Suggestions for a newb, please?

[stinky]

I did search this sub-forum, so please forgive me if I missed a FAQ.

I'd like to do some modding and I have a few tools (dremel, el cheapo soldering iron ;-) ), but would like to set up a proper work area in my basement. I'd like to keep the budget to a few hundred $ (maybe $500 or less).

Most important, and something that I truly do not understand, is how to keep the area clean and safe. How do you guys cut/grind metal and keep shavings and dust from getting all over the place? I have a toddler and although I can secure my tools from her, my concern about having metal shavings or lead solder around is another story.

I'd like to be able to work with aluminum, copper and brass. Is there such a thing as a cheap small lathe that isn't crap?

Any/all suggestions would be appreciated. If you assume I know nothing, you're probably pretty close.

 

[wquiles]

When you say that you want to do some modding and that you want to work with Al, Brass, and Copper, that is a very wide spectrum of work. Can you help us narrow that down, specifically as to what "things", and the size of things "things" you want to work with? Are you wanting to do both the mechanical/machining side of things and also the electronic side of things? Anything you can tell us will help us give you better advice.

 

[stinky]

When you say that you want to do some modding and that you want to work with Al, Brass, and Copper, that is a very wide spectrum of work. Can you help us narrow that down, specifically as to what "things", and the size of things "things" you want to work with? Are you wanting to do both the mechanical/machining side of things and also the electronic side of things? Anything you can tell us will help us give you better advice.

Thank you for the reply, and I apologize for being too vague. I like smaller lights and single cell, as opposed to larger, and would like to make my own copper heatsinks (which I assume means I need a lathe of some type to modify bar stock??). Would also like to work on lights as large as 2C cell, maybe 3C cell at some point. I would like to be able to modify brass and aluminum hosts, reflectors, etc. Probably not interested in making hosts from scratch, at least not at this point. Not interested in working harder metals like ss, titanium, etc. I have some odd/old hosts that I like (Victorinox 2C, one of these heavy brass things http://www.candlepowerforums.com/vb/showthread.php?t=223195, a CR2 Raw I just picked up, etc) for which I'd like to make innards. I bought some XPG R5s and SST-50s (bare and star) that I'd like to use. At some point I'd like to make drivers, but not a priority at the moment. I know that's something of a brain dump, but hopefully that helps. (btw, I've seen some of your work. verrrrrrrrrrry nice.)

 

[precisionworks]

I'd like to keep the budget to a few hundred $ (maybe $500 or less).

Hang around here for a while & you'll be adding another zero to that figure

For the money, it's hard to beat the quality of used tools & tooling on eBay. I probably have half a dozen tools purchased new, and hundreds of items (hand tools, measuring tools, mill & lathe tooling) bought used on eBay. If you have the time & the patience, it isn't uncommon to spend 10%-20% of new cost.

You may want to make three lists. List #1 are the must have tools - you define what goes on that list. List #2 are the tools that would be nice to have. List #3 are the tools to buy if you win the Lotto. If you concentrate on List #1, the rest will take care of themselves.

 

[gadget_lover]

There are several ways to proceed.

First, the subject of safety.

It's close to impossible to corral all the shavings. Some of them eventually travel with you. There are tricks to minimize the problem.

1) A vacuum nozzle close to the cutting head will suck away many of the chips.

2) a thick foam mat will allow the chips to become embedded.

3) A shop apron will keep swarf out of pockets and folds of your clothes.

4) keep the floor clear around your work bench and you can sweep it very clean every time you use it.

5) use 'shop' shoes and 'house' shoes.

6) Use a coarse welcome mat at both ends of the steps.

Aluminum is not as bad as steel or brass. The thin chips bends easily. Steel chips tend to form nice sharp rigid blades.

7) Solder has lead, but you have to eat it or breathe the fumes a LOT (daily for years) to have damage. Loose solder is not usually a problem for kids. It's just not attractive and does not spill like paint does. Lead based paint is only a problem because toddlers like to chew on woodwork. OSHA does recommend that you wash your hands before eating or smoking after doing a lot of soldering.

Now for the tools.

Even if working by hand, a good vise will hold your work steady while you work on it. It cuts down on accidents and lets you work more accurately. I used a 2 injch screwless vise on my micro mill. http://littlemachineshop.com/products/product_view.php?ProductID=1591] A toolmaker's vise has smooth jaws and holds parts very securely. You can use it on the mill or drill press later. Many hobbyists like the panavise brand of workholding fixtures when soldering and such.

A small drill press is great for drilling and tapping holes cleanly. With jigs (work holding blocks/clamps/mounts) you can repeat the same action with remarkable precision.

A small lathe like the HF 7x12 can often be picked up from craigslist or ebay for $200 to $300 if you check every day, several times a day. Bigger lathes are sometimes available that way too. A 7x10 through 9x20 are small enough to fit on a sturdy benchtop.

There are a dozen threads here on picking a small lathe and more on small mills.

A small belt sander makes a lot of things possible. It can be used to make square things rounded and round things flat. There are threads on that too.

Good luck.

Daniel

 

[sortafast]

keep it clean, keep it clean, keep it clean. Clean after every time you work on something. In my garage I am terrible about it. Its not hard, its just that I am either lazy or pressed for time and say "I'll take care of it tom....." you get the point. A good shop vac will help a lot with this. A good bench is a must, with lots of space. I built a 10'x3' bench and I only have 3sq ft left to do work on after I put a 8x14 lathe, micro mill, bench vise, 2 reloading presses and a bicycle truing stand on it. Also those little organization bin things with the small clear drawers are indispensable. Get 2, one for you light stuff and one for your small tools. Organization is another key component to keeping your sanity. And if you want to get serious about it you WILL need to get a lathe and probably a small drill press at the very least. The mini-lathes would be great for what you want to do, but expect that $500 budget to at least double if not quadruple. But its something that you can do over time. Scour the craigslist. I picked up my HF micro-mill for $150. It needs some parts, but works for now. And I have seen a bunch of smaller craftsmen lathes roll through lately at very attainable prices.