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Old 02-13-2019, 04:47 PM
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milomilo milomilo is offline
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Default Cheap Sine Bar

Saw this on YT and decided it would be useful for me on the mill. Plan on making two of them. One for MetalWolf.

Used a 6" piece of 2" round, milled a 1/2" step in it, drilled 5 holes 1" deep and tapped to 3/8-16 for the mounting plate. Next will be a 6" x 8" x1/2" plate with a series of 3/8" tapped holes to mount small parts on.

The theory is to put the 2" round in the mill vise and tilt the plate to the angle of your choice and lock it down in the vise. Considering adding two outboard slotted arms to stabilize the plate. Have not yet got that part of the plan figured out in my head yet.

Anyway, here are some pics of the 2" round. I have the plates in vinegar now to remove the mill scale.
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Old 02-13-2019, 08:54 PM
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Looking good there...
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Old 02-13-2019, 09:00 PM
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Originally Posted by MetalWolf View Post
Looking good there...
Thanks. I have ran into a bit of a problem. The new face mill I have is not compatible with the draw bar in my mill. The draw bar works fine with all my R8 collets. The drawbar is 7/16-20. So in process of making a new draw bar. Expect it has metric threads. I should find out tomorrow morning if I can find my metric thread gauges.
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Old 02-13-2019, 09:04 PM
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Just use a metric bolt, cut the head off and add on if you have one
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Old 02-13-2019, 10:43 PM
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Just use a metric bolt, cut the head off and add on if you have one
Ain't no metric bolts in my shop. The diameter is 7/16". I have a 7/16"x17" long rod the right length. Have to measure the thread pitch tomorrow if I can find my metric thread gauges. Could buy a short metric bolt, cut off the head and weld it to the shaft I have.
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Old 02-14-2019, 10:05 AM
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Try running a 7/16 tap down the hole first. Sometimes import threads need to be cleaned up. Unless we are talking radical differences like a fine thread metric.

Here is a video from Joe Py that would be useful for setting angles on the sine bar.
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Last edited by Ironman; 02-14-2019 at 12:46 PM.
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Old 02-14-2019, 11:42 AM
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yeah I watch a lot of his videos as well as mr.pett and a couple of others
they make it look so easy... and prolly is for others but in most cases, I would just have to spend the money and buy a set
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Old 02-14-2019, 12:45 PM
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I have a sine bar, and can’t say I’ve ever used one in a mill. Angle slips however are a totally different story, they get used regularly!


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Old 02-14-2019, 01:31 PM
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Quote:
Originally Posted by milomilo View Post
...The theory is to put the 2" round in the mill vise and tilt the plate to the angle of your choice and lock it down in the vise. Considering adding two outboard slotted arms to stabilize the plate. Have not yet got that part of the plan figured out in my head yet...
That's not really a sine bar; you need a second piece of round stock on the opposite end so you can use gauge blocks to set an angle. I can see it being a handy device for holding small parts on an angle but you need an independent method of actually setting the angle.

I would change the plate slightly by machining most of the face down while leaving a shoulder or step on the end nearest the round piece. That would leave you with a square shoulder to rest the part you're machining against. Your part would be located squarely on the plate; all you'd need to do is clamp it down.

Rigidity is going to be a bit of an issue with that thing as well. I really needs a support of some kind on the outboard end. On the few occasions when I've needed to cut an angle in the mill I've clamped a piece of flat in the vise but with a setup like that you'd only be able to take very light cuts before it started to move around.

The attached picture shows a true sine bar--it also shows the shoulder I mentioned above. The two rounds are mounted on the ground bar in such a way that when they are resting on a flat surface the top of the bar is dead parallel to the surface. The two rounds are located so their centre lines are exactly 5" apart. The 5" dimension is just a handy one to use but the rounds can be any dimension apart, it's more difficult to make calculations. By using gauge blocks and a little trig you can set the top face of the bar to very precise angles...
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Old 02-14-2019, 01:34 PM
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Quote:
Originally Posted by greywynd View Post
I have a sine bar, and can’t say I’ve ever used one in a mill. Angle slips however are a totally different story, they get used regularly!
Same here; the sine bar gets used very rarely (there's just no need for angles that precise) but I do use angle plates from time to time...
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