Help with buying a lathe

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LorenzoFlute
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Help with buying a lathe

Post by LorenzoFlute »

Hi all,

I'm looking into buying my first lathe, for flute making of course :)
I did a little turning on a friend's machine but I know little about how to choose one.
I'm a bit tight with my budget so I want to understand exactly what I need.
I was first looking into this type of cheap machine:

Image

But then I learned that the weight is too light and it would shake too much.
So I looked into this type:

Image

These cost around 300-400 euros and generally weight between 30 and 40 kg, but are always too short, around 45cm, we need at least double the size of the longer section to make the bore, so about 60cm. You can buy extensions but at this point the price gets close to this other type (this one in particular is second hand at 450 euros, similar ones I saw at 600-800 euros):

Image

I also see this same type at about the same price but with also attached a "copy machine". I wonder if this could be used to make cylindrical sections like tenons and headjoint, instead of having to buy a metal lathe only for that:

Image

Opinions? Also I know nothing about brands, power etc...
If you think it's really necessary I might consider slightly more expensive machines if I can get to pay month by month.
If anyone's wondering, I moved to Berlin...

Thanks a lot!
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Re: Help with buying a lathe

Post by Latticino »

I don't know what it is like over there, but here in the States there are lots of lathes being "retired" as high school shop programs are closing down. These machines are often the older (WW2 era), heavy cast iron ones that are pretty bullet-proof (at least the wood lathes are). You might need to replace bearings, belts or motors, but the basic machines are quite robust. Of course they are harder to transport and take up a lot of space, but if I was on a budget I'd certainly consider looking in that direction.

It is also a good way to get a good quality metal lathe for well below cost. I picked up a vintage hobbyist's benchtop metal lathe (1914 Dalton) that way for $200 that only needed oilers, a belt and some adjustment.

I haven't made any flutes, yet..., but you might also consider how long a section you need to turn at a time. I know it might be more efficient to bore and turn the entire flute body in one piece, but if you are going to make them in sections anyway, you could make each joint separately. The sections of a 4 or 5 piece flute are pretty short. I think most of the modern flute makers use a fairly sophisticated metal lathe setup with gun drills and steady rests to do the initial boring as well as the tapered reaming. Most likely switching over to the wood lathe for the outer finishing and turning. If I recall Terry has a fairly extensive posting on his process, not to mention plans that he sells http://www.mcgee-flutes.com/making.html.

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Re: Help with buying a lathe

Post by LorenzoFlute »

Yes actually I overestimated the length of the RH section which is actually around 22 cm, which makes a minimum working length of 44 cm. Would be a little tight though...

Sure I read McGee's site over and over again. One new thing I just noticed is that he prefers to turn the tenons by hand, go figure.

Yes I was also thinking about these old metal lathe. Though sometimes they look so huge and complex that I get frightened :D
Here are some I found locally:

http://kleinanzeigen.ebay.de/anzeigen/s ... ref=search

http://kleinanzeigen.ebay.de/anzeigen/s ... ref=search

http://kleinanzeigen.ebay.de/anzeigen/s ... ref=search

But I wouldn't know which to choose, or if it's better to go with simpler new wood ones...
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Re: Help with buying a lathe

Post by chas »

I have a JET woodworking mini-lathe ( http://www.woodturnerscatalog.com/p/216 ... Mini-Lathe ). It's small, but there's a bed extension available, which extends it to 42"/110 cm, which I've found is plenty for drilling. What I like about it relative to an old engine lathe is that it's reasonably portable. When I retire I'll be able to move it without a crane. I use it for almost all my operations -- I use a metalworking lathe for fitting rings, that's about it.
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Re: Help with buying a lathe

Post by Feadoggie »

You'll get a broad range of advice on lathes. It's up to what you are most comfortable using in my book.

Have you looked at Luc Verhoeven's site? http://users.skynet.be/fluiten/how.html I think he displays a good, economical, low tech outfit for his shop. You can learn a lot just by surveying the photos of flutemaker's shops to see what machinery they are using. Many have photos on their sites, if they have a site. Others will have had visitors which have posted photos of the shops on their own social media sites. Google around. You'll learn a lot.

I am not particularly familiar with the machine market in Germany but we live in a global marketplace these days so I am sure what you have available there in new/used machines is similar to what is available here. There are far fewer makers of machines today than there are brands being offered.

I'll tell you what I use, not so much as a suggestion but just to give you another data point to help with your decision.

I make whistles (high E to low C) and the occasional keyless flute. I use both a woodworking lathe and a machine lathe. I've been at it for about fifteen years now.

My wood lathe is a 10" X 38" size with the typical MT2 spindle and tailstock tapers and a variable speed drive. I use this one mostly for rough turning the square wood billets to round dowels. I have also used it for rough boring but I prefer the machine lathe to do that now and everything else besides. It is the similar to the second lathe you pictured but with a bed extension (also rather similar to the Jet lathe that Chas shows). Yes, it is rather portable. I have it bolted to a heavy/high-mass base which reduces chatter from vibration. It is my general wood working lathe for other projects and it has done yeoman duty for me. Still, I would snap up a 14" x 40" variable speed lathe (Jet, Delta, Grizzly, etc. ) if I run into one though. Look at the boring set up on Geoffrey Ellis's site if you get a chance. Pretty darned ingenious.

My current machine lathe is a 10" x 22" beast with a 1 HP motor, fixed speeds (managed by belt changes) with a 1" hole through the spindle, MT4 taper. I am sure you will think that the bed is short. But with that spindle I can place the work well into the spindle to do many operations. So the bed length works for me. I am also not a fan of long body sections on flutes or low whistles. I can do everything on this lathe from start to finish to make a keyless flute. And to the point Chas raised, I do have a 1 ton crane to move it around in the shop. Still I am looking to replace this lathe sometime in the future. The ideal lathe for me, based on my experience to this point, would be a variable speed 10" x 36" machine lathe with at least a 1.25" bore through the spindle.

I will mention that I have three other smaller machine lathes that support very discreet tasks in my shop for making whistles. Those aren't pertinent to spec out here. But it is perhaps worth mentioning that I found the need for these after realizing how much time i was spending changing set-ups on the larger lathe and seeing what variations in repeatability those changes in set-up introduced.

Here's the advice I would give you. Buy the largest machine lathe that you can both afford and house physically (they are heavy and hard to move around). Buy one with more than twice the bed length you think you need. Tooling arrangements can add to your length requirements. The longer the bed, the better. Buy one with the largest spindle bore you can find. Being able to place your work piece inside the spindle bore can reduce your overall bed length requirements. It can also increase accuracy in some cases. The bigger the bore, the better. Variable speed motors are advisable although we all learn to work with fixed speed drives. Better to buy big and have excess capacity than to not have enough. A friend of mine provides this wise council to me frequently. You can always make small things on big machines. You cannot easily or accurately make big things on small machines. Expect to pay as much for tooling as you do for the lathe (sometimes a bit more).

Most of my instrument making friends locally have vintage lathes (Southbend, Hardinge, etc.). These generally came from the demise of local industrial shops ( and there is no lack of shops closing around here). They can be good bargains and great machines. The downside is that they can also be a headache to get operational, to find tooling, to replace worn or broken parts, etc. etc.. Many of these guys spend as much time working on their machinery as they do on their projects. Having a parts lathe becomes the norm. So I would advise that if you buy vintage make sure the machine is already operational and that it has all the tooling you will need to add on. Spares are a plus if you can get them in the deal. But YMMV. There are machine restoration specialists that provide vintage machines restored to "as new" specs and fitted out, including tooling, if you want to go that route. Expect to pay a premium.

In your neck of the woods you might be able to find a decent second hand EMCO Maximat Super 11CD or Super 13. The Super 10's had a 20mm bore - small. The Super 11CD has a 26" bed but a large bore (35mm IIRC). The usual Maximat 11 has a 25mm bore. The Super 13 was available with a 35mm bore and a 39" bed. That'd be good. The Emco's are a good mix of the old and the new. Parts are more readily available too compared to some of the WWII or earlier machines.

You didn't ask about one of these but a milling machine is a very useful tool. Many makers go without one, as I did for the first ten years I made whistles and flutes. A drill press with an X-Y table will do to start. A mill can do so many things for you. They are useful to making reamers, fixtures and jigs. They are extremely accurate used as a setting-out platform. Once again, tooling is as expensive as the mill. When you need one, you need one.

Oh, and I love gundrills. That set-up alone can be a decent investment.

Hope that helps.

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Re: Help with buying a lathe

Post by paddler »

You are probably going to want a metal lathe not a wood lathe. I have both, and I like wood turning, but a metal lathe is much more useful for a flute maker. You can do everything you need on it. This is not the case with a wood lathe ... at least not with precision and reproducibility.

Look for a metal lathe (probably used) with a fairly large head spindle bore and enough bed length to allow you to gun drill the longest flute sections you plan on making. I have an old Sheldon metal lathe with a 1 and 3/8" head spindle bore. That is a useful size for the head spindle (nice and large) because it allows me to place work inside the head spindle and hence I can almost cut in half the bed length requirements for drilling. When looking at bed length, remember to take into account the space taken up by chucks etc, and remember that the remaining bed length needs to be double the length of the longest flute section (plus a bit) if you can't insert work inside the head spindle bore. You end up needing a surprisingly big lathe ... and they are very heavy and difficult/expensive to move. You will also need various tooling, such as steady rests, various cutters, etc. The price of the lathe is going to end up being a very small fraction of the price of this adventure. I'm not trying to put you off, I'm just saying. I've just been through this and would be happy to send you details, pictures etc of what I have and what I learned. Just email or PM me.

You will likely be making reamers. This requires precision metal working for turning the tapers. It also requires some way to cut them. A milling machine is a huge time saver for this, and also allows you to do a lot of other flute work, such as cutting key blocks etc. But a milling machine is also a big heavy machine, and it will probably cost more than a lathe.

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Re: Help with buying a lathe

Post by LorenzoFlute »

Thanks.
A mill machine would be nice but for the moment I'll do without it. About making reamers, I was thinking about finding a machinist to do it for me, if I end up with a wood lathe of course. Good to know about head spindle bore, I didn't know about it.

I still believe that I can do a lot with a wood lathe alone, maybe not as fast and not as precise, but you need to start from somewhere.

So what do you think about the metal lathes I linked in my previous post? Not much description, and anyway it's all in German, but pictures should say something if you are experienced with lathes...?

I realize that a huge size machine might be hard for me to set up.
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Re: Help with buying a lathe

Post by paddler »

It will probably be difficult to find a machinist who will make suitable reamers for you, especially for an affordable price. The problem is that flute reamers are irregular and need to be machined by hand, very carefully, step at a time. Doing this properly takes a long time. Its a kind of labor of love that only a flute fanatic would consider worthwhile. A machinist will likely not be eager to spend time doing this, at least not with the care that you need, and if they were willing they would undoubtedly charge a lot of money. Based on prices around here, my guess is that getting a couple of reamers done this way would cost as much as buying a used metal lathe.

You are likely to want to experiment with making many different reamers, not only for different flutes in different keys, but also to perfect the sound of your flutes in a particular key. I think you will end up finding that reamer making is a core part of flute making. For reamer making you will need a metal lathe.

You can certainly make a flute on a wood lathe. The precision and reproducibility is the key problem you face. The big advantage you have with a metal lathe is that the cutting tools are mounted on the lathe itself, rather than hand held, and can be positioned precisely using compound rest, cross slide controls etc. It makes it easy to cut precise cylinders, bore precise sockets, tenons, etc. Turning the external profile of the body sections of a flute, which may include slight curves, must be done by hand, but this can be done on a metal lathe too, simply by mounting a wood lathe style tool rest in the tool post and using hand tools, as you would on a wood lathe.

Well, this is just the start of a long discussion, but I think that if you get a wood lathe you will quickly find yourself wanting a metal lathe. However, if you get a metal lathe you will easily be able to do without a wood lathe. The cost of a decent sized new wood lathe is comparable to the cost of a decent used metal lathe. I spent more on my new Jet 1642 wood lathe than I did on my used Sheldon metal lathe with 11" swing, 53" bed and 1 and 3/8" head bore (even including delivery/moving costs).

Regarding metal lathes, much of the complexity you see is associated with the thread-cutting gears, which you really don't need for flute making. You also don't need a lot of swing. You just need enough bed length (and only if the bed length is insufficient, a large head spindle bore). The forces involved in flute make and reamer making are relatively low, so pretty much any metal lathe will be capable enough. Older lathes (in good working condition) are a great choice, especially if they are of a make/model for which tooling and spare parts are readily available on eBay. My metal lathe was made in 1944 and its a fine machine - probably much more well made than many modern machines.

Stephen Gabriel sent me a lot of really useful information when I was first looking into this. He is in Germany and could probably point you in the right direction regarding what is available over there. If I were you, I would do some more research and talk to other flute makers before spending money. Its easy to end up buying the wrong tools.

Jon
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Re: Help with buying a lathe

Post by LorenzoFlute »

Yes I understand that a metal lathe is more complete of course. The only things are the availability of these old ones (I have to check the ones I linked) and the weight to carry it around.

About reamers, they don't have to be complex, you can use multiple ones with linear taper, I believe that's how everyone has them.
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Re: Help with buying a lathe

Post by paddler »

About reamers, they don't have to be complex, you can use multiple ones with linear taper, I believe that's how everyone has them.
People do use multiple reamers, including separate reamers for separate sections of a flute and sometimes separate reamers for back reaming at the foot or at joints (and sometimes they back ream using the same reamer). If you do a detailed bore profile you can pretty much see how the flute bore was reamed. I've done this for a lot of antiques and for quite a few modern flutes. I have yet to see any that used linear tapers, though, even in combination.
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Re: Help with buying a lathe

Post by LorenzoFlute »

Uh maybe we are not understanding each others... Take for example the RH section. It typically starts with one inclination, and around the second tone hole it changes into a different inclination, which is slightly less steep. You don't need to make the change of inclination on one single reamer, you can have two ones instead with uniform inclination, and then you drill the first part of the bore with one, and the second part with the other one...
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Re: Help with buying a lathe

Post by tompipes »

You can pay up 800 to 1000 Euros to have 1 reamer made and you might need 6 or more for a flute.
And, if you change your mind about which design to use you have to get more reamers made.

I'd really consider getting a metal lathe so you can make your own reamers.
But there are other types of reamers that you can make without a lathe that can be very inexpensive. You can make a flat/scraper reamer in an hour with 5 Euros worth of silver steel!


In the US, Grizzly have a nice range of Chinese made lathes. I have their 9 x 19 which would be perfect for flute making. I doubt they ship to Europe but there must be a European equivalent company that sell these Chinese made lathes.

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Re: Help with buying a lathe

Post by Casey Burns »

Here is the approach I used early in my flute making career. A friend was tired of lugging his dad's old Atlas metal lathe around and asked if I could store it in my workshop so he could use it occasionally, right at about the time I wanted to start making flutes. Perfect timing. I had just turned my first flute in a quick 24 hour workshop with the late oboe maker J. Douglas Steinke a few months before and was eager to get started. The lathe was fairly simple to set up since there was already a bunch of tooling with it and the first thing I set about making were reamers and drills. Drills were easy - using drill rod. With a hacksaw and a grinder I fastened D bits out of them which cut the wood just fine. Then for the middle and foot joint reamers I turned the tapered shapes on the lathe, filed them close to final dimension, then sanded them to a smooth finish. Then using a hacksaw I cut these into a D cross section. Then more grinding to refine the cutting edge so that these would cut cleanly. The reamers were surprisingly effective and only took a few days of elbow grease to make. Any tooling I needed for the lathe was easy to get at an industrial tool store nearby, where my father worked.

The tooling included the 3 and 4 jaw chucks, a hollow Jacobs drill chuck threaded to the spindle (I wish I could get one of these for my Myford!), another Jacobs drill chuck for the tailstock, dead centers, a live center, lathe dog, and a few other items. I built and purchased steady rests, a hand rest, and other tooling I needed.

Eventually I bought the lathe, as my friend Tim never used it. It also had a vertical attachment and with a little wooden v block and bungee chords I was able to use the lathe as a simple horizontal drill press for tone hole drilling. Now I use a milling machine set up with centers on the table. The lathe I later sold when I purchased my pair of Myford lathes.

Used metal lathes are not that expensive. Myford Super 7s are great if you can afford one. The Craftsman Atlas lathes such as this one for sale in the Seattle area is the type that I started on and perfectly adequate. See http://seattle.craigslist.org/est/tls/4957845145.html. These come up for sale on eBay not infrequently and I've seen them for under $500 - 600. In Europe and the UK there are probably comparable lathes for sale. Just search for "used metal lathe" on Craigslist, eBay and Google. "Myford" is another good search term on Google as it will reveal the sites in the UK that list several used lathes in addition to Myfords for sale.

Wood lathes are possible - especially if you are already good at spindle turning. The metal lathe is still best for turning metal reamers. However, reamers can also be made from wood or aluminum, with a metal blade rendered from a hacksaw blade, screwed and glued to the reamer body. These are surprisingly effective. I occasionally make them when I am prototyping as I can make one in a morning. Here is one article from the FOMRHI journal on wooden bodied reamers: http://www.fomrhi.org/uploads/bulletins/Fomrhi-101.pdf. FOMRHI is a good resource - there are several articles on drill and reamer making. However, I would still recommend the metal lathe. One can use the compound slide as an effective tool to render wood into shapes - and even use it for quickly roughing wood into cylinders, as I demonstrate in this video: https://www.youtube.com/watch?v=hHW051w ... freload=10. This is much easier than turning rounds with a spindle gouge! I use the compound rest to machine the outside shapes on my flutes, and then render the details with hand turning, using a 1/2" square bar mounted in one of the quick change tool holders for the hand rest, and simple scrapers made from auger but files and other files. I also use a few scrapers made by Robert Sorby. I refine beads turned into the wood with double extra slim taper files that are made for saw sharpening. My metal bands are turned more or less the same way.

A little more history - I got into this kind of sideways. I always wanted to make instruments and started making tools, which I knew something about thanks to my father who was once trained as a machinist at the Ford Trade School. This caught the attention of my friend Suzy Norris who asked if I could make her a specific rare type of soundpost setter for her violin making. I eventually did for her and several other violin makers (and still do occasionally) and branched into other tools like finger planes. This gave me an excuse to hang around all the lutherie workshops in Portland and eventually I was introduced to Doug, who asked if I would make the keywork for his baroque oboes. So I did that for a while and eventually asked if he could teach me flute making. The Pacific Northwest was in deep depression at that point in time and it was good to have something rather unique to do!

Casey
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Re: Help with buying a lathe

Post by LewisC »

In my pre-flute days (~20 years ago) my family and I were visiting Asheville, NC and through a friend spent some time with Chris Abell, maker of high-end whistles and classical wooden flutes. He showed us around his workshop. The thing I always remember about the visit was that he said he spent more time making cutting edges and perfecting tools than he did making flutes.

Lewis
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