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Tubing Blocks

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It's also 2.260" wide, so we'll keep this height.
11 / 27

It's also 2.260" wide, so we'll keep this height.

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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