Hi Alec, former O-Ring engineer here. Bit difficult to say for sure from what we’ve seen but I’ll start by saying that O-Rings can be quite hard to push in, normally it would be aided by both a lubricant and a fairly substantial chamfer on the hole lip. These also prevent the O-Ring from getting cut (that little notch you have in the side of the hole might prove problematic there so be careful about that) Secondly and it sounds obvious but have you checked all of your dimensions? The dimension of the groove and of the hole which is defining your total compression. Is it all concentric etc. You can also check what the nominal compression and volume fill is by measuring the diameter of the O-Ring cross section and dividing it by the area of the square that it will eventually be squeezed into. It should be around 1.2-1.35 (so 20-35%). It can be lower but not higher. Depends how hard the O-Ring is. As for volume once it’s all assembled you want about 75% of the volume taken up by the O-Ring. So that’s the O-Ring cross sectional area vs the square slot cross sectional area.

@russellcameronthomas2116

4 ай бұрын

Alex: [shines spotlight into the sky, "O-Ring Super Hero" symbol illuminates the clouds ] Wease245: [jumps into the scene] "HERE I AM to save the day! Former O-Ring Engineer"

@johannesmajamaki2626

4 ай бұрын

KZread comments can be an amazing place. What next, the former bridgeport lead ergonomics designer drops by the offer their thoughts on the handle mod?

@Wease245

4 ай бұрын

@@russellcameronthomas2116 😂

@decoydante

4 ай бұрын

This man O-Rings

@RobTheSquire

4 ай бұрын

I would use a tool similar to a piston ring compression tool to squeeze that o-ring down to size to fit the part.

I know that this will take an extra six episodes, but you should make some tiny tongs to hold the tiny steel to forge with.

@youtubeSuckssNow

4 ай бұрын

And a tiny forge! Tiny everything!

@alexh3974

4 ай бұрын

And a tiny Alec.

@victorpedersen7479

4 ай бұрын

isnt he already tiny look at that lamp@@alexh3974

@imafraidoftoast

4 ай бұрын

tiny damascus

@alexh3974

4 ай бұрын

Tiny set of extra dies for the hammer

Hey Alec, I work in a hydraulic cylinder manufacturing plant. The oring is meant to be slightly compressed, as it is the compression seal. Likely your seal groove is not deep enough. 5-10 thou compression should be enough. A decent chamfer at the entrance side and a bit of force(we call it stuffing) on the piston should get it in there. White lithium grease will help as well.

@kendallguier1378

4 ай бұрын

what i was gonna say needs a deeper groove to squish into

@MightyG100

4 ай бұрын

Can’t hurt to put the seal in a cup of warm water for a while to make it a little softer and easier to compress when you are putting it in. If you are really struggling you can make a tapered ID cone to slide the piston through that gradually compresses the seal as you slide it into the cylinder.

@Pez_Destroyer

4 ай бұрын

Thank you for your comment, I was suspecting that the groove could use a bit more depth! But what do I know, thanks for confirming my suspicion.

@piccalillipit9211

4 ай бұрын

@@kendallguier1378 I was going to say deeper and wider - it needs to maintain the X sectional volume gop from O to 0

@ehsnils

4 ай бұрын

Or a slightly thinner O-ring, that could work too.

All the Bridgeport Mills I have used (and some cheaper copies) have had a spring on the shaft and a screw retaining the handle. To use the handle you have to push it to engage with the castleations and when you let go, the handle disengages. All of them also had power feed and they didn't attempt to remove my forearm everytime it was used.

@buggsy5

4 ай бұрын

Or, lacking a spring/screw - a pouch to hold the handle when not needed will also work.

With the number of mistakes made in this project, I fully expect Alec to end up accidentally making a damascus steel pen by mistake.

@MadmanJnr

4 ай бұрын

Maybe he can make a Damascus power hammer next

I love how insanely impractical and niche this kit is.

If this series was compiled into one complete video after its done, id definitely watch it. Just an idea.

@Afkinator

4 ай бұрын

I feel the same way except you bet I'm gonna be there every time a new episode comes out

@AvanaVana

4 ай бұрын

Make a playlist

The music choices have gotten so much better over the years, gentlemen. Way more enjoyable montage scenes!

@buggsy5

4 ай бұрын

Better, yes. But none of the shots with music are very long - so, to me, they are intrusive.

On our knee mills we have a spring around the shaft you turn to raise the table that presses the handle off the splines and a bolt that retains the handle from completely falling off. This way its natural place is disengaged when you aren't thinking about it but its easy to engage if you need it. I definitely agree with modifying your tools to make them work for you and I'm pretty sure this was a shop modification to our knee mill. Also our Gorton knee mill has a wheel rather than a crank handle which is definitely nice because it doesn't have any whacky bits sticking out.

At this pace I believe he is on track to have more episodes making this tiny power hammer than he has made fixing all of the real power hammers that were restored on this channel. Hilarious!

@brandonquintana9943

4 ай бұрын

Could be longer than his katana build.

@tezcharold

4 ай бұрын

It's a great thing though, this is my fav series ever I think.

@Pez_Destroyer

4 ай бұрын

If you had stayed until the end, you would have noticed that he said he will be finishing it in the next episode.

Regarding the oring not fitting, double-check the specs to see if the groove was not cut deep enough to compensate for the 'squish' on the oring. From what it looks like, you may want to try using an oring with a smaller thickness (i.e. same inner-diameter, smaller outter diameter).

@richfromtang

4 ай бұрын

Yeah I think that ring is too thick or the wrong cross section shape. Might need a square or oval cross section. But I suspect that the ring he's using is just too fat, like you said, he needs one with the same inner dia and a smaller outer dia.

I lost my cookies laughing when Alec goes running by with the machine tools!😅

FINALLY! I didn't realise how much I needed this series until it was taken away from me

I've been enjoying this series a lot. I've been subscribed for a while now. I think you've gotten funnier over the year or so. I don't know if you'd be willing or able to, but.... could you do a budget build series without power tools? How to get started learning techniques of forging and machining?

With the o ring, the length of the groove needs to be slightly longer than the amount you squeeze the o ring by. If it’s a 3mm o ring and you compress by 10%, then make the length of the groove 3.3 to 3.5mm long so it has somewhere to squash into. On the diameter, you want the total radial difference between the bottom of the groove on the shaft and the internal diameter of the bore to be 2.5 to 2.7mm. For fitting, add a small 30 degree chamfer to the bore leading edge and put some lube on the o ring. If in doubt, it’s all standard sealing stuff so you can google it. Love the builds and good luck!

I can't wait for the next version of this series: MAKING MY OWN FULL-SIZE POWER HAMMER We'll probably get up to part 137 before Alec admits defeat.

We spring loaded the handles in our mill so it would automatically disengage when not in use. Saved a lot of bruised knuckles and thighs.

Its amazing to see the difference between a master craftsman and a journeyman. To the unobservant the look the same but if you take the time to watch there are the small movements, adjustments and fluid motions that truly show the difference.

At 00:25 you had me. I missed you Alec!

"I presume you have an idea of how this is all working together". I made a mess just taking my vacuum clearer apart to clean it so I don't have the foggiest of what you're doing. But I'm glad to watch you do it, you clever Brit you.

A long build series has been very missed! I want 6 more parts!!!

RE: the piston/O-Ring... use a wafer thin steel sheet/shim in a way mechanics would insert pistons into cylinder heads on cars/motorbikes - wrap the shim around the O-ring (squeezing it down) then insert the piston, then extract the shim and hey presto, you be in! 🤔😏👌 😎🇬🇧

I LOVE this build. As a lover of the small and insanely hard !, this fits all bills.

Here's a deep cut for those who have been watching Alec for a while... There was a video years ago that used that same first song, and Jaime did some KILLER transitions to go along with the music. I don't remember what Alec was making, but I think it involved the surface grinder in this shop the FIRST time you had it.

Anybody else remember that Alec Steele era where he was obsessed with integral guard chefs knives? Good times

Take the o'ring off the piston and put it in the bore, now check the ID of the o'ring. Check the OD of the groove on the piston. The dimensions should be close, but the piston should be slightly larger. Not much, but slightly. I've always noticed the groove is usually 80% as deep as it is wide to allow for o'ring distortion. ( Just watched to the end....Well done Alec )

@AlecSteele

4 ай бұрын

Thank you very much!!

I cannot get over Jamie's comedic geniuses

This series have been pretty cool, it’s a trip to see powerful machines making tiny parts.

@stupidocanerosa

4 ай бұрын

Behold when the tiny powerhammer will forge a full size lathe chuck!

@jonathanschubert9052

4 ай бұрын

Make him do is again with Harbor Freight machines!

You could say this was a... Tool-Assisted Speedrun. Great work guys.

To get the part with the O ring installed is the same as inserting pistons in an engine. You use a ring compressor. Thin sheet metal wrapped around the part, pipe clamp to compress the ring, wood block and a hammer to drive it into the other part and out of the compressor.

Lol that cute little laugh at the beginning is truly why is subscribed!

I love when he modifies each of the tools that come to the work shop!! When I saw that he cut that key, I just 💀😂

I was just thinking "I could do with an Alec Steele video" and here you be.

What I learnt as an apprentice For the O-ring dimesnions. "W" referring to the cross-sectional diamter of the o-ring. Gland Depth: (0.7-0.8) x W Gland Width: 1.5 x W Normally o rings are 10%-12% larger cross-sectional diameter than nominal value

You can make the O ring thinner. Spin it in something and lightly press fine sand paper against it. Careful for it sands down rather quick. Make it as thin as you see fit.

I just wanna toss out there mad props to your editor on music selection. Well done! It's uncommon to jam out to a build video. Cheers!

Good day Alec, saw the "in-house customised" handle on the mill and had a suggestion of maybe placing a spring between the couplers to ensure it's disconnected. Might end up saving yourself a broken wrist on those long days spent in the workshop when exhaustion and delirium start setting in

The funny thing about your tools is; they’re YOUR tools. Do what you need to with them. I’ve made and modified many tools to suit a specific need or set of needs. Maybe send the piece you cut off to one of the people that complained so they can make use of it.

I love to see it running the next episode Alec. 😁👍🏼😁👍🏼

For your knee handle, as a safety precaution, I think you should bore out a small recess in it and put a spring between the handle and the other set of dogs so that in the off chance that you bump it and engage it without realizing it, it doesn't grab your clothes or hurt you in the off chance there is a body part in the way.

Check out the Parker O-ring handbook, it will give piston/bore and groove measurements by O-Ring size. measure the part you have and see if it lines up with a different O-Ring than you have, or re-cut the part to fit the right O-Ring for the bore diameter.

The o-ring isn't meant to be as wide as the groove it sits in. They seal by steam getting in behind and pushing them in to the opposing face of the groove and the wall of the cylinder. If the groove is 1/8 wide and 3/32 deep, it's likely you need 7/64 cross section o-ring. Or you turned the handwheel 3/32 and only turned a groove 3/64 deep, 3/32 off the diameter. If you're turning something like a groove to a depth you need to double the value on the cross slide dial. I will also say if you're going to be turning small parts you can buy a mounting plate and machine it to fit a 100mm chuck. I did this with our large lathe with a D1-4 backing plate and an 80mm chuck. That square part could have easily been chucked up in a small 4 jaw, parted and chamfered, rather than doing it by hand.

Put the piston with Oring installed in the freezer for several hours. Lubricate the cylinder before sliding the piston and Oring into the bore. The effects of thermal expansion/shrinkage can be surprising

This is the kind of video that you don't just watch, you experience. Absolutely phenomenal!

I bet there will be an 8th part to this series. YOu know, set backs and overruns!

I'm really hoping this mini power hammer doesn't end up being a chattering finger mincer, but, i have a funny feeling about this, being exclusively suitable for finger mincing.

You should drill and tap the shaft on the knee for a retainer screw and washer. Then put a spring between the handle and the machine.

Loved the music. This is one of the coolest things you have made and this is the what episode yet.

Hold the actual press just a moment, can we just appreciate the level of cinematography going on here because it's actually incredible in short words.

The shot direction and editing in this ep were awesome! Looking forward to the next one and the excitement of putting the hammer together!

Small piston ring compressor works a treat ❤

even though its probably able to forge hot steel, i would love to see it forge some good old playdo. alec (and other black smiths here on youtube) have referenced playdo as an example of how working hot metal works enough times that i would find this a very appropiate candidate for the final b roll when the mini hammer is done.

hey Alec. what we did with those z handles on the mill was make a pocket in the engaging part that slides over the handle and incorporate a spring that automatically disengages when you let go of the handle. this was done after i leaned into dis handle and engaged the auto feed. you can guise what happens when one of these Goes round at full force between your legs and goes up😵

I like the sawed off knee handle on the Bridgeport. You could also make (possibly purchase) a small hand wheel that can stay engaged if it wants to be. A far less chance of it getting snagged on something than just a one legged handle. 🍻🍺🍻 Cheers from across the pond 🇺🇲

if you can cut a smooth internal taper in a bit of tube to match the diameter of the chamber you're trying to get a part into, you can lubricate the bejeezus out of it and get that O-ring into its compressed state. Your part passing ahead should give you alignment. Just clean your burrs and maybe give it a gentle tap to get the ring through before it can expand.

Cool project. Glad to see you’re doing well.

Man your shop has grown so much

Happy New Year !

This is random but I’m loving these new background music😍 soooo groovy combined with the visuals haha

Great video Alec and Jamie, looking forward to seeing it run.

This is definitely my favorite series

When you put a cylinder into a block you use a ring compressor to squash them prior to inserting. You could make a collar to compress and then lubricate prior to insertion.

the handle you cut off was easy to make work with a TINY bit of thought before going ham on it. ALL IT NEEDED, was a spring between the teeth of the handle and the teeth on the mill, with a bolt at the end to hold it all together!!!!! the spring keeps the teeth separate when not needed, and easy to use with a simple push when it is needed! you removed all the leverage on the handle by doing that.

7:17 Use a spring and washer for the mill handle.That way it always disengages when you let go.

If it don't fit, force. A motto I live by.

I'm really liking this series. Can't wait to see it run

Cool work, thanks for the video Alec!

about the O-ring issue: just deepen the groove it sits in a *tiny* bit, if that's not enough remove another 0.1mm until it fits snuggly~

You need to either cut the groove deeper for the o-ring, and or get a "ring compressor tool" - you could whip one up with some shim stock and a hose clamp

Fyi, metric O-rings come in a lot more sizes than "imperial" so if the grove in the piston is correct, just start stepping down in diameter 0.1mm until you find an O-ring that fits in smoothly. Should be able to get away with O-rings that with a 5-10% smaller ID so just round down to the nearest standard size.

These videos are kick ass !! Very impressive with how much skill you have!!

I've genuinely been checking every day for the next episode excited to watch after work !!

Also have to remake the Bronze bit for that slippy goodness.

Jamies editing is noticeably better than historically done ... well done. Reminds me of Phil from JayzTwoCents channel.

That laugh at the start brought be right back to COD zombies!!

Use the arbor press and some oil and force that o-ring into the chamber 😄👍

For the O-ring placement, seems to me that Cutting Edge Engineering Australia would be a great person to talk to here on youtube! Your personality and his would seem a perfect fit!

With small engines you use a metal cuff to compress the piston rings to get them to fit into the cylinder. Assuming that is the correct o ring, you could use a pipe clamp and some oil to achieve something similar.

@user-neo71665

4 ай бұрын

Not just small engines that use a ring compressor

@StarScapesOG

4 ай бұрын

@user-neo71665 I only have experience with small engines. Never had the chance to do a complete teardown of a "large" engine. So that is good to know! Thanks!

Alec, I've enjoyed your videos. Thanks for all the fish. Best of luck young man.

For the knee handle, you could have put a spring between it to push it outwards. And put an endplate on it so the handle doesn't fall of the shaft.

I would like to see alec make a series of hand made tools for example, weld on clamps/pullers, tongs, wrenches, things of that nature. None of it has to be perfect just to the point and informative.

you could put a spring on the bridgeport handle so when you want to engage it you have to push it in but it pops out when you let off.

2:48 Stick the o-ring in the freezer, then it'll shrink down for a perfect fit!

Can't wait to see this throw sparks! Ha ha now you have to make a Minnie Sword!

For the handle (around 8:00) you could put a spring between the to part and a stop at the end of the axis

I hope you paint it green just like your big one 😊

Loving this series

For the mill handle they actually make light springs for them that push it out just far enough that the castle groves don't engage; but you can easily push it forwards to engage when you need to use it. As for the O-ring I'd try going down 1 size and stretch it on.. it will lower the diameter of the o-ring just slightly, make sure to grease it up on assembly to avoid it catching.

@captainsupermaket8003

4 ай бұрын

Literally just posted this exact comment 🤣 great minds think alike I guess

Been waiting for this happy new year Alec!! Love the videos!

For the O-ring, make a little compression tool out of a old coke can or something. Allow you to not nick it, and a bit of lube should allow it to slide right in.

u cant imagin how long i was waiting for a new vid ^^ i was looking every day

Maybe try something like a piston ring compressor to get the o ring in the barrel? Can't believe this is the penultimate episode! I've been looking forward to see how you did this in a much more detailed series, Up to now we've had 1.5 hours on this, including promotions. Your viking sword was nearly 6 hours of footage!

I'm really enjoying this project. :)

I can think of two ways to install piston rings: using a compressor and hammering it into the cylinder or machining a slight lead into the top of the cylinder. Hope this may be of some help. Play safe from Elliot Lake, Ontario, Canada.

Use a hose clamp to compress the oring around the outside of the part, but do not clamp hard enough to touch the metal.

Alec there are knee handles that have a spring behind them to automatically pop them out when you're not pushing them in to engage the teeth

@PiecieRoneJones

4 ай бұрын

But he doesn't need one anymore

For the clamp on the toolpost, get an Allen screw with the right hex, and bend it to make a spanner. (That's what I did with my dad's lathe about 40 years ago. (eek!)

Concerning the o-ring, the easiest solution is to dive deeper in the part's box and seek for the right one. It looks it's not the right size. Maybe there's another of the correct size.

For the handle on the Bridgeport: how about a light spring between the handle and the drive bit? That way you have to push it in to engage the teeth and the spring pushes the handle out of engagement when you let go.

Use graphited yarn for a quick fix or machine the grove deeper and use the proper size O-ring. The piston should be snug not tight.