well since i cant sleep i will post some pictures of the 1st two pattern i made for the shaper, i hope to get them cast next week some time, the 1st.

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Gingery Metal Shaper Author: Walkthrough of my machine: For those who dont know, a metal shaper is one of the early style machine tools developed that allows you to plane flate surfaces.

It works by holding a toolbit in a holder attached to a ram. As the ram moves forward and back, the toolbit scrapes and peels off layers of metal by sheer brute force. Mechanical assemblies attached to teh bull wheel, advance a rachet wheel every revolution and slide the table a hair each stroke.

The toolbit is also held in a clapper block, so that on the back stroke, the toolbit can flip up slightly and will not be dragged forceably against the work on the return stroke. Here is a video of one in action not mine The shapfr can set: And the Gingery build is just as intriguing. He set out to build his own metal working shop from scratch using nothing but common shaaper tools.

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Gingery Metal Shaper

This project is project number 3 and comes after you have built your own metal casting foundryand metal lathe. I wish i had pictures of the foundry fired up and working with the molds and molten aluminum.

It was pretty awesome albeit dangerous. So all the aluminum pieces you see in the pictures below were hand cast by me.

They are from an old car transmission I tore apart and broke in to pieces to fit into the melting pot.

Gingery Metal Shaper Video

Learned a lot of things in the process. I actually never really have used the machine which is sad to say.

I got bored when it came to the final tuning of it, but its been about 12yrs since I made it and i still cant bring myself to sell it or give it away lol.

The major modifications i did from the original design was changing it over from a chain drive to a gear drive.

I was lucky enough to have access to a full sized milling machine at teh time to do the critical spacing of the holes. The gears are from an old motorcycle engine. The main gear had large holes machined in teh center and offered no place to shaperr the bull wheel slide used to change the length of the stroke.


If you look close you will see how i remedied this. I used the gear as a steel core and poured molten aluminum into it to give me a shaped surface lol. Similarily, for the pinion, it didnt have a way to mount it to the drive sharf, so I carefully welded a set screw collar xhaper the pinion face so that I could securly mount it to the shaft.

shaped All in all, it was an awesome project and a great way to learn about how to design functional things with minimal tooling. Casting your own metal parts is an extremely powerful capability. I am glad I found this-I too, have built this shaper and I wish I had found it sooner as I could have saved myself about 40 bucks on the bull wheel. Tomorrow I will cast a gear or two to change saper over to gear drive. Thanks for posting this!