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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Feb 24, 2011 - 09:37pm PT
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Came home from work today and.....
They're Here!!!!!
249 drills and collet nuts + 50 collets. I must say they look great.
and....
250 lbs of raw parts and a fat UPS bill later, they are finially here.
I have enough collets to have 50 ready to go as soon as the grips and wrenches arrive. I think I have found an epoxy that will work, just takes a while to cure and I should be able to put the grip on the prototype tonight....field testing over the weekend.
As I start to build them I will post up some more pics on the process. I defanitly have my work cut out for me. Still need to wait for the other stuff to arrive to factor in the shipping costs.
Thanks everyone for being paitent...Still a lot of work to do but this is a big step.
Luke
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utahman912
Social climber
SLC, UT
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Feb 24, 2011 - 11:15pm PT
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woo hoo!
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PhotogEC
climber
In front of my computer
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Feb 25, 2011 - 04:22pm PT
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"Drill porn" is right. Looking good!
--Eric
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SteveW
Trad climber
The state of confusion
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Feb 27, 2011 - 03:50pm PT
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Bump for Luke!!!1
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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Mar 5, 2011 - 01:58am PT
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Well we have incounterd our first hang up in this process.....
The production drills that are sitting in my shop have a major problem with the depth of the collet bore (major by metalworking standards).
I had a chance to get out and drill over the last few days with one random one I selected for myself out of the batch. It worked flawlessly until I tried to remove the bit. Drill bit was stuck in there.
I took the collet nut off completely and still could not get the bit out. I thought it was an issue with an old collet I used and after 30 or so minutes in a vice I finially got the bit out. Here is what happened.
When the Machine shop programmed their machine for production, there was an error on the depth of the hole for the collet. They overshot the hole to much and the bottom of it was not where it was supposed to be (can barely see with the naked eyes and could not tell before the drill was used). The was causeing the drill bit to act like a dowel pin and wedge itself into a taper.
After a long session with the calipers and a real nice day of being on the phone the shop and I came to a conclusion and thought that it would be best to have a new set of drill bodies made. We could just slam a pin in a take up the space, But I want to be able to deliver a product that has no flaws or "may work", especially after all the time I have put in it. I am keeping the collet nuts as they are correct and the collets. The shop ordered new material today and I should have a lead time by Monday.
So what does this mean..... It is going to add more time until they are ready to be assembled and shipped. They were not too psyched about their error believe me. They tried to think of every solution before having wasted all of the time and materials. I wish I could keep them and figure out a way to make them work, but the are all going back to them on Monday. They did stand behind their word.
Really Sucks as we were getting real close to finalizing everything and the grips and wrenches should be here anyday.
I just wanted to thank everyone in advance for being paitent. I'll post up info as I recieve it.
Luke
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HighTraverse
Trad climber
Bay Area
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They should have checked dimensions and finish on the first piece as soon as it came off the CNC. Sorry they had to eat the lot. Hope they learned something.
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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Mar 5, 2011 - 02:08am PT
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I agree, I asked them to pull the first one off and send me a picture so I could see the insert and correct chamfer (you would think that they would mic the thing). Next e-mail came quickly and was an invoice.....I think that they and Myself have had better days.
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Captain...or Skully
climber
The Seas of Stone.
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Well, that's kinda how it goes... I would've assumed that the 1st piece out would be inspected before a production run.
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PhotogEC
climber
In front of my computer
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I would've assumed that the 1st piece out would be inspected before a production run.
I'll bet they do on the next run....
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bubble boy
Big Wall climber
topanga, CA
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I'm getting psyched! Thanks for all the hard work.
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John Mac
Trad climber
Littleton, CO
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Sometimes you just have to wait when QA is involved. I'm sure everyone here appreciates the effort you are putting into this project. Hopefully the shop is not going to charge you for the second run...
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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Mar 7, 2011 - 10:30pm PT
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Thanks everyone. They are chopping the stock for the second run. They are not charging for the second run (they stand behind their word, they will make them correct. I am overnighting them 4 drills out of the production run, and boxing the rest up tomorrow. They are going to insert a pin in the bottom of the 4 I am sending them and shipping them back for me to try out.
They are still running me off a new correct batch of 250 which everyone on the list will get.
I just want to see if this error can be corrected and avoid a bunch of scrap.
Who knows. I know that the new batch will work if they are done correctly this time.
Thanks.....I may send some of the ones with the pin in out to people just to try as I am going to get really busy with these when the correct ones arrive.
Luke
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Damien
climber
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Thanks for all your hard work Luke, they're looking sweet!
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adatesman
climber
philadelphia, pa
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Hey Luke- I've got a print for the original Hurricane here (which I think was posted in one of these threads, but damned if I can find it anymore...) and I'm not seeing anything that would cause that behavior by simply overshooting the depth... Having the straight part of the collet bore undersize, sure, but not having either of the tapers further back (which would simply cause uneven clamping of the collet and reduced holding power) or the flat at the bottom further back (which would just let the drill sit deeper.
Perhaps if they overshot with the initial drilling op and happened to use the same size drill you're working with... Hmmm... Yeah, I can see that happening. IIRC there are 2 sizes of drill/collet... Does it happen with both or just the one?
If this is what's happening, you could likely fix it yourself on your lathe. Simply mount a carbide endmill (has to be carbide on account of the heat treat on the holder, and I'd likely use a 2 flute rather than 4 flute) in the tailstock of your lathe (use a MT->endmill adapter, not a drill chuck) and gently bore it out. Print I have has the bottom of the socket at 0.397" +0/-0.002" (I think... hard to make out), which is just over 10mm (0.3937", or better yet 10.05mm / 0.3957" if you can find it). Gently crank it in until it touches the bottom and then back it out. Unless they went _way_ deep he drill would sit a bit deeper in the holder, but that might be a good thing. Oh, and use the tailstock rather than the toolpost as it will eliminate having to manually get things on center.
Same procedure would work if the problem is the 0.454" +0.002/-0 diameter, but would be nowhere near as easy since you can't touch the taper at the back without screwing up the clamping and it's an oddball size.
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PhotogEC
climber
In front of my computer
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Mar 16, 2011 - 12:42pm PT
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Bump
Any update on the second run?
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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Mar 16, 2011 - 01:49pm PT
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They have the material in have started the production for the corrected second run. I recieved corrected ones from the old batch and they look good. I will post up some pictures later tonight. If I can salvage these and the corrected ones work well ( I can not see why they would not, but I need to try them out) then the over all price would drop as I would have 500 of them and could look @ a W/S option for the corrected ones. I am not sure what route to go.
The wrenches should be here any day and the grips are a few weeks behind schedule according to the company that is making them. I was hoping to start shipping them now.
If anyone wants to give the corrected ones a trial (and try out some different glue options for the grip) run shoot me an e-mail. I'll send you a test drill and grip pre cut. I only have a couple to try out...Just be willing to post up some pictures and results on this thread.
Thanks! Sorry I have not had any new info...this has been a bit of a challenge and have been swamped trying to keep everything flowing smooth.
Luke
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couchmaster
climber
pdx
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Mar 16, 2011 - 01:56pm PT
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BTW, Luke makes a copy of the A5 bolt bag which is totally kick ass and actually has some nice improvements/refinements over Johns design. A bit heavy would be my only critique, but that's a design trade off in which you gain burliness and longevity in return. Not a bad thing to have when you are tossing expensive, critical and sharp objects into a bag and NEED them to be in there and available after that new route sick 50 foot runout as you quickly pump out.
Anyway, just wanted to say.....2 thumbs up for Lukes bolt bag.
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adatesman
climber
philadelphia, pa
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Mar 16, 2011 - 02:00pm PT
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Thanks for the link, Couchmaster. Yup, that's the print I saved a copy of. No idea how I missed it in the thread...
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Luke Malatesta
Big Wall climber
Moab UT
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Topic Author's Reply - Mar 16, 2011 - 02:10pm PT
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here are a couple more pics of the CAD drawing:
Luke
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