Nickel and diming....

This project has been nickeling and diming me for years on my time but now I figured I should just hammer down and build it because I have the tools to do it...

When I started this concept a few years ago with my brother, I knew I could finish it quickly and it would turn out like the Gravity bike and everyone would get stoked but the more I ran with the concept and split off with my brother the more I realized I was becoming a machinist for stuff but I was still missing the CNC part to really make my parts stand out...

I can machine anything by hand to a point but it often requires special attention on things like finish work because its not a perfect smooth finish but cnc offers you a showcase of the machining effort you have put in to it, its why people love aircraft parts and crazy cnc bicycle and motorcycle parts. Theres something about leaving the raw machine marks all over it and not polishing it to a glass like finish that sometime once anodized looks like plastic...

The more I left it sit on the frame table the more it would bug me looking at it but my customers come first and its not to say that I am short on work, what you see on my blog is about 20% of the projects I can show without getting sued or thrown in jail, so it took the back burner... maybe not even the back burner, maybe almost refrigerator with a cover over it...

The day came where after some sweet wheelin and dealin I scored the CNC Bridgeport Boss 10 and did the retro fit to a brand new drive and PLC ready to take on the most complex jobs, then came the teaming up with Autodesk's new company called HSMworks which links to Solidworks and Inventor for CAM ( see the old blog posts for more details) and with those 2 things the door finally opened on making crazy parts a reality... No paying for machining that I can't afford... I would do it myself and let it run all night on crazy parts.

   This is the project my brother and I came up with to build and I have been running with it since it was sketched... Lots still to come but day by day this thing is coming together....

                              

 

So come along with my machining adventure in the next weeks to see this beast come to life...

Machining aluminum softjaws to hold a expanding mandrel

plus it makes a perfect origin 0,0 right away after cutting 

I wouldn't call them softjaws really because it would still hurt if you got them thrown at you, but in the machining world anything made of Aluminum is called SOFT... ha, whatever....

These are the hub blanks Liem made on the Lathe using HSMworks Lathe Cam software

As you can see the one side of the hub was done but the other side needed to be hollowed out, plus I wanted disc rotor mounts and because the Haas Lathe we did the work on didn't have live tooling we were stuck doing it this way.

This is the expanding mandrel in my hand

 

Perfect fit ready for the hub.

Here we go... clearing it out with a pocketing cutting feature.

I didn't use a big end mill because I didn't want a lot of cutting pressure to cause it to possible spin or move on the mandrel...

Don't call me a pussy

 

switched over to a long 12mm ball end mill with relief to do this deep cut

Looks great but it was ringing like crazy so I put this wrist band I got from Autodesk University on it to reduce the chatter, perfect!

VIP status...

check that out!!!

With the mounts for the floating rotor!

On to the next parts

Dropouts on this bike are a wild one too, if you scroll up to the 3d model of the bike you will see the crazy machined dropouts so here we go... making chips.

 

cutting away..

I really like the look of ball endmilling the radius in to things and also the radius on these parts varies so theres no way I could use a normal tool

At the end I did a webbing and the part was held in by a few pieces and then I cut it out with a aviation shear... easy and fast and then I made another side in a mirrored image.

Thinking time... Sometimes its easier to draw and look at a part then using crazy modeling software.

I feel that a lot of newer engineers don't understand how important this is... you don't always need to sit and stare at the computer to make parts, go out in the shop and smell the oil.

Surplus Lockheed 6-4 Titanium

Blocks of it ready to become a king pin steering set up for the cable steering front end.

I really freestyled this part, I hope it works...

Roughing Titanium is a learning experience

If you don't machine it a lot it can be very costly if you mess up...

Called up Tom at Ox Tool to make sure I had everything right, hes rattled off the numbers on the phone by memory....

.375 depth of cut - 8 ipm at about 900 RPM with a .120 step over with a 4+ flute endmill 

He knew it... maybe he has done it before....

Side one getting some ball endmilling

and some clean up in the bearing pockets, you will see in the next weeks how this part works. 

it worked out pretty good, have to debur it and do some finish work on it but I think it will work to get the bike on the ground as a roller, just think this could have been some crazy part at Lockheed... but they were going to scrap it so I put some life back in it by making a mini F22 Raptor style steering link part... Kind of like Lockheed Skunkworks around here...

 

I got so excited about aerospace stuff I had to make a cart....

Built this beast in a few hours out of the junk laying in the off cut pile next to the saw

MLS Aerospace division just got a fresh new cart, off to powdercoating.

 

1938 Schwinn New World

Some times when I look around my shop I see things I love but I feel like if I had to move I would rather not have to move all kinds of unnecessary stuff and sometimes its good to keep the stuff moving thru your shop and the money flowing for the next project.

This time I decided to part with my loved 1938 Schwinn New World... This beast started its life in the West Side of Chicago made in the hand built side of Schwinn where the Paramounts and Superiors were brazed.

Then it was sold to someone in San Francisco in the late 1930s, it spent most of its life in the bay until it somehow ended up back in the midwest in Madison,Wisconsin for most of the 1980s, until I bought it back out to the bay in 2010 back to where it started its riding life . Now its on to its new life back in the Midwest in Nebraska and the story goes on.

Hope he enjoys it.... I know his back won't with those bars I made for it.... But that stand he might be stoked on... 1930s style MLS repair stand ....

Out of hiding for a bit... Good to be back...

The last months have been a wild ride that I wasn't expecting....

Its been just a good old around the clock of building rad stuff to make people smile... My year long full time term of working at the Exploratorium Science Museum ended the other day and but was kept on as a builder/designer part time to keep the fun going so I am super thankful they see my love for building the joys of science. The coolest part of that museum is when they find people like myself and others they really like they give you freedom to do other stuff without any pressure, its really what makes the place such a special place to me and what keep me wanting to bring new concepts and ideas to that place. They see the true benifits with having me more as a freelance dude without the pressure and they really notice the results when they get my true love of my craft in every project I work on for them.

The last months I have also been working on a TV show for a major network as a lead role as a designer/fabricator designing stuff to make peoples lives better that have lost limbs - thats as much as I can go in to detail about ...

The other projects have been for Red Bull and all the events they have been hosting such as the Training Grounds Media events they have been holding, which are Red Bulls enter in to the Esports Online gaming such as StarCraft 2 and other games... They have really just given me freedom to be creative and design some of the most rad trophies for them. The big event for me this year is the America's Cup sailing race, where Matt and I will team up to build one of the most rad trophies Red Bull has seen for their Youth's Cup race using the AC45 boats Red Bull bought... Stay tuned its going to be so rad.

Check out some of the projects ... heres some pictures

Welding away on the Exploratorium's " Bay Window Exhibit " 

There is 5 of these in stainless and 3 in mild steel... 

Its a lot of work... thats all I really want to say....

After the 2 pieces of glass, inner race and bearings are put in the mud samples are put between the glass and its closed up. Once installed on the railing the water is put in to the exhibit and then....

You give it a spin and you get to see how rocks and sands settle from the river deltas in to the bay...

Heavy rock lands first then the swirl of light sands show how it travels.

This photo is Erik Diamond " El Jefe " giving it a spin without the covers on it, so we can see all the bearings spin freely. Overall Adam, Shaun, Erik, Herb, Brice and Jesse and who else I am missing really nailed it with this exhibit, it really fills the side of the museum with some rad learning fun projects. 

After hours I have been working on my Espresso machine

I have found that its not worth risking it by using hole saws and other cutters trying to cut holes in the spheres because of damage, so this is how i do a lot of the bigger holes about about an inch in size. Don't risk your hands or body by trying to drill it with the big sizes. Gabes figure pictured in the top left. 

When setting up the small stainless steam generator I purged it with argon and used lab clamps for the torch and did it on the welding positioner. The foil is set up to cover the other 2 inch NPT fitting but not to hard because i want the argon to escape slightly so it doesn't pressurize and blow out the weld. 

I machined some parts for holding the gauge on the stainless steam ball, still got a lot to do but its a start.

Went out for a ride with Steve Pete, Greg Minnaar, and RatBoy Josh from the Santa Cruz downhill team

Gabe driving me to Oakland Airport so I can fly to Hollywood to film the TV show... 

I feel cool on these days....

The shop truck is like a limo that leaks gas and is missing windows... 

I have been filling orders for Exile Cycles Gas tanks and Gabe has been watching and following along on his personal projects. Hes building a tail for a cafe racer out of a little honda gas tank. 

Its 4 AM does your mom know where you are?

Mine does....

CNC ? yeah right.... I can make it from hand almost just as fast...

Getting wild on the Excello Mill with a big block of aluminum 

Throw it on the old K&T Model H mill for a clean up around the outside

In under a week with the help of Matt Carney on the computer and Seaport Stainless laser cutting we had a custom Giant Hard Drive Trophy for Red Bull Training Grounds in Santa Monica

I weighted the platter disc so it always had the logos perfectly level 

I was so stoked when the kid that won it held it and the logos stayed correct.... Everyone was stoked...

So they asked if I would do the next event in Florida 

So this is what Matt and I came up with in a afternoon .... The event is this weekend so I will show more pictures soon

Red Bull Training Grounds - Orlando, FL

Built this trophy with Matt Carney in under a week turnaround... Custom Billet aluminum keys and full sheet metal construction ... sick !!

A new customer of mine is Boasted Boards

I have been running the prototype production of their wireless Electric Skateboard...

Its so rad.. I got to take it out for a afternoon .... Talk about fast !!!

.000 on the money.... sheet metal parts ! 

I bailed out to Cheyenne, WY the other day to go visit Union Pacifics Steam div. 

So rad...  

Why wouldn't you jump the fence and climb UP's BIG BOY.... 

Back from World Cup Mountain Bike Racing,  Greg Minnaar, His lady Laila , Gabe, and myself made up some good old Sushi... I had to take this photo to show Gregs family and friends hes all grown up and can clean up the kitchen all by himself...

Figured I should learn to make a worm gear....

its hard.... If you want to waste a full day and lots of money on tools I will tell you how to do it...

the Plus side is ... My cold saw is fixed now...

I will have more details on it soon but this is one of my new shop aprons I designed with the help of John from High Above Bag company out of Seattle, WA. This bad boy is so damn sick with the removable pockets and all the goodies... If you really need one... Send him an email... I will be making a post about the design and details about it and how to buy it but if you can't wait... hit him up... Best apron you will buy, the quality and details are so well done....

Espresso boiler time...

Tom the owner of adams and chittenden Glass in Berkeley made me such a rad Lab style sight glass.

These guys make some of the Gov. Labs most crazy glass experiments pieces. Lucky for me, Tom is a huge fan of the Exploratorium and also just down the street from my shop, so he was stoked to help on the project and make this wild glass tube for the water level. 

Top view of the details of the glass and also the fab work

Steam generator... Figured I can get it up in the 50+ PSI safely ...

But who knows... I am just a welder not an engineer....

This is the table I started building for the machine...

Don't ask how my brain got on this one. 

Sometimes it works in a wild way... All freestyle design

Ryan at Seaport cut it for me off some drawings but who knows what it will look like

0% CAD on this project... All in my brain...

Still figuring out how to take a picture of the table... 

Just wait to see how wild the table is going to be ...

Never seen anything like it...

Well enjoy some of my joys in the last months.

Theres more to come but I figured all the piles of emails asking if I was dead or gave up on the MLS site forced me to do some updating and letting you all know I am still here turning the handles making chips and sparks..

I am not an Artist .... I am a machinist....

It happens a lot....

People call me an artist and think I live in a studio....

NOPE.... Wrong.....

I am a machinist that lives in a cold machine shop that smells of coolent...

But every so often I gotta venture in to the art world and throw it down for the kids using some metal...

This time days before the opening, I was asked to make a mini art exhibit to be placed in to the wall, that would serve as a mini art gallery for people to peek in to a hole and see something fun in miniature

( the cool part is - the small window in the wall is a lens that makes the mini gallery appear even smaller, so it looks to be 2x2 inch, but really is about 6x6 when you build it.)

The Compound Art Gallery located in Oakland asked me to do the wall piece, so like normal I waited until the day before the show and then had to rush the concept...

So heres what I came up with in about 2 or 3 hours, didn't even take any pictures I built it so fast, sorry...

So the idea was to make a small stainless steel  cat that said " ART " so I could say I make art...

I designed the tail to make a loop so it can be put on your key chain without it falling off

With the 1 hour old design ready for the laser.....  about 3 minutes later 50 cats were cut....

To the shop to build the box and hammer it out.....

This was the finished product...

A mini power plant that is powered and is designed to be fueled off of " Art Pussy " 

Its designed using Free Range Vegan Steel so I can brag to Artist Chicks about being hip.

Overall .... As it didn't sell at the opening and offended about 40 people, I think it was a success !

Think more then anything I was stoked on the laser drop from cutting the cats...

Was able to make a sweet American flag on my weld shop door. 

That is the Puritan Stitch machine next to it... So damn rad ! 

All this art made me get wild and make some personal projects like this one....

I call it " Light Bulb Scrap "

Its a symbol of an American's boys dream to take over the world but is tragically denied due to fiscal troubles..... Its really to intense to try to describe on my blog.... If you would like to purchase this or other pieces described on this blog post contact my agent..... 

The unknowing drive..... for something......

My life is an odd one somedays and leads me in odd way.... I think living day to day is the key to my sucess and not being alarmed by any suprises that I encounter because of this poor planning....

But on the other hand it makes for a fun and exciting road with so many corners you can't see around that your bound for consitant surprises with lots of ups and downs....

I love my craft and my dreams.... Sometimes I feel like a snowplow pushing anything that gets in the way to the side and moving forward...

 Its stressful....

Sometimes I see things get pushed to the side that I feel could have helped me keep in control or move forward faster but my brain is this agressive plow born to push and make new tracks.... where those tracks lead to on that crazy road is still unknown, as life is full of surprises.....

I set a bunch of goals every year and write them all down on a piece of paper, then cover them with clear tape and put them on my wall leading to my bed room so that I have to look at them everyday....

 This shitty looking piece of yellow paper covered with written goals for that year looks really nasty on the wall, but is totally needed ... I hit a few goals and they made me smile.

Time to set new goals for 2013.... Holy shit talk about raising the bar for myself.... I slept on average about 4 hours a night this year just to make some of the goals that I feel are totally worth it. This next year for the MLS company and myself personally are going to be setting the bar even higher with some bigger projects that are going to twist some brains...

Get ready ....

When I get super busy working on stuff that feeds my shop, I sometimes forget about why I do this stuff and the need to stop take a moment and do something for myself....
Sometimes it takes someone to tell me that... Someone I actually listen to and respect..

Tom Lipton is a dude that I respect.. Hes done the time in the shop and knows his shit! Its good to see these crafters out there and know that after 20+ years in metal crafting you can still do the same thing for your job as you do for your hobby and not get them all mixed up. So when he told me, get back to building that espresso machine because you need to hammer it out and finish it, he was right, sometimes I need that kick in the ass from someone that knows its value to remind me I got it I just gotta hang in there and finish it.

Some background on Tom ( if you want more info check out the rad blog "Nothing to strong ever broke "). Hes one of the best metal crafters I know and the US government thinks so too and thats why hes in charge of some big concept projects at one of the coolest US Gov. labs.

His metal working background leads back to making some cool stuff, such as the first prototype Independent trucks for skateboards, to crazy machines that produced products that are most likely in everyones houses reading this. Doing 20+ years of work in just about every industry leads to some really cool storys too, some of these are on his blog... I first heard about Tom while doing work for Clorox and all the stuff he and the crew built, so like expected it was my job to hunt him down and ask a million questions about making stuff...

His blog might give MLS a run for its money.... We might have to get more half dressed girls around the shop to get the hit counter going again...

The espresso machine has been my personal project for the last months.... I am not going to show you all of it yet because thats some of the surprise in it... But how about some teasers.

All the sweet USA made parts

from left to right

Copper - USA Pen - 800 watt heater - theromstat - high temp float switch

I go off of whats in my brain and what shape I want as I am spinning it

 

Because copper is such a crazy conductor of heat its super important to get rid of a lot of the material so it doesn't require so much amps to weld and also just reducing the weight and making more volume is a bonus for the little extra time spent machining it out.

Using a big 1" NPT tap, I put the treads in for the heater.

Notice using the tail stock to hold the tap straight... Just a tip... Thats why they put the dip on the end of the tap, just for the exact reason.

The spun copper parts of the boiler are 8 inch diameter but I don't have a hole saw that big so I will have to make a bunch of notches with the biggest hole saw I had. I love doing this work on the K&T mill.

still in the quest for more material removal ....

I decieded to mill out.

I did a quick mock up of the legs and everything to figure out where the best place for the heater,float and stuff would be before making the cuts in to the spun parts.

Windows in it and LED light ports ready to go.

 

One problem that welders do all the time

when preforming very important welds....

 

CLEAN THE DAMN FILLER ROD !!!!

 

Good way to mess up a million dollar project... or make something fall from the sky and hurt someone...

 

CLEAN IT !

 

 

Part safety is very important when you get to a point like this on a project..

One drop of the boiler and your done...

Tricks I have learned over the years in medical and aerospace work, is working inside shop traveler boxes so you don't have parts roll off your bench.

Tom has tricks too for doing small stuff by working in clear bags so you don't loose screws or small parts.  

I do a lot of the tacking and fit up with the part in the blue box for safety.

 

Old Timer photo of the copper welds

 

Getting stoked on it....

100% USA made so far and proud of it.