Aidan's Weights & Measures  2           11-2016
 

Here is a close up of the area that still needs to be machined.
 

 

 

Both ends cleaned up nicely and and now I'm going to add a little something that will be two-fold.
 

 

 

I'm going to add a piece of 1/4" thick black walnut to each end. This will give it some contrast and second it will hide the end grain of the base.
 

 

 

I traced around each piece and now I'm cutting off the excess with my bandsaw. These will be glued to each end.
 

 

 

I didn't have any clamps that would hold this correctly so I improvised. First I placed a nice flat piece of steel on my work bench,  glued both pieces to the ends and then added some weight to the top (which acts like a clamp). In case you were wondering, the red piece is a small anvil and the top piece is a small section of rail road track. Whatever works you know...
 

 

 

The next day I removed my weights (clamps) and now I'm ready to machine away the excess.
 

 

 

To machine away the unwanted material I had to make multiple setups. Here I'm machining the bottom and the second step on the right-hand side. Once I was finished with this end, I moved the base to the other side of my vise and repeated the machining. I did this for every side, which was time consuming but worked out great. I also stayed away a couple of thousandths and sanded the remaining material flush.
 

 

 

The next step was to make pockets for all the weights. I did this with a 3/4" diameter end mill. If you look close you'll see that the pockets are not centered. I have a reason for this that I'll talk about later.
 

 

 

With the weights being 3/4" diameter and my end mill being exactly the same size, the pockets were not going to be larger enough. To have the weights fit nice and easy, I moved over .003 in each direction (arrow) which made the pockets slightly larger.
 

 

 

If you're wondering: are the pockets round by doing it this way? No. Will the weights fit correctly doing it this way? Yes they will. And if I didn't tell anyone about it, no one would ever know. Just a little machinist trick here. I also chamfered the holes to aid when putting the weights in.
 

 

 

I'm using a corner rounding end mill with a 1/8" radius on a few edges. I would have used my router table but with this irregular shape now, that wasn't going to work for me.
 

 

 

However I was able to use my router table on the outside edges. Again I'm using a 1/8" radius.
 

 

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