Die Filer From Bar Stock With Video and Plans

**jjr2001** · Jul 15, 2020, 05:10 PM

Starting off this post with a short video of my newly designed Die Filer.
Made from Aluminum Bar Stock, Bronze Bushings, and Drill Rod.
Plans and parts list as well as lots of pictures will be provided.

01_IMG_2631_BackNoTable: This picture is from a 45 degree view top down of the mechanics.
The Die Filer uses the famous Scotch Yoke to change rotary motion to linear push-pull.
The brass strip on the back side is for the adjustable table that is not shown in this pic.
The 3" aluminum home grown pulley is visiable from this side as well as the standard file holder.

02_IMG_2635_ASM_BackSide: Straight on view of the back side with the adjustable table.
Two 1/4" button head allen screws are used for mounting and adjusting it.

03_IMG_2636_ASMside1: This view shows a good view of the Scotch Yoke.
Also note the oiler button for the main drive shaft. Since this bushing is horizontal
I thought it best to provide direct oiling with a small internal oil chamber.

04_IMG_2653_FrontFull: First view of "all the components". Motor, cooling fan, control box.
Motor is a 3 speed Dayton Fan motor. I am using the high and low windings only since I wanted
to control it from a DPDT switch. The motor does not have an internal cooling fan so I added
a 12vdc 80mm computer case fan. In the control box is a 12 volt wall transformer hard wired to
the power cord. So if the cord is plugged in then the cooling fan runs. Toggle switch is on
the top and not visible in this pic.
Large rubber feet and the walnut base are clearly shown. Fan and control box mounting is simply
a 3/8" x 1/2" piece of aluminum bar stock that is drilled and tapped for the box or fan and then
clearance hole drilled for #8 sheet metal screws that are screwed into the wood base.

05_IMG_2661_FrontView: Laying on it's back you can see the Main Lower Bearing Block, Scotch Yoke,
Upper Bearing Block, Tool Holder, Vertical Drive Shaft, Tool holder, and Table. Fan belt is visiable.

06_IMG_2663_EndView: End view from the top down. The power switch is visiable in the top of the pic.

07_IMG_2664_FileHolder: This is the main and first file holder. It holds 1/8" or 3mm diameter needle files.
Below that is the 1.5" diameter "filing catcher". This 3/8" thick tray is mainly to prevent filings to enter
the top bushing. It is retained by two round magnets. I will lift it in order to oil the top bushing.
Removes easily for quick clenaing.

08_IMG_2665_ChipTray2: Top end of the Vertical Drive Shaft is shown and the top bearing block with
bearing is shown. The small round magnet that retains the filing catcher is shown as well as the top bushing.

09_IMG_2666ChipTray1: Chip Tray is shown installed.

10_IMG_2667_RearUpper: Upper end from the pulley side. Shows the brass guide for the adjustable table.
Pulley and belt are shown. Belt is a cog belt that is commonly used on sewing machines.

11_IMG_2649_Files: A few good Needle Files have been slightly modified for use.
Handles were shortened and small flats were ground on the remaining handle.
(no Needle files were damaged beyond use in this project)

Here is a short video of the finished Die Filer.

That takes care of the completed project. Stay tunned for the pictures of the raw materials and
a few construction notes. And the prints.

Cheers, JR

**jjr2001** · Jul 15, 2020, 05:16 PM

This post will have almost all of the parts and pieces used to construct the Die Filer:

IMG_2613_PartsView1: Fourth Picture, Back side of most of the parts after machining.

IMG_2614_PartsView2: Fifth Picture, Front side of the parts. In this view you can see the
counter bores for the Riser and Main Bearing Block in the Aluminum Base.

IMG_2619_UnderSide: Bottom side of the bearing blocks. Note that the blocks both have
a letter F stamped on the front of each block. I want to keep the orientation of these
blocks consistant. After break in I am sure there will be a certain amount of wear that
will be unique to part position so I always want to put everything back in original alignment.

IMG_2621_LowerBearingBase2: Starting on some assembly. Bushings are clearly visiable as well as the
relief/alignment channel for the Top Bearing Block. This is a snug slip fit to help keep alignment.

IMG_2622_LowerBearingBase: Back side of the main assembly with the brass table guide, counter bored holes
for the upper bearing block and main drive shaft bushing installed.

IMG_2627_DriveShaft: Main Drive Shaft with the two spacers. The thin one is on the front side behind the
Scotch Yoke Driver and the large one is on the pulley side. All of these are sitting on top of the adjustable
table. You can see the center hole with elongated slot for the various files.

IMG_2628_PulleySpacer: Good pic showing the position of the pulley spacer. Everything on this shaft is
snugged up and the pulley set screw holds it all together. A note on the pulleys: they were made with
a form tool. I ground the form tool to match the V-belt which had a 15 degree angle on each side. The lathe just
powered right thru...

IMG_2628_PulleySpacer: Wood Base with the brass 1/4-20 inserts installed for the die filer and the motor.
The other 4 holes for the fan and control box are drilled during final assembly. Feet are drilled and installed
from the bottom. (not shown)

That is most of it. But wait.....Prints are up next.

Cheers, JR

**jjr2001** · Jul 15, 2020, 05:21 PM

Here are the prints for the Die Filer

**jjr2001** · Jul 15, 2020, 05:25 PM

A few shots of the tools and tool holders so far.
I find that the unit is capable of fine filing work. However I was thinking that it would make a good
table mounted Jig Saw.

So I made another tool holder from brass with a slot in the top. The smallest end mill I had was 3/32 and that was
a bit thick for what I needed. Adapters were milled from brass to make a tight fit in the slot and a channel was
made in that adapter to fit the tools.

Files may now be inserted from the non handle end. That is the flat end. These files are very small and do not seem
to push the part up when filing. They can grab the part if it is not flat on the table but the files work equally well
no matter which end is held in the holder.

Jig Saw blades cut well. With my little motor they seem to cut 1/4 inch material quite well. I don't think I would
use it on anything thicker.

If you build one please post it.

Cheers, JR

**rebuilder1954** · Jul 15, 2020, 07:24 PM

Great looking project! Where are you sourcing your files? Any generic needle file?

Thanks

**jjr2001** · Jul 15, 2020, 08:18 PM

Hi Rebuilder, I am using some cheap off shore files at present that have been in the shop for quite a while.
The type appear on the bay all the time. I think they will be fine and are disposable.
My good set is Heller Swiss Pattern files and they will not be used.
Next in line is a set of General Tool Needle files and they need to worry since they are my "second choice".

Cheers, JR

**Crusty** · Jul 15, 2020, 08:58 PM

Nice work! I'd like to have one of those.

A bit of trivia that I have to mention because it was drummed into me by my friend Alf Stace, a Scot from Inverness, is that "Scotch is a whiskey, PERIOD!". A person can be a Scot and things can be of Scottish origin or nature, but Scotch is only ever a type of alcohol. His first day in the States I took him to Bonanza Steakhouse for lunch and he mimicked me through the line grabbing a big juicy jalapeno and a big glass of iced tea as I did. When he bit into the pepper his eyes lit up like a pinball machine, he grabbed his drink and started gulping it, only to immediately blow it out all over the table. Once he regained the ability to speak he declared "I dinnah know which was worse, that bloody gherkin or that foul swill" (he thought it was Dr Pepper). I still chuckle about that incident. So anyway, it's a Scottish Yoke.