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Tubing Blocks

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Raw Materials.  2.25 square extrusion cut into roughly 2.25" sections and then similar smaller blocks for rack tubing.  This is how the materials came from Online Metals.
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Raw Materials. 2.25 square extrusion cut into roughly 2.25" sections and then similar smaller blocks for rack tubing. This is how the materials came from Online Metals.

bicycleframebuildinghome machine shopmilling machinetubing blockstubing clamps

  • Raw Materials.  2.25 square extrusion cut into roughly 2.25" sections and then similar smaller blocks for rack tubing.  This is how the materials came from Online Metals.
  • The cuts aren't very square, so the first job is to true them up.
  • Squaring up the vise on the mill.
  • This was an experiment, but it worked pretty well.  I'm setting the block square to the table (and thus spindle) using a machinists square and 123 block.
  • Faced the top and it came out square.
  • Flipped the block over, so the faced part is facing down.  Now we'll face the part facing up.
  • Facing in progress.  Notice how the cutting marks from the bandsaw disappear under the facing head.
  • We need to remove .061" from the block and my knee raises .125" per handle revolution.  So we need to raise it .064".
  • Setting the knee to .064.  When we get to 0 we are done facing.
  • 2.260" high (slightly over the 2.250 that it should be).
  • It's also 2.260" wide, so we'll keep this height.
  • 2.260" in this dimension too, so now we have a big aluminum cube.
  • Finding the edge.
  • 1.130 to the middle.  That is 9 revolutions (9*0.125 = 1.125) plus 5 thou.
  • Starting to drill our 1.125" bore.
  • My mill head can be a little low, so I switched to using collets for the larger drill chucks.  The collets take up a lot less vertical room than the drill chuck.  All of my drills over 1/2" have a 1/2" shaft, so I don't need to change collets.
  • Lots of aluminum after a pass through the hole with a big drill bit.
  • Switched to the boring head to get from 1" to 1.125" diameter.  1" is the size of my largest drill.
  • Done boring.
  • Finished cube with bore sitting on top of a raw cube.
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