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Gingery Shaper Resurrection

YYCHM

YYCHM

(Craig)
Premium Member
I've been wanting a shaper for quite some time now but don't really have the room for an Atlas so I decided to approach @kevin.decelles to see if he would surrender @Johnwa 's Gingery to me. Kevin agreed (Thanks Kevin!). I picked it up Friday morning....

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You really have to see this thing in person to appreciate the amount of work @Johnwa put into this. It's quite amazing and I appreciate now why Kevin snapped it up. I have an agreement with Kevin to return it before ever scrapping it.

In general it's all there except for a few crank handles and graduated collars. I'll be working on those and tweaking some of the mating surfaces and spots that are binding.

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This is countershaft drive assembly. I'm still trying to get my head around how it works. Will probably make more sense once I mount it to something.

Had a really good hour long tour of Kevin's shop. Man he has some really cool older large machines all running. Large lathe that has reverse on the fly. A large shaper with a very long stroke (2.5' ?) where the motor is connected via a 4 speed tractor transmission. The biggest power hack saw I've ever laid eyes on with hydraulic letdown that lifts the blade on the back stroke. Very cool stuff.

Craig
 
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It was good to see Craig. So much is lost in the messaging only aspect of the forum .

Looking forward to updates and hopefully seeing this shaper running in person


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It looks great one thing I saw though is the cross slide mechanism it looks quite coarse on mine it is a finer tooth which will give a smaller stepover giving a better finish.
 
Tom O said:
It looks great one thing I saw though is the cross slide mechanism it looks quite coarse on mine it is a finer tooth which will give a smaller stepover giving a better finish.
Click to expand...

Well..... If John stayed true to the Gingery design the mechanism can be setup to pickup 1 to 6 teeth per stroke, moving the table 0.002" - 0.012" per stroke.
 
KeyWay.JPG


First up on the agenda was a keyway on the sprocket drive shaft to mesh with the keyed drive pulley.
 
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Johnwa said:
I should have the shaper book kicking around somewhere. I’ll find it for you.
Click to expand...

Kevin gave me one that I think he got from you. Red 5-1/2 X 8-1/2 paper back? He had two of them.
 
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One crank handle down..... one to go.

Crank.JPG


Had this broken Utilathe cross feed crank in my spare parts box that would work. Made a 1/2"-3/8" bushing with set screw. How to mount the crank on the mill in order to drill the hole to replace the broken off handle had me a little perplexed.

TNut.JPG


Then it dawned on me to bolt it to a 1/2" T-Nut and mount the nut in the vise. Worked like a charm, including mounting it on the bench vise for tapping.

If anyone has a broken crank or two like this that they would be willing to donate to the project, I'll pay the postage.

Craig
 
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You mean you are not going to turn these classic dumbell handles on your classic lathe?

Would be a great challenge to grind some form tools or use the step turning method to rough out the balls and finish them with a file and emery paper....

Here is a video showing how to turn contours using the step turn method...

 
A couple of more tweaks today....

The table was binding at the extreme ends of it's travel.

RHCollar.JPG


Had to turn a wee bit off the auto cross feed collar on the right side.

LHSupport.JPG


And mill 1/16" off the back of the screw support bracket on the left hand side.


DriveBelt.JPG


And then...… Three trips to PA later... I finally landed a belt that fit's this countershaft contraption:oops: First attempt I measured it using a power cord wrapped around it, too short. Next I measured it with a flexible measuring tape, too short again:( . Third one...… well it's a little too long, but usable.

@Johnwa Did you cast that 9" pulley?
 
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Yes I did. I was a bit worried about the shrinkage flaw on one of the spokes but it seemed to work.
 
A trip to PA is 1.25 hours round trip so when I buy belts I buy 4 sizes on either side. What size worked? Curious to see if I had 3 on the shelf for it [emoji3]


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Craig...envious does not describe me right now, a bench-top shaper was on my "bucket list" for a long time but just never could find one close enough or in my "affordable range" at the time.
Enjoy that beastie.
 
Discovered a delinquent Gib strip...

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On the left hand side of the vertical table slide. Must have fallen out.

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Milled one up out of mild steel and left a hook on the end of it. Supposed to be brass I think?

VGibb3.JPG


This one can't fall out...…..
 
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