how you going guys Kurtis from cutting edge engineering so today we're finally going to be getting our big shaper out of storage and bringing it here into the workshop we've had the shaper for about four years i haven't had the room in the workshop to actually place the machine and play with it so we have had it stored outside in one of our shipping containers the reason we've decided to get it out of storage is the container it's sitting in is actually in the way that 20 footer has to be removed in order for us to fit a new 40 foot high cube container in its place all the materials that we have here stored in the center of the workshop in our pallet racking all of that is going to go into our new container we're then going to put our other 40-foot container which at the moment is used for storing materials and consumable stuff like that 40 feet away from that one over the next coming months we're planning to put an igloo between the two containers to make an outdoor fabrication area so the space in the workshop where the shaper is going to live for the time being is actually where our old milling machine project was so lots of room around it to do anything we need to do to it so let's go get it out [giggle] and four wheel drive i'm helping [giggle] thank you that'll do come on something we gotta go check come on where is it what's that here what's this is that okay is it okay yes righto guys so we got the machine placed in the workshop now i've got it sitting on some timbers for the time being i will build a proper foundation for it when the machine goes into service for those of you who don't know what a shaper does shapers were the milling machines before we had milling machines so you can do steps keyways you can do dovetails you can make v blocks you can make so much on a shaper it's not funny but they sort of got made obsolete when the milling machines came along being that milling machines are so versatile especially the bridgeport style machines and these things sort of got left behind in the past so what the machine actually is this is a german built Klopp1000 h so the 1000 means it is a 1000 millimeter table which is about 39 and a half bananas the h stands for hydraulics so it is a hydraulic stroke so it's all hydraulically driven except for the cross feed is actually electric for your rapid this is the biggest hydraulic shaper Klopp ever made there are three in the hydraulic family you have the 650 the 850 and then the 1000. the overall size of the machine is 3.6 meters long it's 1.65 meters tall and 1.6 meters wide and the weight of the machine wet with all its components fitted to it is about four ton when i first got the machine i was under the assumption by the previous owner that it was a 1940s model machine there's no plaque to tell us it's year of build but after doing some research and meeting a gentleman down south at a another machine shop he has the exact same machine and he was able to print me off a copy of the owner's manual after reading through the paperwork we discovered the machines were produced late 50s to early 60s how did i come about owning the shaper a gentleman i met through my father had a big engineering shop up in brisbane he purchased it brand new and he didn't sell it to me until he actually retired so i'm its second owner when i picked up the shaper i also picked up the Delapena honing machine the machines are around the same sort of era this one's late 50s early 60s the hone is early 60s as far as we're aware this is the first shaper i have ever owned it's probably been about 15 years since i've actually driven one and i decided if i was going to buy a shaper i'd buy the biggest one i could so the reason i have this one i do a lot of keyways a lot of broaching stuff like that and it's quite difficult to broach a keyway about 300mm long or longer so a machine this size will be able to achieve that very very easily without expensive broaches making broach plugs and the risk of breaking a broach so a bit of high speed steel and an extension rod hanging out of the clapper box and we can cut key ways as much as we like so it's been about four years since i've plugged this machine in when i got it everything seemed to work pretty well we're going to plug in and see what four years of storage has done to it okay i think she needs some oil so it seems like the machine's running it's cycling doing everything it's supposed to do it sounds like it needs some oil i can hear the pump cavitating so we'll put some oil in and then we'll cycle it again see how it's going so i've just pulled out the magnet filter the oil should be passing over the magnet filter to pick up any debris it's pretty dry there's no nothing on that at all that's another indicator that it's low on oil must have been thirsty right after topping it up everything sounds a lot better now there's no cavitation from the pumps there's no hammering in the cylinder now we're going to go through a few of the different features the machine has to give you an idea on what it can actually do so we've got two speeds we've got a low and a high the reverse cycle is the same on both of them it is the feed cycle of the ram being pushed out that is slowed down by about half on the low range the other way to control the speed is there is a wheel here that will increase the feed rate of the ram in both gears to achieve the correct surface speed for whatever you're trying to cut so if you're roughing finishing you can dial it in using this other wheel here so the two ranges of feed you've got from 26 feet per minute out to 72 feet per minute and then your high range is from 79 feet per minute out to 108 feet per minute these two things that i adjust on the machine they are what controls the length of stroke when it starts when it stops these are essentially a limit switch the shortest stroke you can set this machine to run is three inches that's it with the two limit switches closed all the way up the longest stroke the machine can run is a fraction under 41 inches you can put a 40 inch job in there providing the tool clears it on its way back it can comfortably run a 40 inch job when the machine's running you can then engage your table step over you do have a rapid on that as well and you do have a lot of different increments you can take it up to depending on what you're attempting to do so the increments go from 10 thou 20 30 40 all the way up to 150 thou so that's quite a big step over the way to engage the table to travel left or right is you simply just turn the lever and every time the machine cycles back it will actually click it around and it'll advance the table whatever increment you've chosen for the table to step over right so the machine also has a rapid feature to advance the table left or right and it's quite simple to use you just put it in gear as if you were going to be cutting something and you push this button so the table size on the machine it is bang on one thousand millimeters so a meter 39 and a half inches and the table is 420 mil in width the maximum distance the table can travel left to right is 31 inches the maximum height the table can be dropped you'll end up with 470 ml between the table and the bottom of the ram and the minimum is 60 millimeters but you can actually hang about 900 mil off the side of the table because there are positions on the side of the table to bolt a job to so the capacity of these machines for their era was quite good with the tool post in this machine it does have a standard clapper box as all shapers tend to have it also has the clapper box lifter so the tool lifter on its return cycle so it doesn't drag the tool across the job we are missing the cable for that so that will be something we will have to endeavor in making there are two ways to advance the feed on the machine one is manually and one is automatically driven you can manually wind the tool post up and down or we do have an automatic feed on this side of the machine every time it cycles back it'll wind the tool post down to take a facing cut on a vertical face the feed down on the head while the machine is running is 35 thousands of an inch there are also two ways to change the degree of the head so you can undo these two bolts here and you can turn the head left or right you've also got the bolts on the back of the head there you can tilt the head 45 degrees either way this is the original vise off the machine it can hold a full 24 inches so the way the vice works it always pulls the job to the center of the vice that's for better support heavier cutting stuff like that it can be rotated around 90 180 whatever you want to do just by undoing four bolts it does need a little bit of work being that there's a few bits and pieces missing like pins to retain the clip on the acme screw vice at the moment's got a lot of um you know gunk and stuff built up on it i'm not going to go and wind that all the way out i would like to clean this before i do it when i first got the machine i thought i was missing the lever to lift and lower the bed after checking out the book the one for the vise will lift and lower the bed and also change out the tool on the clapper box the drive on the machine it is hydraulic but the hydraulics are driven by an electric motor the electric motor that drives the main machine is actually a 10 horse motor and the motor that drives the feed for the table left and right is a three horse motor and they're all original nothing's been changed out to anything of a later date those are all the features that the machine has standard out of the factory uh there is one more thing and that is a leg on the front of the table to support the table under heavy cutting which it can be adjusted down once you've set everything and it will move side to side with the bed i think 99 percent of shapers have that this machine in its current configuration is 99 percent original there is one thing the machine is missing and that is the cable for the clapper box so that's the only thing we're missing we've got all the original spanners the original clamps for the clapper box the tool clamps other than that she's pretty well spot-on genuine what's this what's this he could have opened it there you go oh open you get it what if it's breakable hopefully not [giggle] wait more Homey what's that yes i'll get your mess [giggle] so now we've gone through all the features of the machine and it's and its history we're going to set up a piece of material on the table and we're going to take some test cuts righto guys so i've got a piece of 70 ml biz 80 high tensile plate set up in the machine it's about 25 inches long so it'll be a good test to see how it goes taking a cut that long the tool that's in the machine at the moment is a piece of braised carbide i have noticed the tip is actually damaged and cracked so i'm going to take that out and i do have a piece of high speed steel that came with the machine because i don't have a vise in there i've lost about four inches of height off the table so i need to be very careful where the ram travels to and it doesn't take out the bolts i've used to clamp down the piece of material so i've got about two and a half inches of tool hanging off the bottom of the clapper box not much i can do about that so we're just going to see how it goes with the current setup we have first thing we're going to do is go for about a 16 mil depth of cut or 5 8 of an inch and we're going to go with a 10 thou step over so because we're going to be taking such a deep depth of cut i'm going to put it in low range i'm going to work to within 45 to 50 feet per minute of stroke everything going well will increase the depth of cut and increase the stepover righto so that went really really well um everything seems to work just fine so we're going to increase the depth of cut and then if it handles that we'll increase the step over because i haven't got much more height on my tool than about an inch so let's see how it goes 20 thou we've gone to a full inch depth of cut and a 0.2 step over uh we're noticing a bit of resistance coming back through the tool the tool's got a lot of deflection being how far it's hanging out until we actually get everything sort of more compact and that closer to the tool slide it's going to be a little bit difficult to go any further with that style of testing so what we're going to do now is we're going to decrease the depth of cut and start playing with the feed rates of the step over and also the feed rates of the ram to see what sort of material you could remove in a big hurry go up to 30 thou 20 thou step over from there to there 30 thousands step over from there to there a ten thou step over from there to there right oh so that all went pretty well we were taking about a three mil depth of cut and i was increasing the step over 10 thou every couple of strokes just to see what sort of surface finish we could achieve how the machine would handle it and what sort of swarf we were getting out of it so what i'm going to do now is i'm going to leave it at the eight mil depth of cut now that i've worked up to that shoulder i am going to reduce the feed rate for the step over down to 10 thou per step and we'll see what sort of things we can achieve with that really happy with the results we did manage to make a one inch piece of swarf with a 20 thou step over so there is there is a fair bit of weight in some of these bits of swarf or chips whatever you call them pretty happy with how the machine's running at the moment unfortunately it is not going to stay this way for too much longer what we're planning to do with the shaper now it is going to get a full restoration so it's going to be stripped down to a bare castings and go through and redo everything i'll have the pumps done i'll pull the cylinder out anything that needs fixing up tidying up we're going to do i want this machine to be brand new as if it rolled off the factory floor but being that i am so busy in the workshop i'm not really going to have time to do this project i do have another youtuber friend that's very interested to come up here and help me out and that's maddie from matty's workshop so there will be videos done on the restoration and its progress so keep your eyes out for a future video where we start the restoration thanks for watching are you ready yas [ __ ] and we're simply just going to transfer our old 40-footer we're simply going to put the other 40-footer [ __ ] we're going to put the other 40-foot container where the 20-foot container was yep oh what do you mean do you expect this to work i do [Laughter] it's heavy she's [ __ ] heavy [giggle] if it was to snap where would it on the chain behind me and whip me in the bum this is hard work it is it's [ __ ] heavy jesus [ __ ] [Laughter] one year later [giggle] this is hard work standing here shut up [Laughter] have a go at this [LOUD AF POP] oh my god oh i drove over my bottle of water [giggle] oh stupid water bottle oh i nearly poo'd my pants [giggle] how's your pants yeah good cause i sort of knew what it was [giggle] so it's got the well yeah it has the longer stroke and the biggest table and it's the [ __ ] heaviest under the ram uh call it a ram yeah so it's a hydraulic machine um it's powered by a cylinder underneath the ram they call it a ram so there will be videos done on the resto raisin oh rest of racing [giggle] righto guys so the machine is everything's uh [ __ ] here we go again just uh [ __ ] [ __ ] a guy [ __ ] off keep an eye out for a future episode uh just restart is it an episode or future video future video right right wait how am i going to start that so where i got where am i going from [giggle] 20 30 40 thou all the way out to yeah right [ __ ] that'd be a massive step over we're going to put it into high range and increase the feet per minute to about it'll cut a full 40 inches and every inch matters [giggle] oh pfft oh my god that's so heavy give us a look oh wow what thickness is that [ __ ] extremely that looks crazy that looks [ __ ] angry it's so pretty you could make art with that off you go i'm not going to stop you [giggle] i'm not going to do that OH hey you're a good boy someone's looking for a present oi [giggle] stop Homeless wait wait for daddy that's enough let's just put that back on there and no one will know just wait just wait ah ah ah ah ah aha ah oh [ __ ] HEY [giggle] stop it get it get it it's all gone [giggle] you wrecked the box there's nothing left enough he thinks there's more there's nothing more it's all gone
2022-02-08