*Help* Milling turbo manifold

[Tim.duncan]

Hey guys

just trying to mill the face of a turbo manifold after i welded it, clamped it down the best i could and supported as much as possible. Getting really bad chatter on the left hand side (in the pic)

any tips on how to hold it in place better? was considering welding tabs onto it somwhere

any and all help would be great

[orange32]

Its pretty difficult to get a rigid setup like that. I do a lot of this stuff at work, usually only the turbo face though (head face normally gets done on a belt sander.

Some things to try;

- You can try and take really small cuts in that area with a freshly sharpened tool and file and emery it to make it blend into the rest of the face. As long as it is flat it shouldn't leak.
- Chamfering all of the edges works well for keeping the tool sharp and cutting nicely as does a bit of cutting fluid (wd40 or kero are fine).
- Using a lead hammer or similair (dead blow) and rest it underneath the flange while the tool is cutting on top. You may be able to soak up the vibrations enough to get the finish looking alright.
- If its just that section, stop the cut before it reaches that part and add some clamps to the flange where you have already passed.

Most of this stuff probably wont work terribly well. If you plan on doing a few of these, I'd suggest investing in a large vice and an angle plate, they can come in handy for a lot of jobs.

[sundee]

was going to suggest point 4 above

[Jaredo]

Make a box around your current set up > fill box up with sand > add a little water to sand

Con:
How to clean up sand after

[Casey-G]

surface grind it..

[jdm_510]

try using a boring bar with carbide insert and fly cut it take light cuts and plenty of coolant. also make sure tool is as sort as it can be to prevent any flex if not just draw file it smooth

[ThePotatoSmasher]

You'll probably find that middle clamp at the front isn't actually clamping down on the manifold, the bolt should be as close to the workpiece as possible.