Round holes - is it possibl e ?

Not having a mill I have done these sort of jobs by hand, in 16 g copper would be easier than maching ? Draw the development on thin paper and stick it in position, then drill and file. In steel tube can get to be hard work.

If the vertical pipes are to be silver soldered in, then too-good a fit is not wanted. As long as the holes are the right shape and a close enough (but not tight) fit will do the job fine regardless of surface finish. The original might be salvageable if the holes are trued up with a boring head. (radial holes shouldn't go outside the required shape for vertical ones).

Neil

Thanks to everyone for their interest and help. Now I know it is not a problem, I can look for a suitable company. Thanks for the picture Jason, exactly what I am after.

As a person who mostly reads the messages on this site I have always been impressed by the ability of model engineers to make model steam engines etc. I do not make models but use my machines to make full size parts for my classic bikes and those of friends. Bearing this in mind I have read this thread with some interest and a great deal of surprise. Without wishing to piss on anybodys parade, and also asking you not to be ofeended.......i have to say that i find it incredible that reg asked somebody to make this item in the way it appears to have ben done. That is a verbal description using terms like parallel holes and maybe not even recognising that a hole created the way is has will only be round when viewed on axis.

I served my apprenticeship as a tool maker, and I well remember the first day when the Toolroom Manager told us nice wet behind the ears newbies "Remember this and it will serve you well all of your toolmaking life. Always, but always have a drawing with dimensions and tolerances before you cut any metal." As a result even today I keep a book on my workbench, and everything i make is drawn and dimensioned before I start work, regardless of whethet it is a simple wheel spacer or a reworked cylinder head.

I was most concerneed when reg offered to prepare a drawing so that we could understand what he meant. It begs the question how did you transmit the information to your original supplier? They refunded your money and offered to remanufacture, after you obviously explained the problems and you refused. Why on earth didn't you simply prpare a drawing and then let them remake?

MadMike. How wrong you are. Not a verbal description at all. Took in drawing and a cardboard mock up done to the best of my ability, bearing in mind that I am a farmer and not a time served tool room engineer . Anyway, I do not appreciate my efforts being mocked - I can see this forum is not for me.

I am asked by my wife and all her friends at the WI to say thank you to everybody that posted a reply and assisted in this combined Christmas present / retirement gift. The finished result was a real success and the clock looks superb in its housing, with the two tubes now firmly fixed in a sapele base. The recipient was more than delighted. Festive greetings to you all.

Just designed a part in my head and made it. Would have been nice to include a shoulder to press the bearing up against. The words above are very true.

From time to time, I am asked to make something. No drawing as very often the 'customer' doesn't know how to draw what he or she wants. All they want is for it to work. As engineers, we often have to lead the customer. For instance, I have just made an imitation Bugatti rocker box cover for a Triumph engine! No drawings, just an old Triumph rocker cover and a photo of a Bugatti engine and a big block of cast aluminium.

Note, the rocker box is too long for the milling table, so I had to machine one end, then slide it along. Careful packing, wedges and clamping was required to make sure that surfaces were flat and true. No drawing and a satisfied customer.