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  • Oops!

    This is a thread to which no replies would be a good thing- nobody makes mistakes do they

    Made up a metal bar with multiple drilled and tapped holes. The holes needed to be square to the bar. Got set up on the drill press and drilled pilot holes, then saw that they weren't square to the piece. GUNH- (four letter word, a bit softer than the usual one). Found that I hadn't tightened the lock on the table, with the result that there was a forward lean to the table and the holes went off kilter. Ok- change to larger bit, crank table to correct height, make sure to lock table. Ok. Drilled out again to size for the tap- usually the hole will straighten out some, if not fully. Got that done. Mounted the tap so I could get all the starts going in straight, set table height, begin. Get two or three threads started for each hole, then transfer to vise to finish tapping all the holes. Got that done, de-burred, run tap through all holes again to clean them up. Threaded in a piece of all-thread and looked at it- Fword this time- all the holes were parallel to each other, but crooked in the piece of bar. Check drill press table- yup, forgot to tighten table clamp again

    Ended up inserting pieces of all-thread into each hole, then clamped it upright in the mill and faced the important side of the bar, problem fixed.

    I know my table is square to the spindle axis when it is clamped- I've checked it with a sweep and it's within about 10 thou across the width of the table- not bad for a drill press. But not if you don't tighten the clamp-
    I seldom do anything within the scope of logical reason and calculated cost/benefit, etc- I'm following my passion-

  • #2
    Well, it wasn't machining, but electronic work. I was working at my first TV station job on the night shift. In between other tasks (like airing the programs), I was soldering a connector with about 25 pins on a cable. It was one of those military style connectors with a nice metal shell and a proper clamp for strain relief. So I carefully stripped all those conductors and soldered them oh so neatly into the pins. Then I reached for the connector's shell, which was sitting on the tool cart next to me. Did I mention that the cable was already pulled through the floor from across the room, another job that took a couple of hours earlier that day? Absolutely no way of putting that shell on the cable after soldering the wires.

    So, I oh so neatly unsoldered all those 25 wires, took a short break, and then soldered then back again. And I then reached for the connector's shell, still on the cart where it was before. Ahhhhhhh!

    I am sure I had some unkind words for myself, but I can not recall exactly what they were.

    Once again, I had to unsolder all those 25 wires. This time I did make sure the shell was on the cable FIRST. A 45 minute job turned into 3 hours.

    I never told the boss about that one but there were other stories. We've all done these things.
    Paul A.
    SE Texas

    Make it fit.
    You can't win and there IS a penalty for trying!


    • #3
      Amphenol circular connectors?
      Been there, done that, but not twice in a row....
      Weston Bye - Author, The Mechatronist column, Digital Machinist magazine
      ~Practitioner of the Electromechanical Arts~


      • #4
        I don't know anyone who has escaped the plug on wire, thread wire through hole or all it's variants, I did one on a night shift, the one where the pins are crimped to the wire with a coax crimp thingy, 2 electricians sat watching me poker faced as I did it with the shell still in the bag, not a word out of them til the last of dozens of pins was scrimped and pushed thru the plate, where barbs hold them in.
        Nice guys.


        • #5
          I'm surprised the table didn't swing being that it wasn't tightened to the column.
          I've noticed with my Delta that downward force will tilt the table a bit, just how much deflection with how many pounds of force ...... I don't know, never measured it.
          You've got my curiosity, I'll have to check.



          • #6
            Clumsy bastards.
            I have 'never' done anything like that.

            Ow letgomearm.......................

            Actually didn't happen to me but a friend who is terrified of heights and he had to climb to the top of a chimney at a local power station to fit a camera.
            Got right to the top only to realise he's left the mounting bracket back down in the van.

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


            • #7
              On a somewhat related thingy we had a guy climbed up a chimney, then fell down the chimney!, inside!
              There was a tether on his harness that snagged a bit of rebar on the way down and caught him after about 80', took a helicopter to get him out, he's scared of heights now too!


              • #8
                I've never ever had to tear a motor completely apart after just assembling to turn all the piston rings around the RIGHT way. Nope not me.


                • #9
                  Originally posted by Weston Bye View Post
                  Amphenol circular connectors?
                  Been there, done that, but not twice in a row....
                  Been there done that ... ... twice in a row


                  • #10
                    Originally posted by vpt View Post
                    I've never ever had to tear a motor completely apart after just assembling to turn all the piston rings around the RIGHT way. Nope not me.
                    Had to do a cam and lifter change one day on a 350 Small Block. Figured I was making pretty good time until I went to drop the pushrods in and discovered I'd forgot to install the lifters. Did I mention I had installed the intake already and it went on absolutely perfectly? Now the intake is the last thing I put on...
                    Location: Saskatoon, Saskatchewan, Canada


                    • #11
                      The client moved all the computer and communications equipment into another room but when everything was connected up something was not right. We went onto the network and tried to fault find remotely. The indications were that all the cables on the multiplexor were on the wrong sockets, we sent them an email to ensure that cable number one was on the first socket but still no joy and they assured us that cable number one was on socket number one.

                      Nothing for it but to quickly book air tickets, Wellington to Auckland, Auckland to Singapore, Singapore to Karachi, Karachi to Pershawar and a Cessna from Pershawar to Kabul.

                      They were right, cable number one was on socket number one but the German makers of the multiplexer had numbered the sockets '0,1,2,3,4,5,6,7'!

                      I bought a nice carpet while I was there!


                      • #12
                        The first car engine that I ever rebuilt was a 66 VW that I found in a farmers barn with a broken piston on cyl. #3. That is the one that always breaks a valve and smashes a piston. So I found a used piston, cylinder and head and proceeded to tear everything down to clean out the aluminum shrapnel and inspect things. So about 4 hours later the slinger was where it was supposed to be.

                        In the years that followed I drove a long line of VW's and generally found the ones that had blown engines and do the same rebuild but I never made that mistake again.

                        We're humans and therefore fallible. I don't let it stop me form taking on almost any job though.

                        Last edited by bborr01; 02-09-2015, 08:29 PM.
                        OPEN EYES, OPEN EARS, OPEN MIND

                        THINK HARDER


                        MY NAME IS BRIAN AND I AM A TOOLOHOLIC


                        • #13
                          Changing a rear motorcycle tire.

                          After mounting the new tire, I noticed that it did not have a lot of tread compared to the new one that was sitting there leaning against the wall. The second time I did it right.


                          • #14
                            I never make errors.

                            The one time I thought I had, I checked and found that I was mistaken......

                            Keep eye on ball.
                            Hashim Khan


                            • #15
                              I've learned to ALWAYS put the cover/boot/strain relief on BEFORE I put a connector on the wire. Then I learned to always put it on the correct direction.

                              At the end of the project, there is a profound difference between spare parts and extra parts.

                              Location: SF East Bay.