an old end mill was great in an of itself.

@danielelliott3659 4 месяца назад

Excellent video. Thanks for taking the time to do this

@DavidHerscher Год назад

There are nice cast iron kits for die filers available in several places online. Def worth looking into for anyone who has a need for one.

@andrzejporeda7281 Год назад

Bardzo świetny jest ten pomysł na kwadratową dziurę pozdrawiam twórcę tego filmiku 👍👍👍👍

@aries6776 Год назад

Very informative, particularly the broach tool and heat treatment detail.

@spiritburners 5 месяцев назад

I love the Die Filer......Lovely machine

@sparkiekosten5902 Год назад

I can barely afford good "normal" drill bits let alone these fancy square drill bits! I've got drawers full of cheap drill bits which prefer burning through the work instead of actually cutting anything! Now I am told I can't even use the for broaching tools?...Why have I saved all these dull drill bits for? I really enjoyed the intro, made me smile! Keep up the good work!

@markkoons7488 Год назад

Very interesting. Thank you.

@David_11111 Год назад

really enjoy this one thanks

@aguilayserpiente 5 месяцев назад

Fine education. Fine editing and acting.

@TalRohan Год назад

love the off screen supersonic hacksaw use... I am a heat it up and wack a square punch in to it person but I like these methods....except filing I hate filing because its really hard to get decent files here. thanks for sharing

@garyhardman8369 Год назад

Just found your channel. Excellent info, clearly presented. You have a new subscriber Sir!

@ignazachenbach5406 Год назад

<a href="#" class="seekto" data-time="595">9:55</a> this method is my favorite since the concept of "pressing metal away"-and at such a relatively slow speed!-is cool as heck.

@ZoonCrypticon Год назад

A superbe video, thank you very much !

@davedunn4285 4 месяца назад

I enjoyed it very much

@MattysWorkshop Год назад

Gday, great examples, I made a rotary broach and for making hex’s it’s brilliant, cheers

@amalgunaratne6987 Год назад

great idea bro thanks

@RUBIZEN Год назад

Finally! I know I'm not crazy. I saw a video of the Colt factory making 1911's. They were using a "filing machine" to make the cut out on the back of the grip, the area where the spring housing is held. If I recall the machine also lifted the file up a little on the non cut stroke.

@ChibabaDave 13 дней назад

Would it be a shaping machine? A tool being driven to scrape a groove then free to lift up on the back stroke?

@kenworks6068 5 месяцев назад

I learned a few good things today

@kajbyman3006 2 месяца назад

Thank's for the video😀

@antonk4398 Год назад

Great work

@jackdawg4579 Год назад

FYI - HSS lathe tooling works well enough for cutting square holes in a sliding style cutting setup like you used in your quill, and they will generally work with the grind they come with straight out of the box.

@artisanmakes Год назад

Yeah it does work, but I found that the edge doesn't hold up as well compared to silver steel

@whocares457 Год назад

@@artisanmakes Do you mean 1.2210 steel?

@shokdj1 Год назад

I think that square drill bit will be a game changer once it’s released

@kevinschulmeister2054 Год назад

Why start with a round drill bit when your looking for a square hole. Just use a sqare dril bit. Its so simple, but everyone wants to make a video.

@shokdj1 Год назад

@@kevinschulmeister2054 it’s the 1st thing I’ll buy

@christianpaulroldan4010 3 месяца назад

Thanks for the video

@kurtbecker3827 Год назад

If you put isopropanol onto your file, it will be much easier to file aluminum. It prevents the clogging of the file and the finish is so much better. Equally well, I never drill a hole into aluminum without using isopropanol on the drill bit. The hole quality is like night and day.

@greggroos2271 Год назад

will give that a try

@danielelliott3659 4 месяца назад

I will try that also

@TIMHNL Год назад

I mount my files ‘upside down’, glued into a tube which fits the holder on the die filer. If you put the tube in the lathe Chuck, and the file in the tailstock, you can get them pretty true. Apart from then being downward cutting, the other benefit is that you can fit a handle onto them so you don’t poke your eye out 👍🏻

@timfoster5043 5 месяцев назад

Hilarious intro. And you mentioned Chris from Clickspring, so I gotta subscribe!!

@kennyg1358 Год назад

Pretty neat having Chris as a neighbor!

@drscopeify 2 месяца назад

Great video. For thin materials I use a hydraulic punch with square die.

@pmcKANE Год назад

I personally use round bits in an ever decreasing size remove material approaching the corners, right down to a few angstroms in diameter. Strictly speaking the resulting hole isn't perfectly square, but it's pretty close. Admittedly it does take a while.

@Tornussen Год назад

Very good! I made one turning tool by my self to turn square holes. Here it var som other good examples too.

@Bianchi77 4 месяца назад

Nice video, @<a href="#" class="seekto" data-time="456">7:36</a>, precise square, thanks :)

@billshiff2060 Год назад

For your die filer it should be possible to grind the tip cylindrical to fit the receiver and allow down filing with a bit of loss of stroke but I think it can be managed.

@bc8010 Год назад

Since you made that die filer, you could always make a die filer where the motor is on top and the file cuts down into a hole in the table, it would kind of look like a band saw lol.

@ChefKevinRiese Год назад

Great video!

@artisanmakes Год назад

Thankyou

@WRWhizard Год назад

Here in Turtle Creek / Wilmerding Pennsylvania, USA.there was a company that made square and hexagonal drill bits. It was on Airbrake Ave. This was the home base for George Westinghouse. My math / geometry teacher had one and demonstrated it on a bar of soap. He was teaching something called a loci of points. The way the bit worked was there was a square jig, A block of metal that already had a square hole in it that the bit went into to guide it. With each revolution of the bit, the cutting edge would take off more along the square profile. At first it only cut along the edge, then it would hit the corner and the path would go along the next side of the square. If you ever saw the Spirograph toy it was a wee bit like that.

@fredbloggs4829 Год назад

I know at the end you mentioned there are many other ways, but a push broach with a press is a convenient way to make square holes. The Joe Pi method is really cool. Can that do blind holes as well?

@artisanmakes Год назад

Yeah I don't see why not

@jonroesler8155 Год назад

EDM, including wirecut EDM, is also an option. Along with plain broaching of holes.

@lifco.hydraulics 3 месяца назад

So cool

@jimwhite282 Год назад

Thank you, it was interesting and informative with high production values. How did you determine when the silver steel became non-magnetic? The obvious of bringing a permanent magnet near it, or some other method?

@ferrumignis Год назад

@@mmm365 The whole point is you don't need to measure the temperature, you just get it to the point that a magnet won't attract it. This is the same point that the internal structure of the metal changes to make it hard. It will be a red heat to get it to this point.

@petert9749 Год назад

@@ferrumignis Interesting: the video gives the impression the work piece is short of going red??? Thanks for video. Pete

@Pushyhog Год назад

thanks again.

@over-engineered 2 месяца назад

When I was an apprentice, we all had to make a hacksaw frame each. Part of the design involved filling a 1/4” square hole to a rather tight tolerance - through 1/2” thick steel.

@LaraCroftCP Год назад

@<a href="#" class="seekto" data-time="48">0:48</a> the square Drillbit! Applause, applause, applause😂😂😂

@saijuakshaya1983 4 месяца назад

Thanks for you also

@felixu95 Год назад

Let me know when those square drill bits are ready for mass production, I'll need quite a few of them for this bridge I just bought

@ThantiK Год назад

@<a href="#" class="seekto" data-time="246">4:06</a> -- You should add some air assist to this. There's a lot of build-up of chips in your file, and getting that out of the file during each stroke would probably help it function faster.

@craigtate5930 Год назад

I have also had good luck hammering square HSS bits through round holes in aluminum...obviously you have to protect yourself from the hss chipping/ exploding...but with some simple preparation it works rather quickly

@ThatOneOddGuy Год назад

Aussie old tony

@markrichardson239 Год назад

Excellent!!! O.K., Machinist of 40+ years here in the Jobbing shop, and an Owner. Silver Steel, must be water hardening drill rod in this case. Tempering at 220 degrees... Celsius? ( I am American, Fahrenheit here where 220 would do nothing but boil water ) I have a rotary broach system, but never understood if id cammed to a small degree, but you just broke the truth to me, set at minor angle out of alignment. I now wonder, 1 degree, 2?... 3?? Awesome. Thanks a lot!!!! Mark

@pudnbug Год назад

I have made many cutting tools with 'silver steel' (drill rod, to me), and all I did was heat it to yellow and quench it in oil. Sufficient tempering seems to take place during the cooling process. If I was making a drill, or similar cutting tool, I chucked the tool in a drill press and heated it while rotating before lowering it into an oil can, so it would not warp.

@750triton Год назад

Can you alter standard files so they fit the machine the "wrong" way around? You're not using the whole length of the file, so why not

@wubforceone Год назад

i appreciate the this old tony style intro haha

@neiloconnor9349 4 месяца назад

Did you save the metal filings for thermite? I used to work at a factory job in the 1970s where I filed the mating surfaces of a pair of tweezers. I forced the unfiled tweezers into an opening in a die where a file reciprocated up and down. I had to wear leather protectors on my thumbs and index fingers. I was paid by the piece, and occasionally made OK money for the era.

@Mortmustsepp Год назад

thx dude

@the4thj Год назад

Nice satire! I was not expecting that very funny. First time I felt compelled to comment.

@cedricbrun4241 Год назад

Why did you used salt in the quenching water? I've never seen that before, is it to increase the boiling point or to decrease the specific heat capacity? maybe it's for something else?

@BasementEngineer Год назад

Making a blind hole is much more difficult, especially if only one is required. Many years ago I built a tool that required a 3/8" square hole 3/8" deep to fit a socket set handle to operate the device. A fixed handle was out-of-the-question as it would have interfered with machining operations. I laid out the square hole and drilled 1/16" holes at the 4 corners, tangent with the sides of the square. Then drilled out the middle of the square with a 23/64" dia. drill. Hand work using needle files did the rest. Did not take that long to do this part of the job. Nowadays I would EDM that hole with my shop-built machine.

@feelthepayne88 3 месяца назад

You could also make the tool in two parts, one with the square hole as a through hole and then the other half, either a transition to round socket or whatever and just line up the holes and weld them together. Might not work for every application, but should be a useful solution for some parts.

@FixNewsPlease 5 месяцев назад

We also used an EDM die sinker with graphite blanks or an EDM wire with .031 wire.

@JordanHaisley Год назад

Could you turn the die filer into an over arm version to use standard files?

@DantesAlvesdeSantana Год назад

Bem explicado

@David_11111 Год назад

suggestions for a 3mm square hole in brass ?

@mickandreassen3906 Год назад

Metal shaper with file holding tool works well

@BJCP Год назад

Hey mate, might be a silly question, but could you turn your die filer upside down? This would make the needle files cut on the down stroke.

@vaulthecreator Год назад

That's what my father did about 25 years ago. He also built his die filer and also had the same complaint of the file grabbing and lifting the work. He ended up flipping it and mounting it at the head of a busted drill press.

@artisanmakes Год назад

Yes you could, I might have to braze a shank to the end to give it a bit more length though

@ECL.. 5 месяцев назад

Can you design the filing machine around the files that are readily available?

@vogtland_holz Год назад

Interesting Video, thanks for that 👍

@Aslan117 Год назад

Easy to do with a cnc, you use a triangle endmill and create a non cycloid mouvement by synchronizing the rotation and mouvements

@Jaws677 Год назад

Graet Vidoe ;-)

@kbsanders Год назад

That's right... it goes into the square hole.

@jamesbarisitz4794 5 месяцев назад

A refractory brick makes a nice bed for heating up small parts when heat treating. Two or three make a little chamber to contain the torch heat even better.

@rcaelhachimi7607 Год назад

Bonne travail continu

@mono4643 Год назад

It goes in the square hole!

@kniefi Год назад

What about edm wire cutting? Electrical discharge machining? Can get some crazy tolerances with it!

@runcycleskixc Год назад

There are screw-driven square hole punches that punch 1 mm sheet steel. Prob can handle 2 mm Alu sheets. For a thicker part >>> stack and glue multiple 2 mm alu sheets together.

@Blurgamer17 Год назад

That's right! It goes in the square hole.

@girliedog Год назад

I would love to have a filing machine. Having been wondering if one could modify a scroll saw to do similar work.

@SK-tr9ii Год назад

I saw one made out of a saber saw in a machinist magazine years ago.

@Dzeroed 5 месяцев назад

Start off with some wood, use the metal to make a bridge, frets, and strings, and build a fender strat. Right there are even more ways to make them even MORE metal 😁🤘

@johnlagreca6288 6 месяцев назад

Nice video. Did you need any square holes to make the die filer?

@runasings 4 месяца назад

Dude. Shalom!

@motokicker3462 Год назад

good movie for teaching with idea! I wish to have EDM to uese imprint square shape, especially dead end square hole need that.

@BrucePierson 4 месяца назад

You have a nice collection of machines in your workshop., but most people would not have all the tools that you have, so the old filing the round hole to make it square is about all that most people can do.

@feelthepayne88 3 месяца назад

You need to make an arm for your die filer with two adjustable hold down fingers that straddle the file and keep the work from lifting.

@allinalladityan318 Год назад

Ihv seen a square hole in a solid granite stone measuring about 8ft by 12ft with a thickness of 4ft. The square hole is 2ftby2ft. The stone is part of a sculpture in a temple built about 500years ago in South India. There's also a granite chain measuring about 1ft in thickness for about 10ft in length, hanging over 20ft height.

@user-hu4lh6hg5j 4 месяца назад

is it possible to made one for un quarter bit only I need to punch a thin disk of metal in the form of a un quater bit exagonal to add to a little toole in plastic for 1\4 bit sise jack 47 71

@Akideoni Год назад

Nice cuts! Bet those guys in the chinese mint mints their coins(sand casting) the other way around a dozen centuries ago. Oddly, it was performed as such so it was much easier to work on those round coins.

@danhyde7501 Год назад

How do you know what to use as quenching medium? I’ve seen normal water before and oil sometimes, never seen an explanation of the logic behind the selection

@vx-iidu 7 месяцев назад

depends on the type of Steel you are using

@simona.6298 Год назад

i´ve learned manual metal working for a half year and it is not as good as your hand work😅 Always no i only learn on CNC Machines, but it´s good to learn how it´s made manual or on conventionall machines