Making a DC Generator (Dynamo!)

Making a DC Generator (Dynamo!) - Part 1

Рет қаралды 129,306

7 ай бұрын

This episode on Blondihacks, I’m making a dynamo! Exclusive videos, drawings, models & plans available on Patreon!
/ quinndunki
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Пікірлер: 248

@Blondihacks 7 ай бұрын

Hey everyone- lots of folks asking why I didn’t do the bore on the mill. This is such a common question on every project, that it is in my FAQ. See link in description. The TL;DR is that boring heads suck if you don’t have power down feed. If you were about to ask that, now you can ask something more constructive instead! Win win! Meanwhile, to everyone concerned about the bolt holes being crooked after the correction, they are clearance holes less than an 1/8” long. Trust me, it’s all gonna be fine 🤗. As for why I didn’t use the ends in the vise for fixing the bottom, both ends *should* be pretty square, but only one definitely is and it’s always better to directly reference the critical surface when correcting a relationship. Using the bore ends is an assumption and a compromise. And yes, the mandrel was long enough. 5C collets are single cut and only clamp at the very end. That had nothing to do with the mandrel moving.

@danielmclellan7762 7 ай бұрын

The tappy-tap-tappiest of episodes, without once using the phrase??

@Tasarran 7 ай бұрын

Asked it a few hours ago, now I want to delete it... I didn't notice you didn't have a powered mill quill, and I TOTALLY see how that would really give substandard results if it wasn't mechanically fed... Almost like trying to do single point threading without gears, by turning the handwheel...

@c0rr4nh0rn 7 ай бұрын

I feel like you chose to pass on making a collet joke at the end. Thank you for reducing our punishment for questioning the order of operations.

@goboyz8016 7 ай бұрын

Ahhh totally makes sense. I am using a Bridgeport mill with down feed and a mill without it would be a nightmare unless you had one of those expensive boring heads with autofeed mechanism. Thanks for the comment despite my laziness not looking deeper for the AsknAnswered part of your channel.

@goboyz8016 7 ай бұрын

As a side note I had predicted you were going to setup like you did with the file machine on the lathe crossslide and line bore it. I was so sure you were going to do that, I thought you purposely used the 4 jaw just for teaching. LOL

@polleyjw 7 ай бұрын

One nice side-effect of watching so many episodes is recognizing where various pieces of scrap came from. 😊

@richtes 7 ай бұрын

I’ve always found the key not being remembering where a scrap came from but remembering where you put it

@oldfarthacks 7 ай бұрын

Thanks for the laugh. I have bin there and done that.

@Jaymis 7 ай бұрын

Easily the best "because shut up that's why" this year. The timing and delivery were perfect. Bravo.

@vaderdudenator1 7 ай бұрын

The knowledge of when to stop rather than getting greedy and going for perfect is a hard lesson I still learn regularly. Props to you for knowing when it’s worth it and when it’s not and being willing to show an imperfect object on KZfaq.

@mikewatson4644 7 ай бұрын

Old saying "Perfect is the enemy of good"

@ToreDL87 7 ай бұрын

Flawless function is a perfection unto itself.

@anothermidlifecrisis 7 ай бұрын

I am glad in my own hobby machining world, I spotted the foot to bore mistake as it was happening. The thing that draws me back to this channel is the mistakes and how you teach us how to deal with them. Awesome content as usual Quinn, one of the best channels on YT.

@britannia-foundry 7 ай бұрын

As an Engineer there is a huge temptation to offer advice and point out where you have gone wrong, but then I realised I would be just like every other Armchair Expert, instead I will stay silent and trust that you are learning as much from your mistakes as I am, keep up the great channel 🙂

@firstmkb 7 ай бұрын

I have less engineering education, haven’t ever used a mill or metal lathe, and STILL struggle to STFU. I know all of the “helpful” comments from armchair machinists would wear me down. I think this is part of my learning process - to connect problems with techniques & solutions, then test them against reality (or more knowledgeable people). That feedback illuminates areas I was missing or reveals things I’ve misunderstood. I would also like to be able to build projects like these, and “helping” is easier and cheaper than doing. Thanks for YOUR comment because it pushed me to understand why I feel compelled to add my $0.02 (if that) worth on machining videos!

@RonCovell 7 ай бұрын

Quinn - lots of intricacy with the setup on this part. I love your explanations of when further attempts at corrections may give worse-than-expected results.

@Raye938 7 ай бұрын

Know when to call it and know when to collet. Both important skills for machinists I imagine.

@sblack48 7 ай бұрын

Regarding chatter on light cuts with carbide, I think it was Stephane Goetteswinter who said that this is due to the edge radius that inserts are made with to prolong their life. He has shown lapping that radius down to a super sharp edge allows the insert to take a thin cut at the expense of tool life. I haven’t tried it so if it doesn’t work blame him!

@ColinWatters 7 ай бұрын

13:40 Way back in 1980 I was actually taught "visual averaging" on a signal processing course, a module on my Electronics degree.

@uncouthj4599 7 ай бұрын

I think I need to make a great big sign to sit behind my machines saying "DON'T CHASE PERFECT WHEN ENOUGH IS ENOUGH!" I scrap so much stock that way...

@TheFreshmanWIT 7 ай бұрын

Once you have the bolt holes and need to do the layout (~9 mins!), if you have 2 gauge pins of the size, you can use them as references against the angle plate top (by pushing them through, then resting against the angle plate top), rather than trying to use the height gauge. I found on a few projects it gets you REALLY close as long as you have the right size gauge pins and a reference surface on the top of your angle plates. Side note, I'm envious of the patience you have on your initial setup! I typically just use an adjustable parallel and eyeball it off the vise jaw!

@bloke1987 7 ай бұрын

I was thinking this, plus could you then fly cut the top face to be square to the bolt holes and the foot for easier clamping in the lathe?

@TheFreshmanWIT 7 ай бұрын

@@zacharykarr yeah, you'd need pins that were the size of the hole or smaller, as long as they are the same size.

@electrotsmishar 7 ай бұрын

I am very bad at crafting, especially making near perfect products. These videos fills my heart with joy. Thank you for your video

@canalboating 7 ай бұрын

"It's nice to get lucky once in a while" thanks Quinn made me smile

@ClanChapman1rRS 7 ай бұрын

Heh heh heh! Nice touch with the scratch lines moving slowly across the screen starting at 23:10!

@ryebis 7 ай бұрын

My old bicycles had these dc dynamos for headlamps, good to see people still fancy them :)

@cyrucom 7 ай бұрын

Did you have the one that rides on the side of the tire, or within the front hub? Lots of bikes are rolling on front hub dynamos these days, I have one on my commuter rig! Nice to not have to worry about charging my lights

@ryebis 7 ай бұрын

@@cyrucom I had ones that ride on the side of the tires, pretty compact and I think they put out 6v or 9v depending on the model.

@nerd1000ify 7 ай бұрын

Of course with an incandescents bulb as the light you would probably notice the extra resistance to your pedalling (and woe betide you if you want lights while riding up a hill).

@ryebis 7 ай бұрын

@@nerd1000ify haha yes, that definitely sucked.

@kencarlile1212 7 ай бұрын

As I was watching the 4 jaw setup, I kept thinking to myself, well, self, Quinn knows so much more about machining and precision than you do (as you are a woodworker), she must be doing the right thing. An excellent lesson in recovering from a booboo. Now I will go forth and attempt to cut my dovetails in such a way that they don't break off all of the pins again. 🙂 As usual, I love the "shut up, that's why," and cackled like a fool when you said it.

@WildmanTech 7 ай бұрын

Thanks for addressing the question in my mind about referencing to the bore in the casting.

@christhamilton42 7 ай бұрын

As I was watching this I realised how much I appreciate your commentary, both the style and the content. Just felt you ought to know so that you didn't feel the need to go changing it. Love your work, both entertaining and informative.

@SteveSmith-pv9ss 7 ай бұрын

Just want to say that you are the only person that I make a point to tune in every week. Ive learned a ton and am considering taking up the hobby. Thank you so much! The switcher is looking great!

@daretodreamtofly3288 7 ай бұрын

To be honest I don't know why you were worried about the 20 thou. Unless the thing you're mounting this little gen to is perfectly flat and parallel to the run of the drive, you're going to have to shim it anyway. Ir if you have adjustable stand-offs. Belts and chains have some give in run on top of that. You might be surprised just how far off you can be and not trow a belt.

@MrTapanes 7 ай бұрын

Two things. - You stress the importance of double checking your setup to catch problems early on, but you seem to be undervaluing the utility of just pressing on and then cursing and screaming when you find the error upon completion. - Is "just a skooch" a metric or imperial measurement? :-) have been loving this series

@jimsvideos7201 7 ай бұрын

For some unfathomable reason I envisioned a wizard with a can of dykem in one hand and a suspiciously pointy wand in the other shouting *"I CAST LAYOUT!"* because that's how my weird ball of bacon works.

@guillermocarrillo3959 6 ай бұрын

“ Shut up, that’s why.” That is a great saying for a Blondihacks tee shirt.

@mikestevens8046 7 ай бұрын

Thanks for the variety. I look forward to your show every Saturday morning while having my coffee. Mike

@HelenaOfDetroit 7 ай бұрын

You did a great job, as always. Out of curiosity, would it have saved you setup time if you machined a little bit of the ends of the bore flat and parallel after marking them on the mill? I'm thinking you could maybe use the reference face of the machined foot to make perpendicular and parallel faces on the mill with enough material left over to then take it to the lathe. That way, you could use those milled surfaces to dial the part in and then finish the machining of those faces on the lathe to ensure concentricity with the bore. Just a thought, but idk if it would've saved you any time. I was just thinking it may have been easier, even if it could also seem a bit silly to cut the same surfaces twice on two different machines

@stephenbaker7786 7 ай бұрын

You crack me up with your “shut up that’s why”😂

@generessler6282 7 ай бұрын

Aaaaw shucks... I was looking forward to the explanation of the rotor-making process and then my hopes were dashed. 😢 You are a great teacher in that I saw the problem with the foot coming when you decided against the faceplate setup 😊 even though I haven't ever used a lathe. Thanks for your excellent explanation of all the details that still somehow fit in short-ish vids.

@JohnMGibby 7 ай бұрын

@32:57 "So you kinda have to know when to collet" LOL I see what you did there! 👍

@ToBeeOrNotToBeHoney 7 ай бұрын

ARGH I am not going to be able to sleep tonight! Good lesson to learn about remember that tapping may affect the part in multiple directions...

@MikeT 7 ай бұрын

Looks like a fun little project

@firebird8600 7 ай бұрын

Yay! It's Blondihacks time!!!

@warrenjones744 7 ай бұрын

Just goes to show you, go with your first hunch or something you know is correct, don't be lazy. It always bites you in the backside.(don't ask me how I know that!) Nevertheless as always, you managed to save the workpiece by thinking it through and figuring out what went wrong. I think what I like the most about your channel is you show these errors and how you fix them. For the beginner, less experienced hobbyist that can be so helpful. Heck for those of us that have been doing this for years, day in day out serves as a reminder to not cut corners. Cheers!

@simonfunwithtrains1572 4 ай бұрын

Excellent work, it's nice to see that your tolerance for errors when machining castings is much tighter than mine. Maybe I should up my game a bit?

@CreaseysWorkshop 7 ай бұрын

Oh cool! I just finished making one of these. There are a couple of KZfaq series on it but they all skip the interesting details of the terminal posts and the lifting eye. Also the end bells are clearly designed to be made on a four jaw chuck. I did the body casting on the mill with a boring head. That was very quick and easy to setup. I like the way you used your holes for reference. That’s an excellent trick.

@utidjian 7 ай бұрын

Excellent discussion of the compromises one has to make with castings Quinn.

@AndyCallaway 7 ай бұрын

I think I'll use that from now on... "Why didn't you prepare that report for Thursday's meeting?" "Because shut up that's why." "How come you're not going to work today?" "Because shut up that's why." 😆

@elizabethturner2421 7 ай бұрын

"...you kind of have to know when to collet..." [32: 58] I see what you did there. 😆

@JoggingWithForks 7 ай бұрын

Great video as always. Well shot and the narration is just perfect. There's a fairly simple solution to guarantee absolute squareness of the casting when facing the backside to length. Turn a sacrificial mandrel of aluminium between centres, match casting ID, hold casting on mandrel with half a drop of superglue. If you don't want to use superglue, if it's a repair of an already painted part for example, then split the middle third of the mandrel lengthwise with a hacksaw, drill and tap for a set screw to essentially pry the halves apart ever so slightly. This method does however not guarantee perfect co-centricity. The setup, if made correctly, allows for perfect squareness as well as ease of measuring length with a micrometer.

@joedyhicks9415 6 ай бұрын

I understand that one of the criteria of your channel is doing things with commonly available hobby shop machine tools but I tell you adding a small surface grinder to your arsenal would up your game significantly

@jclark2752 7 ай бұрын

I know setup is frustrating and tedious, but I’ve always admired your results. 🤓 This is most apparent to me in the disgusted faces I pull when watching the work of others… Perfection is eternally elusive, but I admire your determination to recheck time and again where others would accept far poorer results. Bravo!

@johnNJ4024 7 ай бұрын

I've wanted to built one of these for a long time now. Great to see you doing this video series!

@ThePaulv12 7 ай бұрын

Alright Quinn, I have to fess up. I didn't want to watch this vid because I wanted the switcher. Reluctantly I turned on, only to find it was absolutely fascinating. Sorry to doubt you (I'll go and put my hair shirt on as penance).

@raystevens1458 7 ай бұрын

I'm enjoying this build, it's reminding me of the days of leveling and aligning very large motors and pump shafts, always remember that shim stock is your best friend when reaching goals. Love your videos and have learned many tricks of the trade from you, thank you.❤

@roscocsa 7 ай бұрын

I feel like whenever the Walking Dead thing happens, it's not gonna be Ron Swanson, It's gonna be Quinn with the modern amenities like electricity and running water and a functioning workshop.

@mumblbeebee6546 7 ай бұрын

“Putting that indicator where our mouth is” - measured words, Quinn! 😂

@daveboatman4024 7 ай бұрын

I made one of these kits several years ago and it was a fun build. Since it is a generator, you can also turn it into a motor by putting DC current across the terminals. I have mine hooked up to a PM Machine steam engine and it runs a few LED lamps.

@oldfarthacks 7 ай бұрын

So, we should get a charge out of this video, sort of a current affair, a real gem of a joule, if I can field a few magnetic jokes. In other words watts up. Anyway, thanks for the video, this should be an interesting series. Good point on cleaning up, at some point you just have to say enough. I myself have seen full size machines where the casting did not fill in on the edges, leaving gaps of inches, so your model just reflects reality. I must admit Quinn, that I do so love your shutup that's why line. We have all been there and know well the feeling. It's funny how things work out. You went to all the trouble of defining the foot as the base point and in the end it would have been easier to have just done the bore and made the mandrel. Oh well, live and learn. I have a very old PM steam engine kit that I have been hauling around for decades, this has me convinced that I should make the bore in the cylinder and then tie everything else to that, even more so because I will be doing that on the lathe.

@Radiotexas 7 ай бұрын

I built one of these several years ago. Works extremely well. Highly recommend.

@AmateurRedneckWorkshop 7 ай бұрын

That was some clever trouble shooting. I will be back for part 2. Thanks for the video keep on keeping on.

@stephenjohnson6841 7 ай бұрын

Looks like another interesting and great project! Thanks for sharing!

@1885dr 7 ай бұрын

as the spindle turns, these are the trials and tribulations of machining

@jfirebaugh 7 ай бұрын

I've always been fascinated by home-brew power generation. I've seen some very interesting projects with powerful neodymium magnets. If you have a little creek on your property and the laws allow it, building a little dam and creating about 3' of fall for the water will give an impressive amount of power running through a hydro-power setup.

@hajom78 7 ай бұрын

I can google it but thats boring and anti social :). Is that ' a feet indicator? So 3' is 3 feet approx 0.9 meters?

@jfirebaugh 7 ай бұрын

@hajom78 yes, that's right approximately. 1 meter is about 8cm longer than 3 feet.

@hajom78 7 ай бұрын

@@jfirebaugh I have a creek at home, now I got curious and think I need to try this. I should be able to get 1-2 meters drop here.

@Tasarran 7 ай бұрын

You don't need fancy magnets, almost any motor can be modified into a generator... old washing machine, car starter motor, garage door opener...

@hajom78 7 ай бұрын

@@Tasarran Yea, just need to find an old motor. The last one I pulled from a washing machine was a brushless history, and probably not usable.

@davidwilliams1060 7 ай бұрын

I have this kit. Suddenly realize it’s not going to be as easy I thought. Thanks for the path finding for me.

@jamesbooth3360 7 ай бұрын

If you use pins or a stack of blocks to orient the casting in the vise (1st operation) you could make sure the thickness of the resulting base is visually the same on the finished casting on both ends. Also, if you don't have a long end mill for the spot face (2nd op) you could try a cheap drill bit with the point ground flat. I have this kit, but I haven't built it yet, so going to school with your build and an old build from Mr. Pete is instructive. Thanks

@dscott1524 7 ай бұрын

The ability to quit when achieving good enough was most impressive to us obsessive compulsive persons. That takes both wisdom and commitment. It can be difficult to accept less than perfect. Sigh. Not than I am saying Q is OCD, just speaking generally. Fun project. Cheers.

@spooneythebadger 7 ай бұрын

is that a Sprocket mark on your left wrist?😸

@marcfruchtman9473 7 ай бұрын

Thanks for the video. Looking forward to seeing this motor run!

@marcfruchtman9473 7 ай бұрын

Ah, yes... tho a DC generator is the same as a DC motor as far as I know, they have the same physical components and structure, the only real difference is how you use it. But, since the title does say dc gen... I guess I really should say, can't wait to see this generator working.

@stevetheengineer 7 ай бұрын

They used to use white or pink Dykem on castings where I worked that used to do big castings, showed up better than black or blue.

@greglaroche1753 7 ай бұрын

Great. I can’t wait for part 2.

@GillooTube 7 ай бұрын

I'm waiting for the next one with great impatience !

@manythingslefttobuild 7 ай бұрын

Nice small 'beginners' project Quinn, looking forward to the rest of it.

@halfdanknudsen6055 7 ай бұрын

That's why they call it a Call-It chuck! 😊

@raystevens687 7 ай бұрын

Well Gwen another great job for sure.

@mathewmolk2089 7 ай бұрын

Kind of remember Lyle Peterson making one of these a few years back and looked it up. Low and behold, there it was. - Check it out. - Not that you are not doing a top line tool maker job of it, but Mr Pete got it done a lot easier,,,,Yo, ,It's a friggin model motor/generator, Not a precision chronometer,,,,,,,still you are doing an outstanding job,,,,,and giving the customer way, WAY more then they expected.

@tinkeringinthailand8147 2 ай бұрын

Mmmm. Loved it. No.2 next. It's gonna be a late night but hey :)

@me3333 7 ай бұрын

I nearly rage quit and spiked my phone when I saw your cut off 17mm thinking it was a Snap-on but luckily I saw at the last second that it twas a Husky. Not to throw shade at Husky but it somehow seems less bad than cutting a Snap-on. 🙃 On the end result, perfection is nothing more than a more precise "good enough", there's no sense in driving yourself mad chasing perfection when good enough is perfectly fine.

@sportsman1824 7 ай бұрын

Great build as usual

@kendavis8046 7 ай бұрын

I think dynamos are forgiving on such a small discrepancy of the bore. You'll be running LED lighting and charging iPhones with no problems!

@mikehydroseed1282 3 ай бұрын

I just woke up and I’m drinking my coffee, after your first bore for the mounting hole I tried to blow the shavings away on my iPad. Wow, that’s bad.

@tommyt2854 7 ай бұрын

Thanks. Always learn something from your videos and enjoy your touch of humor.... "because shut up" 😄

@edwardhugus2772 7 ай бұрын

When you were trying the 4 jaw chuck, I guess you didn't hear me shouting to you to use the surface plate. Just the constant Back and forth getting plane (a) perfect to throw it off while getting plane (b) aligned was enough for me to use the angle plate. Great job getting it done! RecognizingTHAT problem with your process of frequent checking in itself shows why measuring often is so important. Great Job cant wait to see you use it!

@theseldomseenkid6251 7 ай бұрын

I really appreciated the detective work. Thanks.

@julias-shed 7 ай бұрын

Interesting little project 😀

@NightsReign 6 ай бұрын

32:57 *_"You kinda have to know when to collet."_* Unintentional machinist's pun? 🤔

@paulthomas3782 7 ай бұрын

Good call, knowing when to quit before it all goes south Cheers.

@PersonalStash420 7 ай бұрын

Watching this on Thanksgiving evening. . I have never seen your channel and I have no idea what you are making but it sure is interesting. I bet men are way more impressed with your abilities than your average woman. Just saying i'm impressed.

@sheep1ewe 7 ай бұрын

Thank You! i hawe a turbine/generator kit from Cringle engineering (those kits where really awesome, but i don't know if he make them anymore, i am so glad i got one! The design it just outstanding compared to those Chinese barstock things) i really want to give a try on my "new" late whan it is installed!

@workshop-adventures163 7 ай бұрын

Firstly, thank you for your videos.... i love them. Your fix for the casting base was incredibly cool. I'm only just really getting into hobby engineering, and I find the fix for error, particularly interesting!..... errr maybe coz I'm still making quite a few of them idk :)

@billofalltrades2633 7 ай бұрын

Great video, as always a great learning experience. ❤

@bilbo_gamers6417 7 ай бұрын

Woah, I've been wanting to see something like this for a long time. It's so hard to find details about making your own electrical generators lol.

@AdamZMouchnic 7 ай бұрын

I love the sound of cast iron machining.

@metalshopwithtroy5755 7 ай бұрын

Very good video quinn

@3rdaxis649 7 ай бұрын

Lots of lessons learned in this video for sure:) You could have, once you taped the part parallel on the mandrel, then reset the square collet holder in the vice.

@lambda7652 7 ай бұрын

I would have started with the with a different reference surface. Can you go more in detail about how to chose a starting reference for a casting?

@chevyfahrer 7 ай бұрын

thanks,thats on my todo-list for my steam engine for months.Nice to get a light asskick :)

@markmonroe7330 7 ай бұрын

Excellent presentation. Thank you. A really amazing job and explanation on getting the bore square with the base. Incredible stuff and I really learned a lot. That kit from PM can be bought raw ($59) or fully machined ($109). Would be a lot of fun for you to buy both kits and then compare your machined unit to theirs. I see a lot of their kits come both ways. That said - I wonder how the hourly rate works out when the fully machine kit is only $50 more not to mention the cost of the tools and machines needed.

@paulmorrey4298 7 ай бұрын

Thanks Quinn

@TheDistur 7 ай бұрын

Having worked on a few old machines, the casting and the machining often don't line up anyway. But I get how making it look good feels good.

@VoidedWarranty 7 ай бұрын

Tip for visually asthetically centering in the lathe: sharpie in a tool holder, draw a circle

@paulkinzer7661 7 ай бұрын

I'm eager to know what you plan to use this for, and how you plan to power it. Very cool project!

@paulsto6516 7 ай бұрын

Good show!

@robertberger8642 7 ай бұрын

Good video!

@Rustinox 7 ай бұрын

Looks like a fun project. When finished, you will generate electricity using steam :)

@user-sm1re8xm5p 7 ай бұрын

Did you consider mounting the casting on the saddle and using a boring bar between centers ? if so, why did you prefer your approach to that one?

@ValiRossi 7 ай бұрын

Stepper motors make great generators BTW.

@mathewmolk2089 7 ай бұрын

Didn't know that, Thanx

@29chevbolenschannel40 7 ай бұрын

Very often things don't go to plan and the ability to think and correct for what went wrong is invaluable as you continually show in your videos. Could the housing have been secured a bit tighter on the mandrel by stacking 2 or 3 fender washers (to make the clamping effect less springy) to retain the housing on the mandrel?

@9z4clb 7 ай бұрын

Very cool indeed

@alanharney5278 7 ай бұрын

Quinn you probably know that Mr. Pete built this dynamo kit some time back. I really enjoyed seeing the differences between your approach to the work and his. Lots of similarities too. I know the end product will be the same (i.e. awesome). Thanks for the video. PS - sorry about the Flames not being fabulous this year. But hey! At least the Edmonton Oilers still suck. 🤣