Dear Keith, thank you. Leo is very lucky to have you. Your attention to detail, combined with your common-sense approach - picking your battles - is a reminder to us all of how we should approach any task that is given to us to work on and complete to the best of our abilities.

There needs to be a "double like" thumbs up for those of us who watch a video more than once.... My two cents.

Good morning to everyone watching from Lincolnshire UK 🇬🇧

@breakthroughmadeinusa9184

2 ай бұрын

Welcome aboard Paul!

@leonwiborg1377

2 ай бұрын

AM watching from Danmark to paul

@JohnWilliams-xw2wy

2 ай бұрын

Morning from Wirral UK 🇬🇧

@chrish1657

2 ай бұрын

What about people outside Lincolnshire?

@Paul-FrancisB

2 ай бұрын

@@chrish1657 thanks for the grammar check 😁 I should have put a comma after watching

Jeez theres A LOT of labour going into just the capstan!

@CHICOB4261

2 ай бұрын

It really is! It’s amazing the work that has gone into this one small part of the Tally Ho. I have been watching the Tally Ho project since it started and I have been watching Keith since the beginning. I was very happy to see Keith get involved in the project. I was thinking about it last weekend whilst watching Leo, it’s incredible! Leo is rebuilding a 110’ yacht basically from the ground up. He has been successful in getting people to donate, volunteer, and provide everything that he needs for his personal yacht. He has sold it as a preservation project but it really is just a yacht for him to live and sail on, good job Leo! This is not a criticism of Leo or his motives for his project but a compliment of his leadership,skills.

@TheoSmith249

2 ай бұрын

@@CHICOB4261The good, attracts good.

@user-ym4xy6us5e

2 ай бұрын

@@CHICOB4261It beats donating to bullshit charities run by bureaucratic wokesters, for sure!

Watching a master machinist working, one learns a lot! Not that I will ever do any machining, but it is fascinating to see the care taken on something going into Leo's beautiful and high-class boat. i am sure Leo has watched this whole video and must be so happy that an original piece, a huge piece of Tally Ho will go back in better shape than it was. And electrified! the whole Capstan project, from the initial disassembly, breaking the head, and subsequent re-casting (4 times) is just plain dedication.

It's absolutely wonderful to watch this contribution to the whole Tally Ho effort. Whatever the down sides of YT and social media are in other settings, Tally Ho is the perfect example of the immense good they can accomplish when people of skill and integrity see fit to share. Bless you.

It’s like using an etch-a-sketch. :)

@sheep1ewe

2 ай бұрын

I remember when i was a kid and tried to draw a tractor with round wheels on one of those... Ha ha

@PETERFWESTON

2 ай бұрын

I think that is a great description of the skill level it takes to move the machine head along the curve of the project working in 1000's of an inch. Kudos Keith!

@transmundanium

2 ай бұрын

That's what I was thinking too!

This is the skill level that goes unseen, and perhaps insufficiently rewarded, on our economy. Excellent.

@junkname9983

2 ай бұрын

this is pretty normal for machinists though. A more modern machinist will actually use a CNC to mill those curves more precisely. It's not really extraordinary.

@21228bijoux

2 ай бұрын

Nonetheless, a CNC machine still has to be programmed by a machinist who understands what needs to be done. That's the hardest part. Do more videos of some other projects .@@junkname9983

@nick.caffrey

2 ай бұрын

@@junkname9983 So clever to junk all this experience. Be proud, boy.

@junkname9983

2 ай бұрын

@@nick.caffrey I think it is you and the other guy who are junking the hundreds of thousands of machinist out there who are equally talented by saying this is bit of expertise is unseen, like you're demean them simply because you don't see them doing their jobs on a daily basis.

@kindablue1959

2 ай бұрын

@@junkname9983I think you've missed the point that doing this by hand and feel is effectively more 'precise' for an imperfect piece like this than what pure math of a CNC machine would dictate. Doing it with CNC would require creating a CAD model, and that would never reflect the actual part (unless you did some kind of laser scan, which is totally overboard in this case), and then trying to come up with some effective path strategy that could be programmed. Nibbling out by eye creates the best result that experience dictates, not what numbers dictate. Keith was making decisions on the fly and adjusting according to live feedback and his expertise. Trying to know what would be needed beforehand so you can program it would take 100x as long and likely fraught with errors on a first pass of a one-off job. Knowing how to get only what is needed in the most efficient way is the key to successful engineering, and that's where Keith shines.

Am I the only one holding my breath to see him drill the bolt hole pattern in the plate? A few videos ago, as several commenters noticed, he mis-entered the radius on his DRO when doing the _original_ hole pattern. Transposed 2 digits. So the hole pattern radius is off by 40 thou or something, if I remember correctly. Not enough to matter structurally, but enough to not line up too great.

The Tally Ho is being built about 80 miles from my home in Bellingham and we have expert craftsman doing remote work from thousands of miles away! Amazing support for thi project. I hope I get to see this Capstain after its' been installed on the boat in Port Townsend.

@Trebuchet48

2 ай бұрын

I hope you get to see it too! Tally Ho is about five miles from my home just outside Port Townsend so I see it often and have trod the deck during their open house events!

I find it intriguing that i am so engaged watching you shaving thin layers of metal of a bigger piece of metal but I appreciate your skills and your contribution to the restoration of Tally Ho. 👊

This project would not have happened without your intervention. Kudos.................

I think that’s the best explanation and demonstration of a milling operation I’ve ever seen . Salutations from Oakville Ontario Canada!

Knowing when enough is enough is such a big part of any project. This was fascinating, and I'm really curious to see how the matching piece will be, well, matched!

@AttilaAsztalos

2 ай бұрын

It should have been no more complicated than flattening the area of the bottom three holes and "counterboring" the rest of the holes just enough to be able to insert some spacers up to the plate. I have no idea how Keith is intending to fit the plate...

@paulkinzer7661

2 ай бұрын

@@AttilaAsztalosI'm keeping in mind that how Keith does this is probably not entirely up to him. A very cool aspect to this project is just how many folks are involved in the Tally Ho endeavor. He's in consultation with several people.

Wow Keith that 5 mile run and 2 hours in the gym is doing wonders for your weight loss goals, looking good.

I have arrived here as a wood carver who likes boats you have shown me the Art in a new media thanks 😁

Mr.Rucker what you are doing is a one off custom job. For the person that wants to convert a manual operated Capstan to an electric motor driven Capstan. Whomever you are machining this piece for is very lucky to have contacted you and being you are willing to do this machining job for them,EXCELLENT. Not many Machinists would even consider machining this Capstan.

It really doesn't matter what a master does. It's fascinating to see the attention to detail that a master can bring to bear on a project. There is a wonderful combination of education, patience, feeling for the material and process, and ability to focus the mind. You don't learn all of these in school. Some have to be learnt in the flesh. Add it all together and it becomes intelligence or high art. This is the best of America. This is what it used to do better than anyone. And then you took to hating each other. Sad.

Wow. I was wondering where this was going with milling out the lower areas. The only reason would be if it’s going to be filled in with a plate, but nobody would try to create such a difficult shape for that void, would they? Apparently so! I look forward to seeing this progress.

Thank you Keith! Really enjoying the capstan project!

I am enjoying this from my couch in Surbiton, UK, Keith. Thanks for this series.

Smart, methodical, detail oriented, plan of attack to get a cleaned up surface for the casting. I admire your skill and approach to getting the job done Keith. As a structures engineer I appreciate your focus on getting a surface that supports good clamp up around the fastener attachments. Thanks for sharing!

Hello Keith. This piece gets more interesting with every post. Finding that middle ground on castings is a just a fact of what they are. Give a bit here and take a bit there seems to be the norm when working with them. Be it a piece that weigh pounds/ounces or tons we treat them all the same eh. Seems to me you have done this a time or eight my friend, LOL. Bedding compounds are news to this old and long retired fella, Interesting idea my friend. I am sure Leo has blessed your channel to see how well things are going. The're going great my friend. See you next post for sure.

Keith, You might consider using ITW Philadelphia Orange Resin or ITW Chockfast Orange to fill the void between the mounting plate and the casting. These resins are often used for ship engines, gearboxes, and other equipment. It is intended for marine use. Bob

I sure do miss mucking around like that on a mill. Fun work!😊

I feel so lucky to be able to see this process. I really appreciate it. Wonderful work.

In one sense, you created a 4-jaw chuck with the 4 jacks. Calibration to them and then tie down to their plane. Interesting the size and the issues trying to bring old designs into the 21-century. I still don't have a handle on how the two fit together.

Another steep along the way, thanks Keith for the video.

That's going to be quite the large hole in Tally Hos deck! But when it's time to pull anchor it will all be worth it.

I've been watching some of your older videos (10 years) and I really appreciate how your filming techniques and narrating have improved over the years. 😀

One of the top channels on here. Always looking forward to each new production, and thank you. Excellent.

I feel your work and attention to detail is awesome great job

👍🏻 An absolute professional, meticulous and a long-time expert! Great procedures, measurements and work! 👏🏻 - But we look forward to the new video all week and listen to repeated professional lectures about the work progress for 27 minutes. We are not polytechnic students and are mostly skilled technicians or at least do-it-yourselfers. At most, we will see 15 minutes of work performance itself... And in the next 7 days we will have a new lecture and 15 minutes of work. 😔 I don't know, I think we will see a complete renovation about 6 months after the completion of the Leo Tally Ho construction. Sorry… Good luck!!!

Excellent explanations, Keith. With some bedding compound where it's needed this will be the flattest thing on earth!

Hey Keith… very interesting project. Thanks for doing this for Leo! 🇨🇦

I always look forward to your videos Keith. This one was no exception!

Hi Keith, Nice to see a master at work, I used to work in a manufacturing company , and I all ways admired the skills of the machinist ,now a lot is CAD work but just see the machines doing it so fast now , is mesmerising.

Capstan is looking good Keith

Thank you Keith!

awesome, thank you so much! A joy to watch!

Hmm, what my thought was like machining a shallow counterbore around the lower holes and maybe the partial holes next to the shaft so you can make some spacers that fit right in there. This still looks a little messy, but that makes me more interested to see what's to come.

The uniformity of the casting is a tribute the the skill of the Scots foundry men of 110 years back. Who makes anything now that is likely to be about in a hundred years time?

@trevormitson6026

2 ай бұрын

''Scots foundry men'' where was it built? Thanks

@johnsherborne3245

2 ай бұрын

@@trevormitson6026 Glasgow

Etch-A-Sketch milling!

Happy Friday Keith! 😊🚂👍👍👍👍✌️

I'm pretty sure Leo will be happy with that. Then again, his standards are higher than my own.

crazy, working like in the stoneage....

Chockfast might be of interest in this application.

Nicely done, Keith

Greetings from a slightly damp Bedfordshire.

@peterhobson3262

2 ай бұрын

It's drizzling here in Connecticut as well.

Thank you for sharing.👍

Thanks again good work

Thanks for sharing. Watching from the Relentless drillship in Gulf of Mexico.

Just brilliant, such skill and dedication to precise engineering well done.

G'day Keith. Doesn't look much at a quick glance, but this a complex unit to level & machine out, without ripping the job to pieces. Great job so far, & looking forward to the next stage. Always liked your techniques over the years Ted

Thanks Keith

It's looking really good!

Very nice,looks good..😎😎😎👍👍👍

Big boy Etch-a-Sketch!

Hey Keith, you should write a diet book! Well done, you look good.

boy, Leo better be right on top of corrosion control .. replicating your work would cost a fortune!

I was going to suggest milling away the remnants of the rib with the big hole in it. but I guess what remains of the rib will take twisting loads off the bolts if it fits the plate slot snugly.

5:00 That's a decent method to set it up nice and fat. I was thinking of using a depth mic to the milling table .. but the test indicator is MUCH better :)

If it weren't for the desire to keep as much of the original as possible, it seems it'd almost be easier to machine and/or cast a whole new piece with the additional flange built in to begin with. At the very least, just mill away that strut entirely, as it's not doing anything structural anymore with that giant hole through it.

Good work thanks for the content

JB Weld in the low areas, then re-machine flat.

Hail the algorithm! #TallyHo

With some of the "advice" being given, I suspect, some make comments without watching the complete video/series, and that the casting is around 100 years old, recasting it is not an option LOL

I’m no machinist and admire what you’re doing but saw a few others asking what also occurred to me, so perhaps explaining the rationale for milling down rather than building up with brazing or some other technique would be helpful to us less experienced viewers.

@WhatAboutTheBee

2 ай бұрын

Its a materials problem. The base is cast iron. You cannot add more cast iron. You could add another material, but bonding and the homogenous nature will not be present. Any material added may as well be in the adapter plate. Making the adapter plate to fit the base is a reasonable solution.

Love ure videos.

Great as always! You audio has been sounding like it has a problem, muddy and speeds up and word run together. Sounds like an audio compression problem ?

The issue is whether the decked surfaces are perpendicular to the original central shaft,or not, imho.

Just thinking outside the box. Horizontal borer which you have plus angle plate with rotary table mounted on it equals no access problems.

I would have challenged the spec which placed the largest bored hole right through the spoke. The strength of the casting is in the 4 spokes, not in the web between them. Bore for the gearmotor, placed through the web, and achieve a strong motor mount plate by straddling two spokes, with the bolt circle hitting two spokes symmetrically and the rim. Then mill 2 faces: rim height and spoke height, with no bolts relying on the thin web to take the immense torque of a chain pull.

@frederickstibbert7389

2 ай бұрын

The capstan straddles 2 deck beams & is centered over a big chunk of oak blocking between the beams. It's likely that the new driveshaft location was chosen to avoid the through-bolts that anchor the blocking to the beams or compromising the structural support it provides.

For others who are struggling with visualizing 2/1000" = 0.0508mm or about the thickness of a hair

@voodoochild1954

2 ай бұрын

Actually most human hair is 3 to 4 thousands thick.

@littlejackalo5326

2 ай бұрын

​@@voodoochild1954"aKcHuALLy" he said "ABOUT" the thickness of a hair. 2 thou is close enough to the 3 thou you said. Pedantic af.

@Hoaxer51

2 ай бұрын

@@voodoochild1954, I believe some hairs are thinner than others, I have a reference for that: AvE has a reference chart that shows that the darker the hair, the thicker they are. That’s why a really close tolerance is referenced as “A Blonde One”. Lol

@CothranMike

2 ай бұрын

@@littlejackalo5326 yup, some old folks thinning hair is less than 2k, and I have it on good authority from a Puerto Rican machinist I used to know, Puerto Rican hybrid hair is both thicker and tougher than either of the two breeds used for the mixing. He claimed cut hair can work its way into the cuticle of the skin and burrow deep enough to require deep cuts to the dead skin and live tissue to remove for festering. I was cleaning the metal particle from his eye with a flax seed catcher which worked very well. Since then I have avoided any barefoot walking in hair cutting shops, not too hard as I wear it long now I no longer work in the field.

8:16 .. Keith, the human CNC Mill :) .. literally looks like CNC did it!! :)

Much easier on a rotary table! You could then use the set up to mill the spacer !

@joshua43214

2 ай бұрын

I agree. It would take a really big pallet mounted to it though. He would easily be into a couple hundred dollars in custom fixturing. I do not know if he is charging anything for doing this. A big pallet with a center spigot and fixed posts for leveling would take a while to make, but would save a ton of time down the line.

@MatthewTinker-au-pont-blanc

2 ай бұрын

@@joshua43214I suspect that Kieth has a big enough rotary table to be able to mount the part without too much difficulty!

@Hoaxer51

2 ай бұрын

That’s a pretty big piece he’s working on, would there be enough space for a rotary table?

@MatthewTinker-au-pont-blanc

2 ай бұрын

@@Hoaxer51 In my opnion yes!

@robertmcauliffe6989

2 ай бұрын

Rotary table, mounted on an angle plate on the Lucas HBM would work. Center rotation on previously machined bore. Would take some tool extensions but I think one could achieve a nice planer surface normal to the bore axis.

Would it have been better if possible to have built all of those areas up rather than milling it down? I am thinking (and I don’t know anything compared to you and probably many other viewers) that it would make the capstan stronger whereas milling it down would tend to weaken it. You could have milled the raised surface and then added to that. This is only a question from an observer. Thank you Keith!…this is an edit I guess I didn’t understand what the project was🤪

Keith, as McCoy said to Spock about his guess in Star Trek IV: The Voyage Home: "He means that he feels safer about your guesses than most other people's facts." You guessing you're close enough at two thou is good enough with the internet.

As a non machinist question. Was it ever considered to clean the casting well, then heat the entire casting and pour molten zinc into the recesses to either side of where the through hole was to be?. Then just machine those areas flat and drill/bore the holes afterward. This would insure a perfect flat to mount the motor assembly, and essentially galvanizing it. It seems like a specialty shop would have an oven suitable to ramp temperatures slowly and avoid cracks.

Nice

The hole pattern. Killing me not to see resolution. Off to work, will have to watch the.rest at lunch.

@seapy2398

2 ай бұрын

Think we will have to wait for that one, if they ever reveal it.

@Hoaxer51

2 ай бұрын

There’s a good chance Keith will use those screw in transfer points that he uses all the time to get the hole location perfect. It would probably be the best way to insure that the holes lineup perfectly.

@CothranMike

2 ай бұрын

@@Hoaxer51 always best for a one-off

Cool 😊😊😊

This being an extensive modification of a cast iron piece, I would rather try make sure the axis of the motor mount and gear are correct and modifiy the adaptor as much as is advisabel and complement it with some industrial epoxy bedding compound to ensure full contact.

Lost 2k of accuracy when you moved the head back?

Tallyho is going to be a lucky boat

Surely the mounting plate for the motor should be referenced off the taper spindle bore as that is what will be revolving?

@seapy2398

2 ай бұрын

It seems the expectation is the bore and the facing were done at the same setup on a large lathe, we aren't shown the original machining marks but that was stated. Therefore setting up to the facing should get the job done. At the end of the day this will be low speed, high torque application so a little deviation shouldn't be an issue.

@clivewilliams3661

2 ай бұрын

@@seapy2398 Point taken. The thing is that even Keith commented on the rough finish of the face plate and there would be a direct corelation between the spindle and the electric drive, whereas using the face plate puts it one stage further away. As you say, it will be a high torque, low speed unit that whilst more tolerant, having an axial mismatch between the shaft and the motor will reduce efficiency.

@Hoaxer51

2 ай бұрын

They should be able to shim the motor to get the proper alignment and backlash, it will be a finicky job but no worse than setting backlash on the rearend gears on an automobile. So it seems.

@clivewilliams3661

2 ай бұрын

@@Hoaxer51 I don't doubt that they would have to align the motor whatever the format for machining the mount, its just that its always wise not to have to rely on a cascade of potential tolerances to get the position right.

Looking good Keith! Bedding is tedious. No rotary table?

I would be concerned about the milling into the outer flange where you have left a sharp internal 90 degree corner and took out the curve. Sharp right angle corners from memory, can induce stress fracture propagation away from the sharp corner. Better to have a radius where you can when machining the casting. As you can see there are a number of radius type shapes used both from the casting mold release and perhaps to stop cracking?

Of course hind sight is twenty twenty. Maybe filling the voids between the spokes with brass at the start might have made the job a bit easier . A bit more expensive in materials though especially if you had to fill it with rod .

What about the Stoker Engine?

Rock On

it's the old school dudes for the win with this. restoring tally ho with, ok they did incorporate modern tech, getting the old stuff to work is still difficult. not fun for you but love to see you struggling

I got no idea on how he's going to make that adapter plate in a neat way, Usually cylinders, pistons and ways are so precisely made. It's got me racking my brain which is all good practice for the day I get my first lathe. But I ain't going to be a armchair general on this. Best guess is there is no pretty way to do it and it won't be on show anyway.

This work on the capstan base and adaptor plate to a specification that I'm sure is already in CAD would have be ideal for a decent sized 3 axis CNC mill.

@user-ym4xy6us5e

2 ай бұрын

In Tally-Ho's era a CAD was a man without honour and C.N.C. stood for his opposite: the Charming Nautical Captain.

There has been some weird lo-fi with the audio in the latest videos?

To make your adapter flange I'd start with you babbitt metal and fill in the area you want. Then just cast it in aluminum or even cast iron. Am I wrong in thinking that would be pretty simple?

How are you going to match the two half threaded bits of holes?

Hi Keith. Is there has better way fill those areas. So they match all a round and then milling nice surface or what´s the deal is ?

Would it have been possible to have the adapter plate made of cast iron and just braze it to the piece instead of bedding compound?

@UK_Lemons

2 ай бұрын

To braze a casting this large requires preheating the part to a fairly high and uniform temp. This creates a lot of stress in the casting and risks cracking it. Best avoided on a part like this. Edit... also you only get one go at brazing a large part such as this. Get it just a fraction out and it's ruined your day.

"Etch-a-Sketch" milling.