Duclos Gearless Ep. 4

In today’s episode, I’ll start with some finished parts.

The push rod is made out of cold rolled 1018 mild steel.

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The two bearing blocks and the base plate are finished as well. They are made out of 6061 aluminum.

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Up next, we have what Phillip Duclos calls the pillar shelf. It’s main function is as a guide for the push rod.

It has a deep slot, with a depth of about 3/4 of the materials thickness, where the push rod will ride in. Using cold form material as stock, I was worried it would distort the work piece from the internal stresses while cutting the slot. So, to keep it accurate I proceeded as follows:

First, I roughed out the slot: I left about 0.5mm on all surfaces to be cleaned up.

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Checking if it distorted with a beveled straight edge, we can clearly see the “day light” shining through…  well, we saw that coming…

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Next, milling the back surface, which will be our new datum.

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Front side again, finished the face and the slot.

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Next, I surfaced the top, and finished one side.

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Repeated on the other side with finishing to thickness and length. The two holes for mounting it to the pillars are drilled. The small slot is for clearance of the cam roller.

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A hole for a set screw is drilled (Tapping will be done afterwards on a hand tapper).

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…and finishing the part with chamfers.

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Finished part.

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