help with jigging & set-up

[bherr]

I've attached some photos. Here's my problem. Because the intake has multiple angles its difficult to set-up in a jig. the first step is cutting the throat flush across and at a 90 deg angle to the flange angles. After that is completed I then use a .50 2 flute milling bit to hone out the inside diameter of the throat and the outside to dimension. the next step is to mount the intake against a rotary table so the the flange is horizontal. the then mill the flange down to the proper thickness and then rotate the table to do the other flange. Once this is completed comes the hardest part. I have to drill 2 holes in each flange at a specific distance from the center of the intake flange hole. these holes are offset up and down from center. I have been using a layzer pointer to find both edges in the Y &X plane and then center the drill bit based on these readings. However if I miss the exact center then the hole patterns are off. also when setting up the milling on the throat to surface the throat at a 90 deg angle to the flanges I'm having problems getting the intake exactly plumb both in the X & Y axis. I use a V shaped jig. but thinking about getting a adjustable angle vice that would allow me to adjust in the X and Y axis. any suggestions would be greatly appreciated as I'm new this this milling business. I'm using a Bridgeport Series II interact, some of the photos show my old shopmaster. HELP I need a way to get these hole patterns correct each and every time.

[bherr]

In my previous post I talked about how difficult it was to get the intake throat straight in the X & Y axis, so I decided to purchase a 3-way angle vice. this will allow me to adjust the X & Y angles much easier that the current way IO was doing. I purchased a Vertex 4" angle vice for just $299.99 from a place in Beaver Falls via EBay. I was bidding on a used one that was only 3.5 " and it went for $356.50 + shipping and was used. Lost that bid, glad I did as I got a new one with 4" jaws for less. I guess it pays to lose some bids once in awhile.

With this new 3-way I can adjust the throat easier and a lot quicker and get it right on the money, which is very iomportant as all other milling is taken off the throat surface.

Ben

[gus]

Turn a plug that will fit in the flange bore and guide it by eye until it will lower into the bore

Think about writing a program that will machine a clean up pass on the bore, perhaps kiss the entire outside then change tools and drill the 2 holes.

2 tools, end mill and drill 1 setup for each flange