“Excel” filing machine

[OuBallieParticipant @ouballie]

Just posted photos of the machine.

First project was to make a couple of spanner blanks to make a suitable spanner and handle to use on the square bolts and drive shafts on my Boxford 8" shaper.

The larger of the two blanks, to make the ram operating handle, was first machined to size on my Warco BH600G lathe, drilled then bored to the flat dimension of the drive shaft, before heading for the "Excel"

I know I know, boring heads are not really suitable for use in the tailstock, but I wasn't up for the hassle of finding packing to get my boring bar to C/H

The QC will sort these problems out, once I make a new T-nut and bolt, once I get the shaper sorted. Talk about going round in circles

The Diamond Tool Holder is a must, not only for its ability to remove metal easily, but more importantly, the total ease of setting the tip to lathe centre height.

The "Excel" worked really well, but ones RH thumb & fingers start to ache after a while from the effort of keeping the piece that's be filed pressed against the file.

Patience is needed, however, as metal removal is leisurely to say the least.

The finished blanks turned out almost perfect in shape, with only a hint of play, so i'm well chuffed with my first try at machine filing.

Wonder if the square holes will close up when I weld handles to them. Ant advise please?

Geoff – Time to hit the highway.

[OuBallieParticipant @ouballie]

Just posted photos of the machine.

First project was to make a couple of spanner blanks to make a suitable spanner and handle to use on the square bolts and drive shafts on my Boxford 8" shaper.

The larger of the two blanks, to make the ram operating handle, was first machined to size on my Warco BH600G lathe, drilled then bored to the flat dimension of the drive shaft, before heading for the "Excel"

I know I know, boring heads are not really suitable for use in the tailstock, but I wasn't up for the hassle of finding packing to get my boring bar to C/H

The QC will sort these problems out, once I make a new T-nut and bolt, once I get the shaper sorted. Talk about going round in circles

The Diamond Tool Holder is a must, not only for its ability to remove metal easily, but more importantly, the total ease of setting the tip to lathe centre height.

The "Excel" worked really well, but ones RH thumb & fingers start to ache after a while from the effort of keeping the piece that's be filed pressed against the file.

Patience is needed, however, as metal removal is leisurely to say the least.

The finished blanks turned out almost perfect in shape, with only a hint of play, so i'm well chuffed with my first try at machine filing.

Wonder if the square holes will close up when I weld handles to them. Ant advise please?

Geoff – Time to hit the highway.

[OuBallieParticipant @ouballie]

Just posted photos of the machine.

First project was to make a couple of spanner blanks to make a suitable spanner and handle to use on the square bolts and drive shafts on my Boxford 8" shaper.

The larger of the two blanks, to make the ram operating handle, was first machined to size on my Warco BH600G lathe, drilled then bored to the flat dimension of the drive shaft, before heading for the "Excel"

I know I know, boring heads are not really suitable for use in the tailstock, but I wasn't up for the hassle of finding packing to get my boring bar to C/H

The QC will sort these problems out, once I make a new T-nut and bolt, once I get the shaper sorted. Talk about going round in circles

The Diamond Tool Holder is a must, not only for its ability to remove metal easily, but more importantly, the total ease of setting the tip to lathe centre height.

The "Excel" worked really well, but ones RH thumb & fingers start to ache after a while from the effort of keeping the piece that's be filed pressed against the file.

Patience is needed, however, as metal removal is leisurely to say the least.

The finished blanks turned out almost perfect in shape, with only a hint of play, so i'm well chuffed with my first try at machine filing.

Wonder if the square holes will close up when I weld handles to them. Ant advise please?

Geoff – Time to hit the highway.

[OuBallieParticipant @ouballie]

Saves on muscle strain

[BazyleParticipant @bazyle]

I see you have the alternative type of overarm which I think is aimed only at filing . Some machines have a cast bracket which is desinged to hold a spring to tension the top of a fretsaw blade. I'll post a peicture when the camera batteries recharge.

[BazyleParticipant @bazyle]

I see you have the alternative type of overarm which I think is aimed only at filing . Some machines have a cast bracket which is desinged to hold a spring to tension the top of a fretsaw blade. I'll post a peicture when the camera batteries recharge.

[MICHAEL WILLIAMSParticipant @michaelwilliams41215]

Use chalk rubbings or proper coolant supply when filing this way and keep filing speed down to no faster than hand filing .

Chalk rubbings or coolant will prolong life of files , prevent clogging and minimise scrape marks on work .

A few minutes overspeed or a touch on hard material will take all the edge of your files and only recourse then is to sharpen or replace .

Sharpening is possible using acid etch and electrolytic methods but not easy to get consistent results .

I've never tried this but with modern cutting tools able to cut very hard materials you could conceivably make you own files from HSS . You could certainly make your own carbon steel files . Single cut for preference in both cases .

Michael Williams .

[MICHAEL WILLIAMSParticipant @michaelwilliams41215]

Use chalk rubbings or proper coolant supply when filing this way and keep filing speed down to no faster than hand filing .

Chalk rubbings or coolant will prolong life of files , prevent clogging and minimise scrape marks on work .

A few minutes overspeed or a touch on hard material will take all the edge of your files and only recourse then is to sharpen or replace .

Sharpening is possible using acid etch and electrolytic methods but not easy to get consistent results .

I've never tried this but with modern cutting tools able to cut very hard materials you could conceivably make you own files from HSS . You could certainly make your own carbon steel files . Single cut for preference in both cases .

Michael Williams .

[OuBallieParticipant @ouballie]

Thanks Bazyle.

I look forward to seeing it.

It would be convenient to be able to use such blades.

The machine has its place, but I ended up cleaning the welding on the spindle drive spanner using the bench grinder, then finishing off with a hand file..

So, that's one project down and 20 odd year's worth still waiting, but one can never have enough projects, either real or wishful.

I'm busy right now making a big flat T-nut, then stud, to fit the Dickson to the lathe.

will take a video of the shaper in action.

Geoff – Nosh and coffee between workshop stints.

Thanks for the info Michael.

Appreciated, as I didn't use any such you suggested, although the SPM where at the lowest setting.

Geoff

I see Cornish Jack has what appears to be an "Excel" machine for sale, albeit disassembled, in the "For Sale" page, Machines – Miscellaneous 

Geoff – This post now finalized

Edited By OuBallie on 11/05/2013 13:35:10

[OuBallieParticipant @ouballie]

Thanks Bazyle.

I look forward to seeing it.

It would be convenient to be able to use such blades.

The machine has its place, but I ended up cleaning the welding on the spindle drive spanner using the bench grinder, then finishing off with a hand file..

So, that's one project down and 20 odd year's worth still waiting, but one can never have enough projects, either real or wishful.

I'm busy right now making a big flat T-nut, then stud, to fit the Dickson to the lathe.

will take a video of the shaper in action.

Geoff – Nosh and coffee between workshop stints.

Thanks for the info Michael.

Appreciated, as I didn't use any such you suggested, although the SPM where at the lowest setting.

Geoff

I see Cornish Jack has what appears to be an "Excel" machine for sale, albeit disassembled, in the "For Sale" page, Machines – Miscellaneous 

Geoff – This post now finalized

Edited By OuBallie on 11/05/2013 13:35:10

[BazyleParticipant @bazyle]

This is the cast overarm alternative to the "roller arm support " you have.
The Harvey Butterfly spares list calls it the "Complete Over Arm"

As you can see it has a round mounting where you have a straight rod called "complete cone".
There is a boss half way along the arm which I have now realised is just to allow it to be mounted between centres for turning the mounting bar. It would need an 18 in swing lathe to do that.

The rear of the end of the arm has holes for mounting the hold down.

The head has a prismatic sliding member with gib strips and clamp for holding the top of a saw blade or file. The round rod in the head is supposed to be enclosed by a spring to provide the upward force for the saw blade.

It was named "Butterfly" because it is as noiseless in its running as a butterfly in its flying.

The mfr recommended oil is "#30" whatever that is.

Edited By Bazyle on 13/05/2013 00:43:22

[OuBallieParticipant @ouballie]

Thanks for the photos Bazyle. Saved for future reference.

Must find out how to add photos to my posts.

Here I was thinking it would be a relatively easy accessory to reproduce.

Should have realised of course, that anything produced during that period in history would not be a weekend job to copy, not for the likes of me that is.

Added to my wishfull projects list nevertheless

Don't understand the operation of the spring enclosing the round rod. Brain regularly refused to co-operate.

Geoff – Coffee & listening to Enya

[BazyleParticipant @bazyle]

Spring. At the top of the slide there is just visible a plate held by 2 screws. It has a hole for the rod. Between the plate and main casting there is a long thin coil spring to force the slide up and tension the saw blade. The rod just goes down the middle of the spring to stop it boinging out sideways.
The spring always seems to be missing probably because it is taken out when filing and lost. I think the saw was never used after scroll saws were invented so you are better off with what you have.
A roller rest like yours is on my todo list.

[OuBallieParticipant @ouballie]

Thanks, that's clear now.

Let me know if you need any photos of the roller rest.

I take it your machine doesn't have one?

Geoff – Post Office here I come.

[OuBallieParticipant @ouballie]

Yes I know!

The machine in action video I promised a member last year, but lots has happened since, not all good.

Photos my Album page 3

Geoff – Where has the time gone.

[mechman48Participant @mechman48]

I would agree with your thoughts; either for a light or a blow line off your compressor, so two options to consider.

​George.

[BazyleParticipant @bazyle]

That top block is not original as it doesn't appear in the catalogue of spare parts that I remember. I think you are right that it holds an air line or lamp.

[T.BParticipant @t-b-2]

Hi

I picked up one of these Excel die filers a little while ago that is missing the front bracket that the work table pivots on, this is the part with the needle indicator attatched to show the table angle.

While this is a relatively simple item to make , i would like it to resemble the original part as much as is possible and i can not find a good picture anywhere online that shows this part.

Is there any chance anyone could post or send me a photo of this part please ?

[Mike E.Participant @mikee-85511]

I would say that the block on top is for an airline to blow swarf away.

There is an attachment for an airline on one of the hold down arms of my Opus 120 filing machine, which can be seen in the photos. This machine uses a ball mount for positioning, whereas I would speculate yours would have used something like the arms from a surface gage to position the air nozzle.

 

Edited By Mike E. on 06/05/2018 16:41:56

Edited By Mike E. on 06/05/2018 16:43:31

Edited By Mike E. on 06/05/2018 16:44:13

[OuBallieParticipant @ouballie]

T.B

Two more in my Album page 3.

Geoff – The sudden heat is welcome, but affecting me more than expected.

[T.BParticipant @t-b-2]

Thats great Geof , thank you !

[Colin HeseltineParticipant @colinheseltine48622]

Sorry to revive an old post.

Does the Excel Die Filer cut on the up stroke or the down stroke?

Thanks,

Colin

[Gary WoodingParticipant @garywooding25363]

The video says it cuts on the down stroke.

[Ady1Participant @ady1]

Fabulous little machines, managed to resist buying one so far

The main thing that holds me back is there seems to be a shortage of machine files out there nowadays

When I dd see a couple they were seriously pricey

Definitely useful if you can get one up and running

[Colin HeseltineParticipant @colinheseltine48622]

Gary,

I watched the video but missed the bit where that was mentioned.

Ady1

Yes the files do seen to be expensive. I guess its a case of modify existing as per Harold Hall.

Colin

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