M.M.N.M. Machines and Metalworking in Northern Minnesota
11-2019 Newsletter
50 # Little Giant Ram Build
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This project begins when the ram casting breaks. After a second welding  attempt, a careful look at the fractured casting as well as the amount of time and materials needed for another welded repair, suggested that a fabricated, machined ram of steel was the way to go.
First machine operation was to split the casting at the point between  the 2 1/2 inch plates of the new design. First I  went in with a  end mill,milled in as far as it would reach, them finished the split with a  cut-off disk in a hand grinder.
The original cast ram was made with cores inserted in the mold, to make the pockets for the hammer arms. Machining the ram from a single steel block would make it near impossible to machine these blind pockets, so a built - up design was chosen.
The broken ram is used for the pattern to flame cut the parts for the fabricated replacement. A 3/16 rod is tac welded to the casting, to give some extra material for machining. Tracing torch has a magnetic drive wheel, that follows any ferrous  metal pattern.
​A machined pattern bolted to ram provided a cut part with more  precision and also filled in for parts of casting missing. Once cut, this same pattern is used as a milling fixture.
Below, flame-cuts are matched drilled using  common pattern.
Rams are located in vice by pins on center-line to facilitate easy mirror image parts.
​Ram angle milled with V-block set-up.   Lower right, checking new part against original.
​​Die pocket is milled using the vertical head on Kearney Trecker 2 CH mill
You are invited to view YouTube video about this project, more photos plus some nice shop  action shots. In process, will be released soon.
​Hard die is faced off with carbide cutter, while mounted in ram.