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Between 705 & 1200 SQ/FT From losing everything to being cash-poor and shop-rich in "only" five years!

Workspaces between 705 and 1200 squarefeet.
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GeddyT

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Jun 17, 2015
Messages
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Location
Bellingham, WA
Going to issue a correction. Typing up that last post made me wonder if I can look up order status for that lip seal and see if it's stuck somewhere. I looked up my order, and the price per meter was actually only $1. So cheap, in fact, that I ordered two different profiles just to cover more bases (pudding brain, so I'd already forgotten that detail).

Seems the reason for the delay is that the order hasn't even shipped yet. I wonder if they're waiting for a bigger order so they can make a ton of it and cut a little off for me. Kind of a bummer, but it will be worth it as long as I actually receive what I ordered sometime in the near future.
 
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GeddyT

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Bellingham, WA
Hurco update:

[A tumbleweed slowly rolls across the screen as crickets loudly chirp in the distance.]


With the Hurco update out of the way, what else has been going on? Thanks to a week of too-hot-to-get-anything-done sunshine giving way to too-wet-to-get-anything-done rain, I have a bit of time to play catch-up, so let's hop into the Wayback Machine and go all the way back to December, when I decided to start (and ultimately give up on) yet another grand gesture birthday present for MGT. Too many years ago to remember, we moved the laundry downstairs for a couple of reasons. The first was that we were tearing every wall of the former laundry room out to reframe and side, and we wanted to be able to do laundry in the interim. The other reason was that it would be nice to have an actual mud room for hanging coats, storing shoes, etc. The ultimate ultimate dream for this room, though, was for it to house a large pantry cabinet, something our house has always lacked, leading to... creative kitchen storage concepts.

The "mud room" has been sitting there waiting for some love for an amount of time that I've already established is too painful to contemplate, and I decided MGT's birthday, coupled with giving up on my lower back ever feeling "good," was proper motivation to get started.

The first step, which I didn't take any pictures of, was hanging a few pieces of drywall to fill in the gaps from prior construction. Then I had to mud and tape the corners and seams that would be inaccessible once the pantry were built. Didn't have to make it look pretty, just sealed.

Finally, it was time to start actually building something. I decided that the cheapest, easiest, and most space-efficient form of a pantry cabinet would be to just frame it in place with standard framing lumber, panel it with melamine inside, use some leftover birch ply for floors and shelves, and face-frame with cabinet grade materials.

The framing was pretty straightforward:

2026-01-19+closet+1.jpg

2026-01-23+closet+2.jpg

I realized as I was building this that I was OVERbuilding this, but that's fine. If "The Big One" earthquake hits, I'll have my family hunker down in this closet...

In keeping with cheap-and-easy, here's the melamine paneling and birch bottoms installed:

2026-01-25+closet+3.jpg

Coat and backpack hooks, shelves, and face frame installed:

2026-02-04+closet+4.jpg

I chose poplar for the face frame only because it was the only wood species that had enough in stock in the right lengths that I could get the whole job done. Eventually, it's going to be painted anyway. Unfortunately, this was also the one huge mistake I made with this build. It didn't occur to me until I'd completely finished that I measured/cut/installed the rails and stiles backward. No way was I going to redo it all, so it's just going to have to be "custom"...

Doors installed on soft-close hinges and drywall screwed onto the left side:

2026-02-13+closet+done.jpg

With it then early February and with construction complete, all that was left was finishing the room. You'll notice a 2x4 at the bottom of the last few pictures, disappearing off to the left. This was part of a little scheme that I thought was pretty clever:

2026-02-13+ghetto+scaffold.jpg

I needed to do a lot of mudding and taping and texturing way up at the top of the stairwell, so I framed up a little platform from scrap that I could slide along those two rails that are screwed into the studs. It really makes getting to the ceiling nice back there, and I only smashed my head on the platform once before learning to stand it up and move it out of the way after every use.

With this mud room project, a couple machining projects, and the Hurco way covers going on all at the same time, the ping pong table became no different than any other flat surface in a shop:

2026-02-04+closet+total+mess.jpg

Sadly, I have no pictures of the mud room finished. Because it's not. I got really busy, so I was only able to poke at the drywall work a bit at a time, then, in mid April, disaster struck. We got a combination of ridiculously heavy rain and strong wind, and apparently it was too much for our roof. A leak formed around the master bathroom fan penetration, which dripped down over time and pooled up under the paint in our bathroom. MGT called me in to point out a bubble in the paint that looked like a soccer ball was trying to burst through. I got out a razor blade and started peeling back the damage, water dumping down as I did:

2026-04-15+bathroom+flood.jpg

Not going to sugarcoat it: this one broke me. I was already really stressing out about all of the projects piling up, and having another unexpected one dumped on top was just too much. It was all I could do to spread some schmoo on the roof and seal the leak, but I wasn't getting anywhere near drywall mud for a long while after this. Call it a mental health break. I knew that I had major house remodel work coming (spoiler: that's what I was working on when I got rained out this afternoon), so I might as well just do all of the interior work at the same time now that I had three rooms I'd be working in.

MGT--wisely--gave up on the mud room being finished and just started using it. Still an ugly construction zone, sure, but all of the added storage has been a major improvement to the house!

Anyway, still three machining projects, some car drama, and now some house work to talk about, so I'll be back at some point. I hope life is treating you all well!
 
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GeddyT

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Jun 17, 2015
Messages
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Bellingham, WA
Oof. Sorry to hear about the house priests shenanigans. Hope you've made some good progress since then!
If progress can be measured in bodily pain, I've made a LOT of progress this weekend! Sneak preview:

2026-06-28+teardown+first+weekend.jpg

I'll explain these present day horrors when I'm done catching up on the backlog, though. In the meantime, some fun machining projects that I took on between work and work...

Both of my kids have picky feet. Finding soccer cleats that fit them and don't give them massive blisters or really bad heel pain has been a chore. Eventually, I did what I tend to do and obsessively researched online until I found that certain Mizuno cleats check all the boxes, and the kids really like them. Heel pain gone, blisters gone, no complaints. I had to roll the dice and order them sight unseen, though, because there's nobody in the states that has them in stock. Which made it a bit of a crisis when my son discovered while warming up for the last game of the season with his club team that one of his heel studs was MIA.

In the following two weeks, he'd have tryouts for two different club teams and his high school team, and the nearest replacement pair was in Japan, where they're made. This was going to require a creative solution, so off to the plastic stock shelf! I figured I'd turn a replacement stud on the lathe out of a plastic that sticks well to high strength epoxy adhesive and hope that the sole plate on the boot isn't nylon or something else slippery. Since nearly none of my massive supply of plastic that I bought for peanuts at auction is labeled as to material, the safe bet was just to use some ABS that was labeled as such.

It was a pretty simple part aside from figuring out how to hold it in the lathe chuck (I don't even remember what I came up with at this point, but it must have worked): just a flat-topped cone that's hollowed out inside to fit over a nub molded into the sole plate. After clamping overnight for the epoxy to cure, I was pretty stoked with how it came out!

2026-02-22+soccer+stud+1.jpg

2026-02-22+soccer+stud+2.jpg

2026-02-22+soccer+stud+3.jpg

I'd like to think that it hung on there for most of his first day of tryouts. But I can't be sure...

The other machining project I got up to in the first quarter of the year was for Andrew. He stumbled upon a cheap walk-behind tractor for sale and decided he could turn it into a trail maintenance machine. Specifically, he would adapt a blower and a sweeper to the PTO using belts and pulleys. What he needed from me was a drive shaft for the blower fan. Don't need the Hurco for that, so it was a welcome distraction.

Actually managed an incredibly nice surface finish in this chromoly with my crappy little lathe:

2026-03-11+shaft+1.jpg

And the Dufour handled the keyway with ease:

2026-03-11+shaft+2.jpg

All finished:

2026-03-11+shaft+3.jpg

Last thing for now is that I'm a year past when you're supposed to get your first colonoscopy, and MGT finally threw down and made me get off my *** (no pun intended) and schedule it. It ended up going fine, no major issues, come back in five years, yadda, yadda, but then I noticed this when reviewing the doctor's report:

2026-05-18+colonoscopy+wtf.jpg

What the eff is that supposed to mean!?...
 

bdbecker

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Iowa
What the eff is that supposed to mean!?

Okay, that got me!

Probably just a note for the future so they know what to expect. For whatever reason, my body burns through certain types of pain/numbing agents fast. I woke up in the middle of surgery as they were installing a pin in my toe... not cool. Same thing during dental work, one shot is just not enough. I know there is a note in my dentist's files saying to give me an extra shot mid-procedure.
 
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GeddyT

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Now we hop in the Wayback Machine and travel to Fathers Day.

MGT knew that the graveyard of furniture occupying an entire wall of the shop had annoyed me for some time. Every time she upgrades a desk or a nightstand or a dresser or an end table, the piece that gets replaced is "temporarily" stored against one wall of the shop. There wasn't anything there, anyway, but what this has effectively done is shrink the width of the shop by a bit in the only open work area. It's been a problem for so long that I'd given up and just started using these random pieces of furniture for temporary storage or work tables. You know, flat surfaces on which to pile stuff and then walk away.

She decided to do something about it for Fathers Day. And, because she's smart, she asked first instead of taking the surprise route. She knows how picky I am with certain things. I told her it was a fantastic idea and I'd love to have some actual shop furniture lining that wall. A row of steel cabinets under the windows, capped with a nice worktop. I could easily fit a dozen feet of cabinets in that space, so some careful shopping was in order to avoid the project budget ballooning out of control.

Of all places, she found that the cheapest matching steel cabinets with a combination of drawers and shelves are mail order items from Target. I had no idea what I was in for until I saw the boxes that they came in. Boxes impossibly small for large cabinets.

Turns out these things wouldn't have been out of place coming from Ikea. Complete assembly required, all screwed together instead of welded/riveted. I spent an entire afternoon watching both the men's and women's soccer teams play friendlies (both 2-0 losses) while assembling four cabinets, so no small task. Once assembled, I was decently surprised at how strong they were, but there was a problem: I wanted these cabinets stacked side by side like a single unit, but they couldn't be shoved flush together because the sides were a scatter plot of domed screw heads. My solution was spacer strips of birch ply between cabinets to hide the gaps and screw heads, with sheetmetal screws keeping the cabinets attached to each other:

2026-06-07+cabinet+flop+1.jpg

I think this took a whole extra afternoon.

2026-06-07+cabinet+flop+2.jpg

Once they were all attached together into one big unit, I used a laser and bolts screwed into the caster mounting locations to level them on my wavy floor. Also annoying and time-consuming.

My first plan for a worktop was butcher block, but the long and narrow shape of this row of cabinets was going to mean having to buy and discard a lot of extra. It was going to be pretty costly. Concrete and rebar is pretty cheap, though, and I do like a concrete countertop...

I decided countertop mix would be overkill for this, opting instead for relatively cheap high strength crack resistant mix. This would end up being a huge mistake, but I wouldn't know that for some time because of how long and tedious of a job it was getting things formed up and ready:

2026-06-07+cabinet+flop+3.jpg

My next biggest mistake was in caulking the gaps. Or, more accurately, not caulking all of them. I caulked every seam between cabinet and form board, but it didn't occur to me that these cabinets were only screwed together: There were seams in the tops of the cabinets themselves. Not caulking those seams was about to cause me a LOT of cleanup, which I discovered immediately after I started dumping wet mix into the forms:

2026-06-07+cabinet+flop+4.jpg

You can barely see some of the drips running down the inside of the cabinets and pooling on the bottom. This picture was taken after quite a bit of cleanup, then returning the next day. One aspect of the pour that I was pretty happy with was my improvised ******** that I made by hollowing out some random plastic stock and pressing it onto an SDS bit:
2026-06-07+cabinet+flop+5.jpg

This might have worked a bit TOO well! Or maybe I just mixed my concrete a bit too wet. Hit it with the SDS, and there would almost instantly be a puddle on top. Regardless, I was pretty happy with the rough result after taking off the forms and wiping things down a bit more:

2026-06-07+cabinet+flop+6.jpg

There'll always be a haze on the inside of the cabinets, but I'm not too bothered by it. What I was bothered by was what happened when I came back several days later and tried diamond-polishing the surface with diamond pads on the RO sander. This worked really well for my bathroom countertop, but the only thing it achieved here was making another huge mess:

2026-06-07+cabinet+flop+8.jpg

It pretty much instantly evaporated the sand and cement but had zero impact on the aggregate, leaving the surface even rougher than before. I have several theories as to why it didn't work this time:

  • Wrong mix. You don't want tufts of fiberglass on your countertop surface. Also, aggregate is bigger.
  • Too much water in the mix, plus all of that moisture vibrated to the top before polishing.
  • Too soon. Not fully cured before polishing.
If I had to guess, it was a bit of column A, a bit of column B, and a lot of column C. In the end, though, I was out less than $700 for about 10 feet of cabinets and countertop, and I figured I'd just coat the countertop in polyurea to smooth it out and be done with it. Here's as far as I got on the project before I had to put it off for more pressing problems:

2026-06-07+cabinet+flop+9.jpg

I wish I could say that they still look like that, ready to be finished and filled with various sundries, but instead they look like this:

2026-06-25+MGT+new+battle+station.jpg

That's MGT's battlestation, on the big butcher block desktop that I made her, on my new cabinets. Until I finish rebuilding her office, this is where she'll be doing her work. And since this work is photo editing, it means that the lights can't be on while she's working. Which means I'm frequently without a shop until her office is rebuilt. Which is nice.

I still haven't even gotten around to putting anything in three out of the four cabinets...
 

Coolabah

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Jun 6, 2010
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2nd Floor, 3rd on the Right,Narooma, Australia
Now we hop in the Wayback Machine and travel to Fathers Day.

MGT knew that the graveyard of furniture occupying an entire wall of the shop had annoyed me for some time. Every time she upgrades a desk or a nightstand or a dresser or an end table, the piece that gets replaced is "temporarily" stored against one wall of the shop. There wasn't anything there, anyway, but what this has effectively done is shrink the width of the shop by a bit in the only open work area. It's been a problem for so long that I'd given up and just started using these random pieces of furniture for temporary storage or work tables. You know, flat surfaces on which to pile stuff and then walk away.

She decided to do something about it for Fathers Day. And, because she's smart, she asked first instead of taking the surprise route. She knows how picky I am with certain things. I told her it was a fantastic idea and I'd love to have some actual shop furniture lining that wall. A row of steel cabinets under the windows, capped with a nice worktop. I could easily fit a dozen feet of cabinets in that space, so some careful shopping was in order to avoid the project budget ballooning out of control.

Of all places, she found that the cheapest matching steel cabinets with a combination of drawers and shelves are mail order items from Target. I had no idea what I was in for until I saw the boxes that they came in. Boxes impossibly small for large cabinets.

Turns out these things wouldn't have been out of place coming from Ikea. Complete assembly required, all screwed together instead of welded/riveted. I spent an entire afternoon watching both the men's and women's soccer teams play friendlies (both 2-0 losses) while assembling four cabinets, so no small task. Once assembled, I was decently surprised at how strong they were, but there was a problem: I wanted these cabinets stacked side by side like a single unit, but they couldn't be shoved flush together because the sides were a scatter plot of domed screw heads. My solution was spacer strips of birch ply between cabinets to hide the gaps and screw heads, with sheetmetal screws keeping the cabinets attached to each other:

2026-06-07+cabinet+flop+1.jpg

I think this took a whole extra afternoon.

2026-06-07+cabinet+flop+2.jpg

Once they were all attached together into one big unit, I used a laser and bolts screwed into the caster mounting locations to level them on my wavy floor. Also annoying and time-consuming.

My first plan for a worktop was butcher block, but the long and narrow shape of this row of cabinets was going to mean having to buy and discard a lot of extra. It was going to be pretty costly. Concrete and rebar is pretty cheap, though, and I do like a concrete countertop...

I decided countertop mix would be overkill for this, opting instead for relatively cheap high strength crack resistant mix. This would end up being a huge mistake, but I wouldn't know that for some time because of how long and tedious of a job it was getting things formed up and ready:

2026-06-07+cabinet+flop+3.jpg

My next biggest mistake was in caulking the gaps. Or, more accurately, not caulking all of them. I caulked every seam between cabinet and form board, but it didn't occur to me that these cabinets were only screwed together: There were seams in the tops of the cabinets themselves. Not caulking those seams was about to cause me a LOT of cleanup, which I discovered immediately after I started dumping wet mix into the forms:

2026-06-07+cabinet+flop+4.jpg

You can barely see some of the drips running down the inside of the cabinets and pooling on the bottom. This picture was taken after quite a bit of cleanup, then returning the next day. One aspect of the pour that I was pretty happy with was my improvised ******** that I made by hollowing out some random plastic stock and pressing it onto an SDS bit:
2026-06-07+cabinet+flop+5.jpg

This might have worked a bit TOO well! Or maybe I just mixed my concrete a bit too wet. Hit it with the SDS, and there would almost instantly be a puddle on top. Regardless, I was pretty happy with the rough result after taking off the forms and wiping things down a bit more:

2026-06-07+cabinet+flop+6.jpg

There'll always be a haze on the inside of the cabinets, but I'm not too bothered by it. What I was bothered by was what happened when I came back several days later and tried diamond-polishing the surface with diamond pads on the RO sander. This worked really well for my bathroom countertop, but the only thing it achieved here was making another huge mess:

2026-06-07+cabinet+flop+8.jpg

It pretty much instantly evaporated the sand and cement but had zero impact on the aggregate, leaving the surface even rougher than before. I have several theories as to why it didn't work this time:

  • Wrong mix. You don't want tufts of fiberglass on your countertop surface. Also, aggregate is bigger.
  • Too much water in the mix, plus all of that moisture vibrated to the top before polishing.
  • Too soon. Not fully cured before polishing.
If I had to guess, it was a bit of column A, a bit of column B, and a lot of column C. In the end, though, I was out less than $700 for about 10 feet of cabinets and countertop, and I figured I'd just coat the countertop in polyurea to smooth it out and be done with it. Here's as far as I got on the project before I had to put it off for more pressing problems:

2026-06-07+cabinet+flop+9.jpg

I wish I could say that they still look like that, ready to be finished and filled with various sundries, but instead they look like this:

2026-06-25+MGT+new+battle+station.jpg

That's MGT's battlestation, on the big butcher block desktop that I made her, on my new cabinets. Until I finish rebuilding her office, this is where she'll be doing her work. And since this work is photo editing, it means that the lights can't be on while she's working. Which means I'm frequently without a shop until her office is rebuilt. Which is nice.

I still haven't even gotten around to putting anything in three out of the four cabinets...
Wow I'm sure MGT will be thrilled with that option although a sacrifice/inconvenience for yourself. But this is of course what us decent guys do for our other halves.
Might I just with all due respect say- you have made the temporary situation just a little bit too good.
Did you at least make sure of a few random annoying but harmless splinters or something in the bench top ?
Yeh, all silly jokes aside, loving your thread and those cabinets turned out great.
 

zanyad

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they look like this:

2026-06-25+MGT+new+battle+station.jpg
Shiny! :thumbup:

Are you satisfied with the cabinets themselves?
 
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GeddyT

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Location
Bellingham, WA
Shiny! :thumbup:

Are you satisfied with the cabinets themselves?
For the price, they're pretty decent. I think I wouldn't trust them to hold up too well if used as roller cabs on the included casters and moved around a lot while full of heavy stuff, but they might. Even though they're screwed together, they seem sturdy enough. I would prefer to not have to deal with assembly, but at an hour of assembly per, I earned a decent houly wage vs prebuilt!
 
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GeddyT

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Another fun little manual machining job involving Andrew's abused and constantly broken mini excavator:

It started in May, with Andrew asking me to what we could do about a seized track idler wheel. He brought it over, and we pressed it apart. The stock setup for this wheel is a typical arrangement of deep groove ball bearings with circlips for retention and a stepped shaft for inner race locating. There was no need to worry about destroying any of that when pressing it apart, as it was already well and truly borked. Once again, this metal welded to that metal, leaving the shaft pretty much worthless and the idler wheel itself full of extra steel in the way of replacing any parts.

The big problem is that the cast wheel itself is very expensive to replace so I needed to somehow restore it. It's also too big for my little lathe, so it would have to be done with the boring head on the Dufour:

2026-05-17+idler+bore+cleanup.jpg

He hovered while I machined, and, pass after pass, we moved further and further into "upsized bearings" territory. When it was all said and done, we had a smooth bore perfectly sized for cheap replacement ball bearings. I'd have to make an oversized replacement shaft, cut some circlip grooves, etc. Andrew decided he wasn't having it, insisting instead on converting to a solid bronze bushing so that he'd never have to deal with this again. I tried to talk him out of it, knowing the cost of bronze, but he persisted, buying a chunk of bronze on eBay that was easily more expensive than a replacement wheel would have been, but with enough material to convert the other side's idler when it (inevitably) goes ****-up.

Took a while for Andrew to get the bronze in hand and link up with me again, but, a bit over a month later, he dropped off the chunk of bronze and a length of shiny one-inch steel rod long enough for a replacement shaft. I asked him what kind of steel, and he responded something to the tune of, "Shiny and hard." So I had that going for me.

Bronze is bronze and machines freely, so taking it to the correct OD (press fit for the bore I left in the wheel) went without drama. Or pictures. But I did grab a shot of the test fit for the inner bore:

2026-06-27+idler+rebuild+1.jpg

My old broken ripper mill is exactly an inch in diameter and slipped in the bore like the proverbial glove. Next was cutting to length, shown here...

2026-06-27+idler+rebuild+2.jpg

...and boring out dust seal pockets on each side, not shown at all...

Bushing and wheel:

2026-06-27+idler+rebuild+3.jpg

Bushing pressed in and shaft machined:

2026-06-27+idler+rebuild+4.jpg

And all assembled:

2026-06-27+idler+rebuild+5.jpg

A static picture doesn't tell the tale, but it was buttery smooth and perfectly balanced. Huge success! Can't wait to do it again...
 
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GeddyT

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One more update for today because I don't want to cut big holes in the wall of the house during a thunderstorm...

This update is going to be about my luck with vehicles. Bad luck, specifically. There is a cruel irony in the fact that my friend--who could easily be fooled into heading to the store for some blinker fluid--can buy a used Altima that came from a rental fleet and get 150,000 trouble-free miles from it, but I buy a brand new Honda that needs three engine rebuilds and new CVs within the first 70K. (I think I've already told that story of why I'll never own another product with a Honda H on it earlier in this thread.)

The first vehicle I bought was an old Ford Courier, freshman year in college. I bought my first new vehicle when I was 23 and started working where I still work. Between those two vehicles, the string of bad luck, self-inflicted disasters, and poor purchases was so bad that I could forgive someone for thinking I'm exaggerating if I told them the story. In that span, I went through (and I do mean "went through," as in, "no trace of any of these vehicles remaining") eight vehicles. (I swear it was more, but I can't remember.) I was young and broke, so I kept having no choice but to buy cheap cars, and those cheap cars kept exploding on me.

For my sake as much as that of the story, a brief summary in chronological order:
  1. 1978 Ford Courier: Owned for two years, ran increasingly poorly until it just wouldn't run at all. Gave it away to a mechanic at work, and he found that all the main bearings were loose.
  2. 1988 Honda CRX Si: Had it for about six months. Loved it. Somebody changed lanes into me on the freeway, and I flipped/rolled it four times. Suffice it to say it did not survive...
  3. Chevy cargo van, can't remember the year: This was a replacement for the dead truck. Had it for one summer, the last summer I ran my house painting business. Always ate oil, and I once let it go too long without adding more, so the engine seized. It was towed before I could recover it, and the bill for towing and impound was more than I had, so I told them to keep it.
  4. 1982 Porsche 924 Turbo: Bought it with the insurance money from the CRX crash. Because I'm dumb. Awesome car, but it ate three cam lobes on a cross-country trip a few years after I bought it. On the bright side, it got about 40 mpg for its last thousand miles... I ended up towing it home from Arizona, but I never got around to fixing it and eventually gave it away.
  5. 1984 Honda Prelude: Great car. Had 240K miles on it when I pulled the engine to rebuild and upgrade it as part of a school project. Fresh from the machine shop, the engine was stolen out of my carport. Rest of car was hauled to the scrapyard.
  6. Audi 5000, can't remember the year: Only the second automatic on the list, which was lame, but at least it was the first car I ever owned with automatic climate control. I think I may have gotten six months out of this one before one of the rods decided to leave the engine.
  7. Late-eighties Ford ******: My brother was working at a car dealership at the time and told me about this "great" car that came in on trade and that I could have for next to nothing. This one set the record for futility, leaving me stranded on the fifth drive with an exploded water pump. Timing belt snapped on the sixth drive. I gave it to the same guy I gave the Courier to, as towing it would cost more than it was worth.
  8. 1991 Honda Prelude: Honda took a step back with this one. Not as good as the '84 for some reason. I think I drove this for about a year before it got completely smashed up by an uninsured drunk driver while parked in front of my house. He sped away, multiple people reported the license plate number to the police, and the police couldn't be bothered to find him. I kept driving that car for a couple of months, getting wet every time it rained because the top of the driver's door was bent out, and eventually limped it into the dealership to trade it in on my first new car. It was sputtering and lurching as it rolled onto the lot, and they were pissed that they agreed to give me $500 for it.
I did the math after the fact, and I could have been leasing a new luxury sedan for what I was spending to drive and maintain total shitboxes for a bit over four years.

All that backstory told, my luck hasn't really improved much since, which is having a pretty big impact at this very moment, specifically with our van.

I think I've said it before, but I'm a minivan guy. Freaking love them. The sliding doors, the car-like drive with truck-like cargo capacity, the versatility. They used to get pretty crappy fuel economy, though, so I was looking to change that when I was so pissed at Honda for our Odyssey, well, odyssey... that I was willing to take it in the shorts trading that pile of **** in on a new van. And Chrysler had just released a plug-in hybrid that every car media outlet was calling the greatest thing since sliced bread.

On the fuel economy front, they were absolutely right. This thing has been awesome in that regard. On the other hand, it's been in the shop three times now with hybrid system issues (it's the same system that Toyota has had sorted for decades, but Chrysler gotta Chrysler...), the last time having the whole traction battery replaced, which took like a month. These vans have had so many problems, in fact, that Chrysler has extended a lifetime hybrid system warranty to every one of them. Which is like gold, I figured.

Until I was wrong.

This was my van on the first weekend of May:

2026-05-01+van+dam+age.jpg

There's quite a bit of it that you have to take apart to get to the radiator, but that's getting ahead of things. To keep this already bloated story as short as possible, the van went into limp mode while MGT was driving my son to a soccer game. No CEL, no indication why, just a cartoon turtle on the screen and "Propulsion Power Reduced." It's done this before. Usually, it's just the battery over-discharging, and you have to drive it a bit or stop and restart it to clear the condition. Either way, before she could pull over, power was restored, and she continued on. It did this three times on her way to the game, so she called me. She also popped the hood and looked things over, and the only thing that looked out of sorts was that one of the many coolant reservoirs was way near the bottom, below the low fill line.

I met her there and had a look. I saw the coolant was low, but there was still some there, and it was late enough that I couldn't buy any more anyway. And it was parked in a tow-away zone, so I decided to just limp it the four miles home on slow surface streets and look it over the following day. The turtle came up right away, but I didn't need full power for that trip, so no big deal. It was going fine until about a mile before my house, when a new message popped up on the screen. Something like, "Pull over immediately. Vehicle shutting down."

And boy did it! By "immediately," it meant about four seconds. I didn't even have time to get off the road. So I blocked one lane of the road for almost an hour (funny story with a police officer, but this is already too long) while waiting for a tow truck to get it the rest of the way home. This was April 30th, and the spoiler to this story is that we still don't have that van.

I wanted to make sure that the dealer wouldn't make some excuse to not honor the warranty, so I figured I'd give it a good look-over before having it towed in. So I took the front wheels and bumper off and peeked around. The only thing out of sorts was the front radiator (the one for the hybrid components) was wet, as if from a small leak. There was also a small (size of a softball, maybe) damp spot on the driveway that would have been under the engine when the van was parked the previous day. I removed the front radiator, brought it to the shop sink, filled it with water, and couldn't find it leaking anywhere. So I dumped it back out, plugged one end, hooked an air line to the other, gave it a quick blast, and found a tiny pinhole leak near the top. Right over the leak, stuck in the fins, was a pebble about the size of something you'd have in a goldfish bowl. "You've got to be kidding me..."

Figuring I might be able to skip the dealer altogether and fix the problem for cheaper than having the thing towed, I bought a radiator, swapped it on, topped it up, and looked up the bleeding procedure. Then wished I had looked up the bleeding procedure first... It involved starting and stopping the pump, opening and closing a valve, etc. I had no means of doing any of that, so it looked as if I'd wasted my time and would have to have it towed to the dealer anyway.

And that's where things get interesting (yeah, yeah, "FINALLY," you're saying...):

Some time after dropping the van off, I got a call from the mechanic, who was really confused and wanted to hear every detail of the story. I told him the story, and he put me on with the service manager, who I had to repeat the story to. The service manager told me that this was going to be a huge repair and that it's not a warranty issue. The damage was the result of "continuation" after a collision with the tiny pebble. They say that this should be a comprehensive claim with my insurance company.

My next call, then, was to my insurance company, where I told the same story I'd just told the shop to about three different people. Then I waited a few weeks. Then I got a letter in the mail with a check to reimburse me for the radiator repair and a pat on their back for a job well done, closing out the claim. As to the rest, that's on Chrysler.

And what's "the rest"? It's $13,600 in parts and labor to replace the transmission, inverter, pump, etc. Pretty much the whole hybrid system. Obviously, that's not something I had budgeted for, so I was quickly back on the phone with both the dealer and insurance.

I waited for MONTHS while the dealer and the insurance duked it out, sometimes taking calls from both in the same day, complaining about the other being unreasonable. Finally, the dealer said I either needed to authorize the repair or come get it. It needs fixed, so I authorized the repairs and am probably looking at having to pay out of pocket.

So I've got that going for me. Which is nice.
 
OP
G

GeddyT

Well-known member
Joined
Jun 17, 2015
Messages
1,248
Location
Bellingham, WA
The list of projects for which a CNC mill would come in really handy has been growing out of control, and this has really been weighing on me. There are a lot of things in my life that haven't been in their right place, and this is a big part of the feeling that the walls are closing in that I've been troubled by for the better part of a year. In spite of being incredibly busy, I made some time to start working on the Hurco way covers, hoping to have the machine up and running so I could blow off some steam between late summer projects. I will not be blowing off steam anytime soon, but at least I made some progress...

I figure it's smart to work from high and back in the machine to low and in front, that way I'd avoid climbing on the newly rebuilt covers as much as possible, so the Z-axis cover was up first. It also helps that it's relatively small and straight. First step: get the four pieces clean and rust-free.

Ladies and gentlemen, this setup here is not to be trifled with:

2026-07-26+cleaning+ways+2.jpg

I'm always into trading time for minor tool expense, and I figured a wire brush on the grinder would make short work of the rust and grime--sort of like a shell mill for surface passes when milling. What I found instead is that I was holding a death trap. I had to be really quick on releasing the trigger when, in about half a blink, that wire wheel caught, jumped, and was suddenly INSIDE my underwear, playing backup instrumentals for Frank and The Beans. Shredded through shorts, underwear, and skin before I could even get my finger off the trigger.

So I only tried it one more time...

This time, it bounced a little higher, warping through my shirt and removing a layer or two of belly skin. Not the weight loss plan I had in mind.

I decided 800 grit sandpaper and WD-40 would be just fine for the rest of the cleanup... Interestingly, it worked better as well.

With the panels mostly clean, it was time to get the lip seals in. First step was prying up the retaining lip. Second step was painstakingly removing the hard, black plastic remnants jammed up in there. It chipped out like hardened phenolic resin, which is really weird for a channel that should have never had anything but soft rubber in it.

2026-07-26+cleaning+ways+1.jpg

Then it occurred to me that I still hadn't even opened the box from China full of replacement lip seal, so I wasn't even sure if I got the right stuff. It was so cheap that I'd ordered two profiles, hoping one would fit. Bingo!

2026-07-26+lip+seals.jpg

Man, I can't help but rant like an old man at this point. This lip seal cost me $1 per meter. One. Dollar. I need 16 meters to finish this job, and I don't need to do that math for you. The only domestic outlet that would sell me this same profile quoted me FOUR-HUNDRED DOLLARS before shipping! People complain about all of our manufacturing going overseas, but there is zero chance that it costs 2500% more to extrude rubber domestically.

Anyway, the complete lack of seals wasn't the only problem with the covers. There's also the complete lack of guide way protectors and rubber bumpers. The former keeps the ways from going cockeyed and getting damaged while also keeping the cover sheet steel from contacting and scratching the extremely expensive and precise linear ways on which the machine axes ride. Once again, the plastic that was there had gotten extremely brittle and largely disintegrated. Being impossible to buy, I would have to remake these sliders myself out of something durable. I have a ton of nylon on hand.

2026-08-07+way+cover+slides+1.jpg

Natural nylon chips look EXACTLY like fingernail clippings. I couldn't stop laughing about this.

Test fit:

2026-08-07+way+cover+slides+2.jpg

And fitted in place:

2026-08-07+way+cover+slides+3.jpg

I had to make six of these total, and the tolerance is stupid-small. Hurco should have left a lot more room to account for material wearing, but there's exactly 2 mm between the way cover and the linear rails. Not a lot of meat before you're touching metal to metal. My replacement slides have a lip for locating (and more strength and surface contact), meaning I had to machine them individually, which was pretty time-consuming. The correct way to make these would have been on a 3D printer, but mine decided it didn't want to live anymore, and it was pretty crappy even when "working." I had planned on finally picking up a legit printer, but all major purchases are on hold until we figure out who's paying for all of the work on the van. So it is what it is.

As for the rubber stoppers that pop into holes in each guide and prevent them from clanging together when fully collapsed, I attempted to make these as well. The local hardware store sells rubber corks for $5 a pop, so I bought a half-dozen of them and chucked one into the lathe to straighten, shorten, and make a retaining nub to shove through the hole. After this turned into a complete disaster, I bought enough automotive hood bumpers off Amazon to do the whole job for about the price of one of the corks I'd bought, and they fit perfectly.

Anyway, one cover down, four to go. I've been informed that things will stay that way until MGT is back in her office...
 

Jrad235

Well-known member
Joined
Nov 23, 2012
Messages
110
Location
Colorado Springs, CO
My brother in Christ, TWO POINTS OF CONTACT at all times with spinning wheels of death involved. Glad you survived! We use 7-10" concrete blades on our large grinders and between those and the 16" concrete saws I have a healthy respect for rotational momentum. Nice job on the ways covers!
 

M.Brane

ALLIANCE MEMBER
Joined
Feb 11, 2024
Messages
1,970
Location
1 hr N/W of LA LA Land
I have the greatest respect for wire wheels of any kind. Found many little pieces of wire embedded in my clothing. Face shields are mandatory. A co-worker of mine had one walk across his face while working in a cage he was building. If not for the safety glasses he would have lost an eye. As it was he had a deep abrasion across his face, and this was someone who was experienced in metalworking.
 
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