Introduction to Practical Machining Projects
During my early days studying machining, I engaged in a variety of projects that provided a solid foundation in the craft. From crafting simple keychains to forging hammers, each project was an essential step in understanding fundamental machining techniques. Over time, I realized that while items like keychains and chess pieces are quickly lost or broken, the tools I manufactured have stood the test of time, remaining in my toolbox and serving me daily even after 12 years.
Building tools that I made myself instilled a deep sense of pride and satisfaction. These tools not only perform reliably but also symbolize the skills I acquired. To help aspiring machinists develop their skills, I’ve compiled a detailed list of practical projects. Unlike decorative items such as turner’s cubes or ornamental widgets, these projects focus on creating essential, functional tools that you’ll use regularly—be it weekly or daily.
For each project, I will provide comprehensive details including the Bill of Materials (BOM), the equipment required, and the technical drawings. Many of these projects are based on my own experiences, with some enhancements to improve their utility as working tools. The projects are designed to be accessible for beginners but also challenging enough to foster skill development. Below is a table of contents for the projects covered:
- Slide Hammer
- Machinist’s Hammer
- Toolmaker’s Vise
- Micrometer Stand
- Dial Indicator Depth Attachment
- Caliper Depth Attachment
- Caliper Center Distance Attachment
- Vee Blocks
- Edge Clamps
- 123 SuperBlocks
- Tap Guide
- Screw Jacks
- Vise Brake
Detailed Project Descriptions
Slide Hammer
If you often work with pull dowels—common fixturing elements in many shops—then a slide hammer is an indispensable tool. This project is straightforward, making it ideal for absolute beginners. It provides an excellent opportunity to learn the basics of turning and machining.
This slide hammer is specifically designed to extract ½-inch dowels from tight-fitting holes. To enhance its durability, it features a replaceable ¼-20 set screw that securely holds the dowel during extraction. I prefer making tools from stainless steel to maximize longevity, but steel or aluminum can also be used depending on your budget and material availability.
Bill of Materials (BOM):
- Ø 2.0” x 4-5/8” long stainless steel (1 piece)
- Ø 0.50” x 12-1/8” long stainless steel (1 piece)
- Ø 1.0” x 5/8” long stainless steel (1 piece)
- ½” E-clip (1 piece)
- ½”-13 x 1” socket head set screw (1 piece)
Drawing Files:
Download the Pull Hammer Project drawing set for detailed specifications.
Machinist’s Hammer
Almost every machinist has crafted their own version of a machinist’s hammer at some point. Variations exist across different schools and shops, but the fundamental design remains similar. I’ve modified my own over the years to improve comfort and functionality, adding flats to the handle to prevent slipping and drilling a hole at the bottom for an Allen key, making it a versatile tool for leverage and minor adjustments.
This project is excellent for learning taper cutting on a lathe. By locking the compound rest at a specific angle, you can cut both the male and female tapers with a single setup, ensuring smooth, lasting surfaces. The handle can be customized for balance, with heavier brass inserts preferred for a more tactile feel.
Bill of Materials (BOM):
- Ø 1.25” x 10.125” steel (1 piece)
- Ø 1.25” x 2.125” steel (1 piece)
- Ø 1.50” x 1.25” steel (2 pieces)
Download the Machinist’s Hammer drawing set for detailed plans.
Toolmaker’s Vise
This project caters to advanced students and professionals aiming to craft a high-quality, durable vise. Traditionally a tool and die maker’s project, it emphasizes skills like job planning, grinding, heat treating, and precision machining. Using A2 tool steel provides stability and ease of heat treatment, reducing the risk of cracking associated with other steels like 4140.
The vise’s design incorporates allowances for grinding and finishing, with optional CNC engraving for personalization. When completed, it’s not just a tool but a piece of functional art that demonstrates craftsmanship and attention to detail.
Bill of Materials (BOM):
- 2.5” x 2.5” x 6.125” A2 tool steel (1 piece)
- 2.5” x 2.5” x 1.4375” A2 tool steel (1 piece)
- Ø 1” x 1.0625” long 4140 heat-treated steel (1 piece)
- 3/8-16 x 2.25” socket head cap screw (1 piece)
- CL-2-SW spherical washer (1 piece)
Download the Toolmaker’s Vise detailed plans and instructions.
Micrometer Stand
While less common in educational settings, a micrometer stand is an incredibly practical tool. It allows precise measurement checks, especially when dealing with tiny or awkward parts. The stand’s craftsmanship offers an excellent opportunity to practice slotting, threading, and surface finishing techniques on both mill and lathe.
The design emphasizes both function and aesthetics, with a combination of brass and steel giving it a professional appearance. Building a micrometer stand reinforces core machining skills and results in a highly useful tool for any measurement-intensive task.
Bill of Materials (BOM):
- 1.5” x 2.5” x 4.625” steel (1 piece)
- 0.75” x 0.75” x 2.0” brass (1 piece)
- Ø 0.625” x 1.875” brass (1 piece)
- Ø 1.5” x 0.75” brass (1 piece)
- ¼-20 x 1” long set screw (1 piece)
Download the Micrometer Stand plans for detailed step-by-step instructions.
Dial Indicator Depth Attachment
This accessory enhances the functionality of a basic dial indicator, allowing you to measure depths of shallow steps or gauge the depth of damaged areas with precision. It’s a straightforward project that helps develop skills in milling and threading, including grinding and undercutting techniques.
The design tolerances are forgiving, with the main goal being a smooth, functional surface. Making this attachment improves your understanding of aligning components and creating accurate, repeatable measurements.
Bill of Materials (BOM):
- 1” x 1” x 2.125” mild steel flat bar (1 piece)
- Ø 0.625” x 0.625” brass bar stock (1 piece)
- Dial indicator (1 piece)
Download the Dial Indicator Depth Attachment plans for detailed diagrams and instructions.
Caliper Depth Attachment
This simple yet highly functional attachment is designed for Mitutoyo 6- and 8-inch calipers, with compatibility extending to most other brands. It provides a platform for practicing small-part machining, slotting, threading, and aligning.
This project is material-efficient and fully homemade, with the possibility of adding heat treatment and polishing for hardened steel bodies. It’s a versatile addition to any workshop for precise measurements and calibration tasks.
Bill of Materials (BOM):
- 1.5” x 0.5” x 3.125” mild steel flat bar (1 piece)
- Ø 5/8” x 0.625” long brass round bars (2 pieces)
- Calipers (1 pair)
Download the Caliper Depth Attachment plans for detailed drawings and assembly instructions.
Caliper Center Distance Attachment
A straightforward yet precise tool, this attachment helps measure the center-to-center distances between features or parts. It’s ideal for marking, measuring bolt circle diameters, and verifying alignment.
The project involves working with a collet on the lathe, aligning and cutting slots accurately, and tapping small holes. It’s a cost-effective project suitable for classroom settings, with minimal material requirements.
Bill of Materials (BOM):
- Ø 0.375” x 1.875” long stainless round stock (2 pieces)
- 4-40 x 0.125” long UNC half-dog point set screws (4 pieces)
Download the Caliper Center Distance Attachment plans and detailed instructions.
Vee Blocks
Vee blocks are essential tools for holding round or irregularly shaped workpieces securely during machining. They’re invaluable for precision jobs, and their construction helps develop skills in planning, milling, heat treating, and grinding. For added practice, you can make the clamps with a bandsaw and perform detailed layouts.
Creating a set of high-quality vee blocks enhances your workholding proficiency and ensures accuracy when machining complex parts. Using materials like 4140 steel provides stability and durability, especially after heat treatment.
Bill of Materials (BOM):
- 2” x 2” x 2” 4140 steel (two pieces)
- 2.5” x 2.5” x 0.5” mild steel (two pieces)
- 1/4-20 x 2” hex bolts (two pieces) with half-dog tip machined to prevent sticking
Download the Vee Blocks plans for detailed diagrams and assembly notes.
Edge Clamps
These compact clamps are perfect for securing long flat workpieces or plates. When precise thickness control is necessary, the 1” thickness can support workpieces on 123 blocks or other supports. They are versatile for various operations, including drilling and milling.
Designing and manufacturing these clamps offers excellent practice in slotting, drilling, tapping, and grinding. Their adjustable nature allows for creative workholding solutions, demonstrating the importance of problem-solving in machining.
Bill of Materials (BOM):
- 1.25” x 1.25” x 4.125” 4140 steel (one per clamp)
- 1.5” x 1.5” x 0.5” 4140 steel (one per clamp)
- 1/2” UNC x 1” long flat head socket cap screw (one per clamp)
Download the Edge Clamps plans for step-by-step instructions and detailed drawings.
123 SuperBlocks
These innovative, stackable blocks are more than simple tools—they’re a demonstration of creative machining. By arranging threaded holes in specific patterns, you can bolt these blocks together with socket head cap screws, making customizable fixtures without interference from bolt heads.
While not designed for heavy-duty applications, these SuperBlocks are perfect for setup, positioning, and inspection tasks. They add a fun and functional element to your workshop and showcase advanced problem-solving skills.
Bill of Materials (BOM):
- 1” x 2” x 3” A2 steel, oversized by 0.035” (one per block)
- ¼-20 x ½” socket head cap screws (two per block)
Download the 123 SuperBlocks plans to create your own versatile set.
Tap Guide
This simple but highly useful tool ensures taps stay straight and aligned during threading operations. It’s an excellent project for practicing precision milling, drilling, and alignment techniques. You can use mild steel or upgrade to tool steel such as 4140 for increased durability and heat treatment options.
The key learning is in accurately locating the vee and aligning the tap, which enhances overall threading quality and consistency.
Bill of Materials (BOM):
- 1” x 1” x 4.125” steel (1 piece)
Download the Tap Guide plans and detailed instructions to help you master tap alignment.
Screw Jacks
Another classic project, screw jacks serve as mechanical lifting devices. To improve their functionality, I’ve included drawings for riser blocks, which significantly extend the travel range. Making a set of six, with two riser blocks per screw jack, provides ample reach and versatility.
This project is ideal for learning CNC lathe operations, understanding clearances, and working with unilateral tolerances. It offers a comprehensive experience that combines design, machining, and assembly skills.
Bill of Materials (BOM):
- Ø 1.0” x 8” long 4140 heat-treated steel (one)
- Ø 2.0” x 40” long 4140 heat-treated steel (one)
Download the Screw Jacks detailed plans for manufacturing your own set.
Vise Brake
This innovative project transforms your standard vise into a sheet metal bending tool. Its design incorporates magnets for quick attachment to any steel vise and adjustable die sections for different bend radii. It’s a practical tool that provides accurate, professional bends in a basic shop environment.
Constructed mainly from mild steel, it can be upgraded to 4140 and heat-treated for increased longevity. The project teaches fundamental sheet metal forming principles and enhances your understanding of workholding and die design.
Bill of Materials (BOM):
- 2” x 2” x 6.125” mild steel (two pieces)
- 2” x 0.25” x 2.125” mild steel (three pieces)
- 8mm x 3mm neodymium magnets (eight pieces)
- ¼-20 x 1” long socket head cap screws (nine pieces)
Download the Vise Brake plans to build this handy sheet metal bending aid.
Conclusion
These thirteen projects serve as an excellent starting point for students and beginners in machining. While decorative or novelty items have their place, creating practical, durable tools fosters pride and provides lifelong value. Building these tools not only improves your technical skills but also leaves you with a set of customized, functional equipment that will serve you well for years to come.
Beyond these projects, many other tools can be developed by beginners, including parallels, dial indicator articulating arms, C-clamps, drill point gauges, edge finders, tap handles, magnetic chip shields, lathe dogs, center finders, live tailstock centers, fly cutters, CNC tool height presetters, and bushing installation tools. If you have suggestions or additional ideas, please share them in the comments. And if you found this content helpful, consider sharing it on social media to help others improve their machining skills.