Need some help building this very simple bracket

[Jbrates]

Ok so I just want a little input as to how YOU would make this. The material is 3/16 steel. Any input is appreciated. My original plan was to use a 4 inch hole saw to cut the arcs. The drawing is a little confusing. It is one piece.

 

[bad_idea]

Just one? Lay it out on the plate. Drill the holes. Cut it out with a grinder. Takes a little work with a cutting wheel, then clean up with a flapper wheel.

 

[Kevin54]

If you have the material, I can whip one up for you for a couple of bucks

 

[Jbrates]

Thanks for the suggestion badidea. Im not the best at cutting arcs with a grinder. The problem is I need to make 12 of them. Thanks Kevin, the only problem is i need a bunch of them, and would like to be able to make more. I do not have an acetylene torch or plasma cutter, or mill. Is a big *** hole saw out of the question?

 

[Thumper68]

For 3/16th inch plate I would just use a jig saw with a good blade if I didn't have the proper tools.

Mark it out and clamp it to some 1/2" plywood and have at it.

The hole saw will give you lots of chatter.

 

[Fender1325]

Perhaps a band saw, or maybe a cylinder sanding attachment on a drill press. Cut as much excess off with a grinder, then use the correct size cylinder to get the correct arch and have at it.

 

[brianpgriset]

Ditto. Jigsaw will be fine for one.

 

[Techie1961]

I've had very good luck with hole saws and then a bit of finishing. When I read the first post, I was thinking it would be better with a jigsaw but since you're doing 12, you can optimize the layout and a hole saw would work well. You'll get a nice radius and it will chatter a bit when you first engage but that would be chamfered off anyway.

 

[larry_g]

If it were me with limited tools I would lay out the pattern on a 5" wide piece of material 40+ inches long. Use the hole saw to drill six 4" holes down the length on 4.5" centers. Then make the straight cut with a jig or hack saw. The secret here is that the hole saw puts the radius on 4 pieces at once, making an even cut.

Partial sketch, not to scale.




lg
no neat sig line

 

[steel 35]

If I had the hole spacings I could have been half way done @ $7.75 each at my door but that's a long way from yours.

 

[gorilla]

The radius's on that part make it hard to make even with a conventional milling machine. Easy but expensive on a CNC mill. The best method would be a CNC plasma cutter or a water jet. In my experience that's about 10 min for programming and about 1/2 hr run time on a water jet. Our local water jet guy charges $50.00 an hour.

 

[Kevin54]

The radius's on that part make it hard to make even with a conventional milling machine. Easy but expensive on a CNC mill. The best method would be a CNC plasma cutter or a water jet. In my experience that's about 10 min for programming and about 1/2 hr run time on a water jet. Our local water jet guy charges $50.00 an hour.

That's a simple part on either a conventional mill and even easier on a CNC. On a conventional mill, all you have to do is have your holes in, set your reference location, rough in the radius, then switch over to a boring head, and use that to cut the radius.

On a CNC, it's just a simple program to profile the outside shape, then a pocket routine to clear out where the radius is.

But if you don't have the equipment, then it is not a simple piece to make. jbrates...my offer still stands.

 

[Jazz1]

Since you have to make 12 of them I would get the best hole saw I could afford so they would be exactly replicated. Patience and cutting oil as well.

 

[purplezr2]

How soon do you need them?

Shoot me a PM maybe I can help you out.

 

[4 FN 27]

Ok so I just want a little input as to how YOU would make this. The material is 3/16 steel. Any input is appreciated. My original plan was to use a 4 inch hole saw to cut the arcs. The drawing is a little confusing. It is one piece.

If it were me with limited tools I would lay out the pattern on a 5" wide piece of material 40+ inches long. Use the hole saw to drill six 4" holes down the length on 4.5" centers. Then make the straight cut with a jig or hack saw. The secret here is that the hole saw puts the radius on 4 pieces at once, making an even cut.

lg
no neat sig line

Larry has the right idea to do it at home...

Or I can cut them...12 pcs @ 26.19 each plus freight out.

.187 304-2B SST, Laser Cut, Deburred.

Already have it programmed...

 

[zkling]

1-5 by hand, depending on tolerance, bandsaw and belt grinder.
12+ and had other things to do? Find someone wth a plasma table that won't bend you over. $26 each is absurd. Hell I'd mill you as many as you want for $26 each.

Couple hundred? Find a die and press shop to stamp them.

 

[gorilla]

That's a simple part on either a conventional mill and even easier on a CNC. On a conventional mill, all you have to do is have your holes in, set your reference location, rough in the radius, then switch over to a boring head, and use that to cut the radius.

On a CNC, it's just a simple program to profile the outside shape, then a pocket routine to clear out where the radius is.

But if you don't have the equipment, then it is not a simple piece to make. jbrates...my offer still stands.

Kevin, are we Agreeing or disagreeing? after 40+ years in the shops I know how to make that part but I also know that work like that is much more cost effective done by other means then milling. Installing a Omax water jet and using it to rough machine tooling plates just about doubled the efficiency of our Hass horizontal mill.

 

[bullnerd]

I would have them laser cut. I have had very low quantity 3/16 steel PO parts made by this place In the past. They are well known in the offroad and buggy building world. You couldn't buy the material for what they will cut and ship them for. Then ,when you need more just call him up.

http://www.google.com/url?sa=t&rct=...e.com/&usg=AFQjCNGVb722C5MuljwPjGVdnFNtMeFWbA

Contact this guy, Ive used him many times.
Miguel

[email protected]

 

[mike13u]

I can cut that with great quality on CNC Plasma. All twelve $168 shipped ($14 each). Private message me if you are interested.

 

[gahrajmahal]

Lots of great GJ resources for small part manufacturing. Thanks everyone.

I love Larry G's home suggestion. Brilliant!

 

[Whiskeymike]

What are they for? I have a CNC plasma, so I'd cut them on that. If I didn't, I'd cut them on a horizontal band saw and then the curve with a portaband mounted.

The hole saw will work, but I bet you go through a couple of them for 12 cuts unless you get a good brand.

If you run out of options send me a note. I could cut them in 1/4 for material plus beer and shipping. 3/16 would be a pita as I'm out and don't need any at the moment.

 

[jimgood]

I love Larry G's home suggestion. Brilliant!

I thought so too. Just needs to be 6+" wide and adjusted to account for cutter kerf.

 

[bullnerd]

I can cut that with great quality on CNC Plasma. All twelve $168 shipped ($14 each). Private message me if you are interested.

Holy smokes!

Ive had GK ship parts to my house this size for 2 bucks a piece!

Larrygs way is basic old school layout/holesaw technique, nothing wrong with that.

 

[mike13u]

Holy smokes! Ive had GK ship parts to my house this size for 2 bucks a piece!

Good luck with that. Anyone making twelve custom parts and shipping them for $2 a piece won't be in business very long. Does someone give you free A36 plate steel? He needs a 67" x 37" x 3/16" piece of plate to begin cutting his parts on. Can you get it to him for $24?

 

[Griff93]

PM sent.

Yeah at $2 per someone is losing money. The material costs about that. You guys that are having sticker shock about the guy with the laser cutting quote apparently aren't in tune with what laser cut parts cost. I think he also put 304 SST as the material which I only saw steel in the OP. Plasma is much cheaper but also isn't suitable for certain applications. Water jet is more expensive as well. Our local guys charge $165/hr.

 

[yaidunno]

If your dead set on making them yourself, Larry's layout will give you the best results.

With 12 needing to be made, I wouldn't think twice about having them burnt/cut out. Mike's price seems to be right in line. I'd expect to pay $10-15 ea, given the small run.

 

[kkroger]

A little late to the party but I would just use my CNC Plasma Table... Center punch the holes with it then drill them on the drill press, I could use either that or the CNC Mill, OR the Caveman tools, Probably start by laying it out on some flatbar instead of a plate...
Drill holes probably use the bandsaw for the arcs, then cut it off and finish it up on the sander...
I've never had a hole saw chatter so you could probably do that pretty easily too...

 

[bullnerd]

LOL! The OP never stated what tools he has to use.

Mike, I said similar size.

 

[kkroger]

LOL! The OP never stated what tools he has to use.

Mike, I said similar size.

Well since he mentioned using a 4" hole saw to do the arcs I am presuming that he at least has a drill press.....

 

[Kevin54]

Kevin, are we Agreeing or disagreeing? after 40+ years in the shops I know how to make that part but I also know that work like that is much more cost effective done by other means then milling. Installing a Omax water jet and using it to rough machine tooling plates just about doubled the efficiency of our Hass horizontal mill.

Sure there are more cost effective ways. If you have the more cost effective machinery to do the part. But not everyone has a laser, waterjet, or CNC Plasma.

All I was saying is that if it is ran on a mill, it is a simple part to make. Drill your holes and use them to clamp down through, then mill your profile. You can stack 4 at a time to run them.

 

[yaidunno]

Well since he mentioned using a 4" hole saw to do the arcs I am presuming that he at least has a drill press.....

And a large, gear reduction one at that!

A 4" hole saw requires lots of torque, and at 75 SFM should be run at roughly 70 RPM. This wont be happening on a drill press from a box store.

All the more reason to have a someone burn these out for you.

 

[4 FN 27]

1-5 by hand, depending on tolerance, bandsaw and belt grinder.
12+ and had other things to do? Find someone wth a plasma table that won't bend you over. $26 each is absurd. Hell I'd mill you as many as you want for $26 each.

Couple hundred? Find a die and press shop to stamp them.

Kind of funny I think I did the OP a favor...all the hero's (I say this in jest) are under bidding me...

You have to consider we are a business, not a mom and pop shop or a guy with a CNC Plasma table in his garage (my hat is off to all of you who do, I have the utmost respect for ya'all). I through the quote out there as an option knowing full well somebody would step up and make the offer to do it less as Kevin54 already did...God bless them all, what a great group of people.

We process 6 million + pounds of CRS, HRP&O, Copper, Aluminum and whatnot every year. There are 500+ open orders on the floor at any given time. We are job shop. Build things to customer specs from one off washers to assemblies the size of a phone booth.

Things to consider running a 90 man fab shop is the number of hands an order has to touch. Sales, Order Entry, Engineering, Production, Operators (Shear, Laser, Deburr, Inspection, shipping) Shipping, Invoicing, Accounts Receivable. Not to mention we will use a blank roughly 16 x 20 inches to make 12 parts assuming I have a full sheet or a drop from another job on hand. A sheet of 304-2B 48 x 120 is 315 lbs @ 1.75 roughly per pound delivered ($551.25)...and a guy on a fork truck has to unload it and check it in and 2 guys to shear that tiny blank off and put the rest in the drop rack. They are all fairly compensated above industry standard.

3 Choices of where to cut it:

Pulsar 1212 Laser: machine cost $310K (preferred on small blanks)

EX4500 CO2 Laser: Machine cost $470K (not including the Automation, Load/Unload)

NXF4000 Fiber Laser: Machine cost $875K (not including the Automation, Load/Unload)

I love competitive bidding. You may win on price but quality, customer service and value add engineering support is our selling point. Our customer base is broad and deep and they are for the most part happy. 40% of what we make stays in state, 45% ships across the country and 15% ships outside the us. The Gov has not helped in anyway to make us more competitive with the import business. Thanks to Obamacare we had a 12.3% increase in Health Care this year over the 3.3% increase last year...and we pick up 50% of that increase so our employees don't have to feel all the pain.

Now if the OP would like 1000 pcs I can do them for $5.73 each nested on the Fiber Laser. Lights out running over the weekend on auto pilot assuming we have the sheets on hand.

I love this business and the people that I have the pleasure to work with everyday. I go back 30 years with a lot of the guys in the shop. We were all once young pups and now we are all looking forward to retirement while helping educate the changing of the guard in the younger generation. And putting dollar bills in the box to ship out with the parts I would not have this pleasure or opportunity.

 

[readhead]

Perfect opportunity to buy more tools.

 

[mbatarga]

Good luck with that. Anyone making twelve custom parts and shipping them for $2 a piece won't be in business very long. Does someone give you free A36 plate steel? He needs a 67" x 37" x 3/16" piece of plate to begin cutting his parts on. Can you get it to him for $24?

67 x 37 ? 67x37=2479 sq inches ?

rough dimensions of the part is 4 x 6, qty 12 4x6x12 = 288 sq inches
did you mean 67 x 3.7 ?

 

[steel 35]

How soon do you need them?

Shoot me a PM maybe I can help you out.

I hope the OP Has considered this at least.
This is a simple job for some but should not take a multi million dollar set up & 90 guys to do it, (Jest) one.

 

[tarbellb]

Kind of funny I think I did the OP a favor...all the hero's (I say this in jest) are under bidding me...

You have to consider we are a business, not a mom and pop shop or a guy with a CNC Plasma table in his garage (my hat is off to all of you who do, I have the utmost respect for ya'all). I through the quote out there as an option knowing full well somebody would step up and make the offer to do it less as Kevin54 already did...God bless them all, what a great group of people.

We process 6 million + pounds of CRS, HRP&O, Copper, Aluminum and whatnot every year. There are 500+ open orders on the floor at any given time. We are job shop. Build things to customer specs from one off washers to assemblies the size of a phone booth.

Things to consider running a 90 man fab shop is the number of hands an order has to touch. Sales, Order Entry, Engineering, Production, Operators (Shear, Laser, Deburr, Inspection, shipping) Shipping, Invoicing, Accounts Receivable. Not to mention we will use a blank roughly 16 x 20 inches to make 12 parts assuming I have a full sheet or a drop from another job on hand. A sheet of 304-2B 48 x 120 is 315 lbs @ 1.75 roughly per pound delivered ($551.25)...and a guy on a fork truck has to unload it and check it in and 2 guys to shear that tiny blank off and put the rest in the drop rack. They are all fairly compensated above industry standard.

3 Choices of where to cut it:

Pulsar 1212 Laser: machine cost $310K (preferred on small blanks)

EX4500 CO2 Laser: Machine cost $470K (not including the Automation, Load/Unload)

NXF4000 Fiber Laser: Machine cost $875K (not including the Automation, Load/Unload)

And if that is not enough cost to cover well there is property taxes of $3364 per week and at the end of the run assuming we make 20% on the job we get to give the Fed and State 49.45% of the profit.

I love competitive bidding. You may win on price but quality, customer service and value add engineering support is our selling point. Our customer base is broad and deep and they are for the most part happy. 40% of what we make stays in state, 45% ships across the country and 15% ships outside the us. The Gov has not helped in anyway to make us more competitive with the import business. Thanks to Obamacare we had a 12.3% increase in Health Care this year over the 3.3% increase last year...and we pick up 50% of that increase so our employees don't have to feel all the pain.

Now if the OP would like 1000 pcs I can do them for $5.73 each nested on the Fiber Laser. Lights out running over the weekend on auto pilot assuming we have the sheets on hand.

I love this business and the people that I have the pleasure to work with everyday. I go back 30 years with a lot of the guys in the shop. We were all once young pups and now we are all looking forward to retirement while helping educate the changing of the guard in the younger generation. And putting dollar bills in the box to ship out with the parts I would not have this pleasure or opportunity.

Respect.

 

[motobilt]

I can cut them today. We have 3/16" loaded on the plasma table right now. Call me at 334-699-6300 if I can help.

 

[4 FN 27]

I hope the OP Has considered this at least.
This is a simple job for some but should not take a multi million dollar set up & 90 guys to do it, (Jest) one.

Millions yes, 90 guys no...only 89. I will supervise...LOL...I am good at that...

 

[wbrian63]

If you're going the hole saw route, you definitely need (as other's have said) a better drill press than the off-the-shelf stuff from a big-box store.

I have a 17" Delta that would do the work - and if you're similarly equipped, here are the things you need to consider.

1) The table must be near to exactly perpendicular to the centerline of the chuck. You want the hole saw to make even contact all the way around the cutting arc. A little off to the left, right, front or back will cause the hole saw to grab and that will most likely snap off the pilot drill.

2) Put the table up as high as you can in relation to the cutter. Less extension on the quill will make the drill press more stable.

3) Run it as slow as you can, and leave the belt a little bit loose, so when the hole saw grabs (and it will), the belt will slip and lessen the torque shock to the setup.

4) Clamp the part to the table 6 ways from sunday. You do not want it to move even a little bit.

5) Use a cutting fluid of some sort. I've got some really nasty sulpherous (sp?) oil that I use when threading water pipe - that works well. You want something that won't boil off with heat.

I used the above techniques to cut arcs out of a piece of 3" x 1/4" wall square tube. Only broke one piloting bit.

It took three days less than forever...

 

[purplezr2]

Good luck with that. Anyone making twelve custom parts and shipping them for $2 a piece won't be in business very long. Does someone give you free A36 plate steel? He needs a 67" x 37" x 3/16" piece of plate to begin cutting his parts on. Can you get it to him for $24?

I see needing about 36"x8" piece of steel to cut these.

With a which is about 2 sqft of material, at about 15.4lbs for 3/16 material.

I pay about .50lbs for steel so the steel would cost about $8.50 with tax, shipping would be roughly 6-10 bucks with flat rate boxes, which I believe these all would fit in one box.

I know you need to make a profit, but my math is not aligning with yours what am I missing.