Machining a New Nut for an EX1200 Cylinder Rod

🔧The process involves drilling, boring, turning, and threading to create a custom nut for an EX1200 cylinder rod.

🛠️Upgraded tooling, including a spade drill and new boring bars, improves efficiency and precision in the machining process.

💡Gouging off the old nut was a faster and more efficient method compared to machining it off in the lathe.

🔩The custom nut is designed to lock in place with the help of an M20 grub screw, preventing it from undoing itself.

💰The entire job, including the machining and the custom nut, costs about half the price of a genuine Hitachi nut, providing cost savings for the customer.

Why did you gouge off the old nut instead of machining it off?

—The piston was covering part of the nut, making it difficult to machine it completely. Gouging off the nut was a quicker and more efficient method.

Can't you just repair the damaged thread by welding and machining?

—Repairing the thread with welding would result in a different tensile strength and potential heat affected zone risks. It is better to replace the nut completely for reliability and longevity.

Why did you choose a spade drill for drilling the new nut?

—A spade drill offers a wide range of sizes and point increments, allowing for drilling over a hundred different size holes. It also provides better performance in drilling induction-hardened material.

What is the purpose of the M20 grub screw in the nut?

—The M20 grub screw acts as a locking mechanism, preventing the nut from undoing itself. This ensures the stability and security of the nut in its application.

How much weight was removed from the original material after the machining process?

—After machining, the nut's weight was reduced from 38.4 kilos to 16.2 kilos, resulting in a significant reduction.

00:38Introduction to the machining process and the task of creating a new nut for an EX1200 cylinder rod.

01:26Starting the process by drilling and boring the nut to size using upgraded tooling, including a spade drill.

02:50Drilling a hole through the nut using the new drill and showcasing the versatility of the spade drill system.

04:24Explaining the features and advantages of the new SPK brand spade drill, including its wide range of sizes and insert options.

05:52Upgrading the coolant system to ensure efficient drilling and avoid burning out the drill tips.

10:01Showing the results of the drilling process and the surface finish achieved in the nut.

18:08Threading the nut using upgraded boring bars and achieving accurate thread dimensions.

33:20Answering common viewer questions about the machining process, including the choice to gouge off the old nut and the risks of repairing the damaged thread.

44:20Final thoughts and wrap-up of the project, highlighting the successful completion and cost savings for the customer.