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job done beautifully wrong

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  • job done beautifully wrong

    Ok, so I'm human. I'm using this topic to help ease the frustration of a job well done- what? done perfectly wrong! I carefully milled some slots evenly spaced, equal depth, and with a smaller slot centered within each, and, WRONG SPACING! I'm laughing now, but I'd like to laugh even harder. So if any other of you humans would grace us with one of your blooper, hey, we could leave the post hole stories behind! By the way, I wanted to rename this topic 'tales from the scrap bin' but it seems I can't.

    [This message has been edited by darryl (edited 02-19-2003).]
    I seldom do anything within the scope of logical reason and calculated cost/benefit, etc- I'm following my passion-

  • #2
    Dang. That's tough.

    Nope. Not me. Never screwed up a single job. Except maybe the 22 1/4 tooth gear but we didn't use it so that doesn't count as an official screw-up.

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    • #3
      I'd like to see a picture or drawing of that gear!
      And its mate!
      ------------------


      [This message has been edited by Herb Helbig (edited 02-19-2003).]

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      • #4
        You must refer to those items in your scrap box as experiments, not mistakes. That way people who see them will believe you to be the genius you are and not some total screw up.
        For instance, that perfect mirror image of the part you just spent three evenings making was to prove the set up methods.
        Jim H.

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        • #5
          I seem to have repressed the memory of most of mine, but I've certainly had my share of "learning experiences."

          F'instance, I'm in the middle of building Edgar T. Westbury's "Kiwi" engine. I made 9 rocker arms before I got two good ones. In my defense, I will point out it's a fairly intricate part: http://users.rcn.com/sas.ma.ultranet/kiwirocker.jpg , but it still shouldn't have taken me 9 tries. And the errors were mostly really dumb stuff.



          [This message has been edited by SGW (edited 02-19-2003).]
          ----------
          Try to make a living, not a killing. -- Utah Phillips
          Don't believe everything you know. -- Bumper sticker
          Everybody is ignorant, only on different subjects. -- Will Rogers
          There are lots of people who mistake their imagination for their memory. - Josh Billings
          Law of Logical Argument - Anything is possible if you don't know what you are talking about.
          Don't own anything you have to feed or paint. - Hood River Blackie

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          • #6
            Hey Forrest,
            Will your 22 1/4 tooth gear fit my 42 and a 1/2 splined Alfa Romeo half shaft?

            It's easy to be one hole out on a dividing head and the error is acculmative. Pays to do a dry run first.
            In my case the guy went ballistic, I learnt a *lot* of new words that day. What made it worse he took the new shaft to a local top notch high priced company and they did exactly the same <g>.

            Thankfully those days are gone with the help of Tony Jeffree's Division Master.
            Unashamed plug for http://www.divisionmaster.com

            Ironically enough this afternoons job is to mill the melted and welded on copper windings from the bottom of 67 slots on a large DC fork truck motor. As some of these larger motors can cost in excess of $4,000 it's well worth the time and effort to repair them.
            What would have been a 2 to 3 hour job has now been reduced to about an hour.

            John S.
            .

            Sir John , Earl of Bligeport & Sudspumpwater. MBE [ Motor Bike Engineer ] Nottingham England.



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            • #7
              I was taking the machinist's program at the local community college. Was doing first project (evaluative) on the lathe. We called it a test bar, CRS specs called for knurling, multiple diameters, etc. tolerances +/-0.005. I was holding 0.003 and feeling pretty cocky. Was turning last diameter (0.5) Cutting dry, miked and got 0.040 over, took remaining incrementally, hit it with a bit of emery. took it out of the lathe had a smoke and took it to the instructor proudly proclaiming my ability to hold close. He miked 0.5, and it was 20 under. He looked at me and only said, "Go look up coefficient of thermal expansion"! Haven't had a cocky day since

              ------------------
              John B
              John B

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              • #8
                Darryl, my luck runs the other way. I make a part, and then figure out what ELSE needs modified to make use of it. In fact, just the other day I had my first perfect day in the shop. Every cut, slot, hole, EVERYTHING I did was within a thou or less. Didn't want the day to end, but was afraid if I pressed on, Fatigue would invite Mr. Murphy in for a party on my tab. My worst? 1973. While transferring a high speed oscilloscope to the clean room cart, I dropped it. Off to Texas Instruments it went: 2 months and $3000 later it was back. Dropped it again while unpackaging it... Depressing to recall the moment, even 30 yrs later!
                I'm here hoping to advancify my smartitude.

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                • #9
                  I don't have a scrap box. I have a box of good parts that have some of the chips removed already.

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                  • #10
                    Do many many many minor screwups add up to a major screup like the scope? Sorry to rub it in gizmo. I make a bad part almost every time I turn my lathe on.

                    The only major screwup I can come up with is a job I miss quoted. I had a cusomer bring in a very rare instrument that I didn't want to repair, so I quoted him what I thought was a very excessive price. After preping and replating the instrument 3 times I finally got the repair back to him. I think I made 10 cents an hour when I got done.

                    Matt

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                    • #11
                      Ooh, the 'scope! I can relate. Many moons ago I bought my first 'scope. A whopping 15 meg, dual trace. What a beauty (then). I got it home, and when I could get back to it (domestic stuff in the way) I plugged it in, then clicked the power switch. Uh oh, what happened ? Lights were out, fridge stopped, in fact as I looked around, there were no lights anywhere, the neighbors, everyone's power was out. My scope did that? Huh? As it turned out, at the moment I turned it on, someone had hit a pole with their car, and knocked the transformer off, it was dangling just feet above the hood. The poor guy inside just stared at it, afraid to move, do anything. Nothing I could do, either. What, get out the voltmeter? The sidecutters?
                      I seldom do anything within the scope of logical reason and calculated cost/benefit, etc- I'm following my passion-

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                      • #12
                        I was building a dividing head with an exact copy of my lathe spindle so I could use my chucks and other goodies with it.

                        Took a hunk of tool steel and spent a fair amount of time on it, even cut the MT#3 socket. Left the threading for last. Double checked everything (I thought) and set the compound gearing for 8 tpi. Quickly checked it (note "quickly") and cut the thread. Beauty! Measured just right with wires. Bastard did not fit! Threaded it 7.5...

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                        • #13
                          Oh boy. Well for some reason the first of many to come to mind is the following. I was working second shift in a shop that did machine, welding, and sheet metal work. One night when I came in, there was a job waiting for me and one of my coworkers to do. Basically, it consisted of about two dozen two foot square sheet metal lids with a lip bent all the way around and a notched corner. We had been given a poor copy of the print, and were having a hard time decyphering which way the lips of the lid were bent relative to the notch. We made one part, and we started to doubt ourselves, and after a bit of discussion decided that it was backwards. We then ran the rest of the parts the other way. They looked like a million bucks, and we left them in the inspection room for the morning shift. Yep, you guessed it, we had them right the first time. The owner of the shop was called in to inspection. He had a look at them and said even though they were wrong, they looked so nice he didn't have the heart to say anything to us! And he didn't! We did them right the following night.

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                          • #14
                            Thrud, hope you didn't wast a lot of time machining a register on that spindle.
                            The last shop I ran had a sign over the office door "Mistakes made while you wait". I didn't take it when I left.
                            Jim H.

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                            • #15
                              I guess it is only right that I chime in as well. Luckily I don't have any long term reminders about it, but about a year ago I had a little bathroom plumbing project to do helping my brother out. Mostly easy stuff. heat up the fittings and replace a bathtub manifold. One pipe had to be cut and it wasn't possible to hacksaw it. It was just a little 1/2" copper pipe and I just happened to have handy my 4 1/2" angle grinder. Safety goggles weren't handy. I figured I could close my eyes and turn my head and go right through that copper with one quick cut. About three quarters through, the pipe bound and fragmented the blade. A piece impacted my eye sure as hell. I looked in the mirror, and with my good eye I could see a 3/8" bloody wound in the white of my eye. Long story short, I had to have a doctor check to see if it had punctured my eye. So a doctor probed the hell out of it with some kind of stick and I didn't like that very much. Luckily eyes are very fibrous and tough and heal well (sometimes.) I'm more sold on those nerdy safety goggles than I ever was. It's those quick "one-time" chances that will F#%& you up. Other than that, I still have all my parts. My eye did healed up well.
                              Spence

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