Switch handles for the Deckel. 

Nicely done! You prove on a regular basis that cool stuff can be done with basic equipment, the knobs and plate came out great.

Thanks for the shootout Michel. And also for all the informative and entertaining videos.

And again you managed to make my belly sore from laughing. haha. That shaper does magnificent work. I'm impressed. And your aluminum parts turned out great. You obviously improved your cooking recipe. Those knobs look awesome. Well done Michel. Gilles

Gday Rustinox, shapers are not as slow as people say and the shear tool did a much better finish then the fly cutter, the knobs turned out perfect, great job as always mate, Cheers

Interesting use of the angle grinder and I like the simple furnace for melting aluminium, nice job.

Good video again. I was not sure if you could HANDLE IT ! lol.😊

Great video, especially the ending. Take care.

good stuff, keep it going... 👍

We really like your milling machine it would be very large in the micro machine world, but it can make our fixtures, nice to see you sharing her. Shaper yes but having the mill make its own panels for the switches is her way of earning her way. Nice knobs you made. Lance & Patrick.

Nice work, Michel. I like the angle grinder held in the toolpost. I might copy that idea. All the best, Mart in England.

Now you need to make a model of that milling machine to put beside the model shaper you built.

😄

I have never understood the reluctance of machinists to use a ten euro ( 2nd hand ) nine inch grinder with one euro cutting wheel to over cut the dimension or more specifically rough cut to oversize. They prefer to go straight in with expensive cutters on expensive machines spending oodles of time creating loads of chips which need scooping up rather than throwing the residual piece in the scrap pile. It must somehow be against their religion. Nice video.

Wow it was going so good and then he blew up the whole place. I wonder if any of Belgium is still standing.

Brilliant 👍 🇬🇧

Michel, that cutting speed comparison was very informative. Nice dished knobs, clever. Thanks.

Good one . The mill would have chomped that away in a fraction of the time that a shaper would . Once you get used to that mill it will be easier . I always worry about switches with conductive knobs , in case something inside the switch malfunctions . 👍👍👍

THE KNOBS ARE A WORK OF ART, NICE JOB

Great Michel 👍👍👍👍👍👍👍👍👏👌 Kev (Mr F's W) UK

Very creative use of the angle grinder right at the end there. Well done.

Hey Rusti, Thanks for the shout out! Signed Jimmy

Hello Michel, Good video... I like the saucepan foundry casting... See you next week... Take care. Paul,,

The cutting speed of your mill is limited by its power. A safe speed for a HSS cutter is 20-30m/min at 0.05mm/tooth in mild steel. The depth of cut and width is limited by power and rigidity. 1mm depth of cut for a 10-20mm end mill is very conservative. No reason you can't go 5-10mm at a time. Using a power calculator from Mitsubishi I get a 20mm cutter, 10mm depth of cut at 80mm/min (0.05mm/tooth *4 teeth at 400 rpm) = 700w (~1 hp). That may be pushing your mill given its age, but that still gets the job done in under 2 min, not 30. Cutters need to cut not rub, and using 1mm of a 30mm cutting flute is like taking one slice off the end of your block of cheese and throwing the rest in the trash bin.

Great work Rustinox. Casting that aluminium was brilliant. Those knobs look superb. Tony

Michel, Another very informative as well as entertaining video. Randall in Kentucky, United States of America

G'day Rusti. Nice set of knows. The tool post grinder was a good way to create the dished ends, well done. Cheers Peter

Perfect planning as always Michel 👌, elegant solution as always. Thanks for sharing.

Awesome! Very clever use of the angle grinder. Great project love the ending.

Great Video. Glad to see you had REALLY long wires from the main switch as we could see the result from a distance! lol John, Australia.

Niffty tip using the angle grinder (@@)! You made the Germans very proud,,they look better than the original ones I think :>),,,Glad you like the orange juice tip on our last video. Panel for creator stickers hopefully will be completed by this Sat and video. I will post our mailing address in the video, and be Honored to post yours to help premote your channel. Mrs Bear sends her best to you, and loves watching your content. Bear.

Great video. Fantastic ending! I also do some metal casting, watching you @14:00 ! Get a full face shield, they are cheap as chips!

Great video Michel, I see you often favour the shaper for finishing and speed, The project turned out lovely, take care, cheers!

Love the way you use the grinder on the lath. Quite creative. The last shot - I almost spit my coffee all over the keyboard.

Great trick with the angle grinder, did you part off with it as well 🤔🤔🤔😁

Hi Michel , Those knobs look way better than the original ones and they will never break ! Thanks for the video - it sure did brighten up a dreary wet day here in Sydney Australia !

Michel Good Job Good Job Now that you have been vaporized Can I have the shaper ?

I like your technique with the right angle grinder, it is a very interesting procedure. Very explosive ending it made me laugh out loud.

Great job Rusti, really fun video and fantastic results (well apart from the minor malfunction with the main switch). Jim is a pseudonym for James in the UK/US and probably OZ as well. Cheers, Jon

Another great video. Are you using any degassing agent to help get rid of the bubbles when you melt aluminium. ?

good video rustinox

Dude you really had me laughing with that one. Nice looking knobs.

Knobs came out nice. Too bad you blew up your local power plant.

Thanks Rusti, that was fun. Of course I feel an even greater need for a shaper now…

that last bit was so funny,, keep them coming(still laughing)

Your switch has much more personality than the Germany made.

Hello Rusti, Keith from Michigan. My Lathe is running and made a functional item. First comment, your Shaper won't collect dust. If you can have good parts from your Mill. You 😉 will certainly see setting up a Mill. Yep they are easy to get quicker job setups 😃..

Last scene made me laugh real hard :-D good work.

Good one mate you made me smile 😃 😊 from trevor Jones

Ok you got me! The nuke made me jump. Lol

You handled that with no problems 👍

Nice to have more toys than you need😉😂

well they came out very nice

Lets hope Mr Putin"s main switch is missing !

🤣awesome, couldnt stop myself from laughing. and i learnt a thing or two too.

I would have guessed the mill would be faster. I like the new saw. Have a fantastic weekend Michel.

Very Very Nice, Michel...

Well Done , Again !

Works perfect!

Like the finish!

Hi Michael, great video - thanks. Did you / will you resume your marine career? Mike

Brilliant!!!

Oops....LMAO

Did not expect the apocalyptic ending 😮 Hope it’s not a premonition 🥴😢 Some lovely shaper, milling, lathe and aluminium casting. Fabulous result with the two new knobs. As always, thank you Michel for another informative, interesting and entertaining episode. 👏👏👍😀 Andrew

Very well done - huge improvement on the castings - and I really liked the angle grinder finishing touches. Hope your recovered alright from the nuclear radiation Best wishes Adrian

Very nice, as usual. I'm definitely going to have to try grinding my own cutters for the shaper soon, you make it look so easy. I would like to get a better finish. I like the finish I get, but it could be smoother. Thank you for the shoutout! Sorry about the blank paper, I just wrap the stickers in an extra sheet of blank paper to help keep them from getting bent or messed up in the post. I guess I'll have to start writing a note... 🙂

Hi Michel ☺ thanks for another interesting video mate, this time the aluminium casting turned out pretty good, and you made two excellent control knobs, and a backing plate,nicely done. Cheers my friend,stay safe, best wishe's to you and your's, Stuart UK.

Excellent work. Interesting to see various ways of doing things when tooling is limited. I'm surprised that the Shaper would have been faster than the Mill although I think your feed rate and depth of cut on the mill could have been faster and larger.

That shaper with the shear tool leaves a fantastic finish on the surface. Much nicer than the mill, although I am sure it is smoother than it looks. 👍

That end shot seems a little daring in todays climate. Down and dirty melting will get the melt job done. Have seen those same blow hole problems on casting done this way recently on u/t. It appears to have worked out in your utility job. Thanks for the look, as always enjoy your methodology.