Cutting a squish band without a lathe. Hilbillys welcome!

[Wagnerwerks]

I just realized this may be old news, but it's new to me...lol


So I came up with something today and I think it's worth sharing. While I was working, I was trying to decide how to cut my squish band in one of my 27 or so current saw projects. The base on this one was easy as it has a flat bottom. The inside was a bit more complex. I know sanding them works well, but it takes a while and I'm not patient sometimes. I came up with this little apparatus. All I used was a sawzall, an old sawzall blade, epoxy, a grinder, and a worn out piston.

First I cut a slot through the top of the piston. I then cut a chunk of saw blade that was a little big in the slot and stuck out the top an 1/8 or so of an inch. Then epoxy the inside and out to glue the blade in the slot. After the epoxy dries, carefully grind the blade nice and flat with most of the 1/8" still remaining. Also grind the edges flush with the piston. After it looks nice and tidy, bevel the blade on the grinder ( I used my chain grinder because is has a nice thin wheel. ) so it makes a "cutting edge" going opposing directions on the top. (Hopefully the pic will explain better than me.). I used a chisel in the bottom of the piston to turn it and cut the band. It's crazy quick and looks great. Here's some pics.

 

[Wagnerwerks]

And the final product? Here it is.... There is a tiny bit of chatter, but I think that's because my blades are sharpened at too much of an angle. A light final sand should be all it needs.

 

[Wolverine]

You better apply for a patent... quick. The only thing that let me down (a little) was the lack of duck tape.

Seriously though

 

[Wagnerwerks]

I just hope it helps people out. I love to build crap.

I did have an idea for an improvement. I think if the blade was cut in more off center it would cut down on chatter.

 

[wcorey]

Necessity is the mother of invention...

Chatter seems to be an issue to some degree with most mandrel style squish cutters.
Playing with rake/angles sometimes can minimize it, you want the least you can get away with and still be cutting.

I find being very smooth and even handed while cutting is more the trick, once the chatter starts it wants to get worse not better.
Also mount the cutter in a vice and spin the cylinder around, seems easier to apply even pressure that way.
Find the treemonkey video if you haven't seen it.
Try not to take too much off at a time... if the chatter starts to get bad, you can sand it down a bit then cut some more.
In the end, a final finish sanding is the best remedy.

The blade may be just too narrow and digs in too much, you might have better luck grinding down an old flat file.

 

[drf256]

Great job WW

 

[WKEND LUMBERJAK]

I just realized this may be old news, but it's new to me...lol


So I came up with something today and I think it's worth sharing. While I was working, I was trying to decide how to cut my squish band in one of my 27 or so current saw projects. The base on this one was easy as it has a flat bottom. The inside was a bit more complex. I know sanding them works well, but it takes a while and I'm not patient sometimes. I came up with this little apparatus. All I used was a sawzall, an old sawzall blade, epoxy, a grinder, and a worn out piston.

First I cut a slot through the top of the piston. I then cut a chunk of saw blade that was a little big in the slot and stuck out the top an 1/8 or so of an inch. Then epoxy the inside and out to glue the blade in the slot. After the epoxy dries, carefully grind the blade nice and flat with most of the 1/8" still remaining. Also grind the edges flush with the piston. After it looks nice and tidy, bevel the blade on the grinder ( I used my chain grinder because is has a nice thin wheel. ) so it makes a "cutting edge" going opposing directions on the top. (Hopefully the pic will explain better than me.). I used a chisel in the bottom of the piston to turn it and cut the band. It's crazy quick and looks great. Here's some pics.

Excellent

 

[Lee H]

Nice job, Very creative.

 

[jmssaws]

I've cut chambers and bases all kinds of crazy ways,make no difference how you get there just so long as your there.

 

[WKEND LUMBERJAK]

I just realized this may be old news, but it's new to me...lol


So I came up with something today and I think it's worth sharing. While I was working, I was trying to decide how to cut my squish band in one of my 27 or so current saw projects. The base on this one was easy as it has a flat bottom. The inside was a bit more complex. I know sanding them works well, but it takes a while and I'm not patient sometimes. I came up with this little apparatus. All I used was a sawzall, an old sawzall blade, epoxy, a grinder, and a worn out piston.

First I cut a slot through the top of the piston. I then cut a chunk of saw blade that was a little big in the slot and stuck out the top an 1/8 or so of an inch. Then epoxy the inside and out to glue the blade in the slot. After the epoxy dries, carefully grind the blade nice and flat with most of the 1/8" still remaining. Also grind the edges flush with the piston. After it looks nice and tidy, bevel the blade on the grinder ( I used my chain grinder because is has a nice thin wheel. ) so it makes a "cutting edge" going opposing directions on the top. (Hopefully the pic will explain better than me.). I used a chisel in the bottom of the piston to turn it and cut the band. It's crazy quick and looks great. Here's some pics.

What are you using for your handle?

 

[Redfin]

What are you using for your handle?

" I used a chisel in the bottom of the piston to turn it and cut the band."

 

[Stihl working Hard]

Awesome job therelooks great

 

[Canadian farm boy]

This is really a cool idea. Best part is that it works and works good. I'm gonna have to give it a try.

Anyone got any ideas about how to cut the base without a lathe?
I've sanded a cylinder base to help tighten up squish but what if I want to take .030" off? I'd be there for days sanding. Lol

 

[Brewz]

I have been planning a dual purpose dead piston
slotted to hold a HHS cutter that can be removed and the top fitted with emery.

Personally, I am never in a rush when cutting. I would rather do it slow and accurately..... not saying yours wasnt.

I made this with an old piston and it worked well.
Just chiseled out slots for the wrist pin housings and it hammered in tight. Took .010 out in a few minutes but I think if I needed to remove more, your idea of the saw blade in a slot would ensure a square squish

 

[huskihl]

This is really a cool idea. Best part is that it works and works good. I'm gonna have to give it a try.

Anyone got any ideas about how to cut the base without a lathe?
I've sanded a cylinder base to help tighten up squish but what if I want to take .030" off? I'd be there for days sanding. Lol

I took .060" off the base of a slantfin 044 jug trying to get the exhaust down because of a gouge at the top of the ex port before I had a lathe. Measure all 4 corners, cut a 50 grit sanding belt in half, and, rotating the jug 90° each time, slide it across the belt. Took me an hour and a half.

 

[Mastermind]

Great idea. Before I was brave enough to mount a jug backward in the lathe, I always cut squish by hand. Good job.

 

[stihl_head1982]

me likey

 

[Wagnerwerks]

I have also used the sandpaper method, but the one thing I liked about this is that I can do a ton of them and not lose the sharp nice corners. Soo... no changing paper.