Curt's Machine Shop

Curt has a 6" lathe, Bridgeport mill with digital readouts, band saw, disk/ belt sander, and layout table in his shop.

Curt's Machine Shop

Curt has a 6" lathe, Bridgeport mill with digital readouts, band saw, disk/ belt sander, and layout table in his shop.

Curt's 6" lathe

The lathe was used to machine all of the round stock used in the project to make parts such as the gear inserts and main shaft.

Side Handle Mount Machining

A V-Block was used to position the material used for the side handle mount in the mill's vise.

Side Handle Mount Machining

A V-Block was used to position the material used for the side handle mount in the mill's vise.

Side Handle Mount Machining

A V-Block was used to position the material used for the side handle mount in the mill's vise.

Worm Insert Maching

1" diameter round stock 6061-T6 aluminum was used to make the worm insert located inside the worm of the wormgear set.

Worm Insert Maching

The worm insert being turned down to size.

Worm Gear Insert Machining

1" diameter round stock 6061-T6 aluminum was used to make the worm gear insert located inside the bronze worm gear of the wormgear set.

Worm Gear Insert Machining

Putting the 3/8" diameter hole through the insert so the worm gear can be mounted into the blocks.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Block Halves Machining

The two block halves that hold the gear set in position were machined in two parts so the gears could be easily mounted. They were machined from 6061-T6 aluminum.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Maching in Worm Insert

The worm insert had a 1/4" keyway that was machined along the exterior surface and a 1/8" keyway that was broached through the inside hole for the main shaft.

Keyway Broaching Tools

The broaching process was a learning experience for both Curt and I as neither of us had ever done it before. These tools were made to allow us to perform the broach. Making these tools took much longer than I had ever estimated but was done successfully in the end.

Main Shaft Machining

The main shaft was machined from a 6" long Craftsman 3/8" drive extension.

Main Shaft Machining

The main shaft was machined from a 6" long Craftsman 3/8" drive extension.

Completed Main Shaft

Here i the completed main shaft after it was turned down to the correct diameter, shortened to the correct length, and had the keyway cut down its length.

Frame Rail Scrap

The frame rails of the project were water jet cut by Cutting Technology Inc. in Auburn Washington. This saved time by not having to cut the overall shape with the mill.

Frame Rails

Here the frame rails can be seen. This was right after I picked up the pieces from the water jet cutter. They were cut very precise and only had to have the holes added to them.

Me Laying Out Some Parts

Side Frame Rail Holes

Here we are machining the 1/2" lightening holes into a side frame rail to decrease weight.

Completed Side Frame Rails

The side frame rails are identical except for the two small mounting holes to mount the side handle.

Curt Working on the Frame Rails

Tapping the Mounting Screw Holes

The frame rails are held to the main mounting plate with stainless steel screws. The ends of all three frame rails had to be drilled and tapped.

Checking the Spacing

Here I am measuring the spacing between the mounting hoes to ensure everything will go together without issue.

Top Frame Rail

Completed top frame rail with all holes needed for mounting.

Worm Gear with Insert

Here is the hardened worm gear with the aluminum insert installed and the spring steel 1/4" key to tie the two together.

Completed Block Halves

Here are the completed block halves that house the gearset. Both blocks are different as each serves a different purpose in the completed adapter.

Frame Rail Set

Here is a picture of the frame rails mounted to the mounting plate to see how they line up with each other.

Frame Rail Set

Here is a picture of the frame rails mounted to the mounting plate to see how they line up with each other.

Curt Making Sparks on the Anvil

Here Curt is using a cutoff wheel to shape the anvil to its final size. Because the Blade set is from a commercial set of cutters they had to be modified to fit.

Completed Anvil

Here is the anvil in its final shape with the mounting holes in place.

Anvil Fit Up

Here the anvil is installed into the block half so that the mounting holes can be marked to be drilled and tapped to the correct size.

Completed Worm Gear

Here is the main shaft fitted into the worm gear with the bushing and keys installed. From here the bearings are installed and it can be dropped into the block halves.

Completed Worm Gear

Here is the main shaft fitted into the worm gear with the bushing and keys installed. From here the bearings are installed and it can be dropped into the block halves.

Worm Gear Installed

Here is the completed worm gear installed into one of the block halves. Once the other half is installed the gear will be sandwiched and locked in place.

Worm Gear Installed

Here is the completed worm gear installed into one of the block halves. Once the other half is installed the gear will be sandwiched and locked in place.

Frame Rails Mounted

Here the frame rails and mounting plate were mounted onto the impact gun so the overall size of the tool could be seen.

Lying Out Mounting Holes

Here we clamped the blade to the worm gear so we could use a punch to mark on the gear and bushing where the mounting holes needed to be placed for a perfect match up.

Lying Out Mounting Holes

A 1/4" spacer block had to be placed under the blade so that the center punch would line up correctly.

DeWALT Tool Modification

Here you can see where i modified a DeWALT tool to allow the bit to fit further into the impact gun. This allowed for the correct geometry to be obtained through the rest of the attachment.

Messed Up Blade

The first blade didn't allow for proper hole placement in the bushing and gear material so we tried to place another hole further out. We ended up getting a new blade and starting over and learning from our mistakes.

Second Blade Modification

Here we used the digital readout on the mill to mark where the first set of holes were. From there we adjusted these locations for a better placement in the worm gear.

Blade Comparrison

Here is the original blade on the left and the second blade on the right. On the second blade the set of holes on the right were placed further from the center axle hole to get the bolts further into the bronze gear for strength.

Worm Gear Bushing

Here is the worm gear bushing with the tapped holes so the blade can be mounted to it.

New Modified Blade

This is the second blade we modified with the outside mounting holes placed at a larger distance from the center axle hole.

Blade Mounted

Once the blade was complete I mounted it to the worm gear so that I could see what parts of the gear were needed and what parts could be removed.

Laying Out Gear

Here we marked what part of the gear we wanted to keep and what could be cutoff and discarded to help save weight.

Cut Gear

Here is the gear after we cut off the excess with a band saw.

Finished Gear

Here is the gear after it was cut and milled flat and smooth with a milling machine.

Blade Testing

Here you can see how the blades match up with each other.

Completed Gear Set

Here is the gear set mounted into the block halves to see how the blades rotated past each other.

Completed Cutting Tool

Completed Cutting Tool

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