Thread: Waldown 1962 Drill Press Restoration WIP

Originally Posted by thumbsucker

Costing (So Far)

1. $390 Drill Press
2. $040 Poly Strip Discs & wire brush wheel from http://www.smithandarrow.com.au
3. $040 Sisal Mop, Calico Loose Flap Wheel & compounds from http://www.polish-up.com.au
4. $300 New Spindle & Bearings from http://brobo.com.au
5. $002.5 3 Phase 4 core cable
6. $012 Round Electrical lugs
7. $012 Forked Electrical lugs
8. $040 Crimping Tool
9. $011.51 Josco 60mm 60 Grit Coarse Sanding Flap Wheel
10. $011.51 Josco 60mm 120 Grit Fine Sanding Flap Wheel
11. $400 Powder Coating

Presumably items 2,3,6,7,8 have some life left in them
I wouldn't bother with powder coating.

Yep, a few items do have a life let in them but they still cost me money to acquire.

I do not have space or equipment to spray, I had to strip the machine and work outdoors in the garden on a makeshift table when Melbourne weather allows.

My workshop is for wood only, grease, oil, and metal dust & shavings must be kept out.

Power Coating is more durable then paint. I just deliver the machine to power coater and then pick it up. The mere convince is worth the money.

Where is the update photos of the drills progress? Has it been finished?

I have started a new job, that has completely taken up all of my last two weeks.

I have made arrangements with some kind folks to repair the holes in the table and a few other defects plus resurfacing the foot and the table.

I hope to probably get above done next week.

I will keep you updated.

Originally Posted by thumbsucker

..... I have made arrangements with some kind folks to repair the holes in the table and a few other defects plus resurfacing the foot and the table.

What is your plan for repair of the holes in the table? Earlier in this thread I think you mentioned welding them up and surface grinding. What is the cost of doing this?

I'm asking because I have some holes in my drill table that it would be nice to tidy up. I've tried TIG welding some chipped corners on an old table saw table, which worked fine but the resultant weld and surrounding cast iron was extremely hard to file. I ended up angle grinding to close, then hand lapping with a coarse grinding stone. I'm curious how much a professional surface grind would cost.

Graham.

Due to the kindness of some blokes over in metalworking, it will cost be virtually nothing. Kbs PensNmore has donated some cast iron salvaged from another old machine, and kwijibo99 will be offering the use of his machine shop to weld and then use a fly cutter to clean up the surface. The finish will not be surface ground looking but it will be flat and even, and will retain a factory look to it.

Having paid for commercial surface grinding in the past, I would say most shop would not want to take on such jobs and if they did they would charge a pretty penny for the work, due to the setup time required.

That sounds like a good solution. I'm curious to see how the surface finish comes out across the welded areas. I hope you put photos up when it's all finished.

Graham.

Original tables aren't surface ground either, just milled.

Originally Posted by DSEL74

Original tables aren't surface ground either, just milled.

Yes, but milled across a uniform cast surface. My question above was about how the surface finish will appear over the heat affected and filler material areas. Will there be a discontinuity?

It looks like cast iron filler will be used. Thumbsucker, any more information on how this will be prepared and used as filler?

Graham.

The replacement spindle came today from Brobo. However there are two problems:


1 - The spindle does not fit the part (see photo). The spindle diameter is 16.5mm the hole is 16.3mm.


2 - No bearings came with the spindle, Brobo said the spindle came with bearings included.


I have contacted Brobo asking a please explain.

This Saturday I will be going over to kwijibo99 place to repair the cast iron. I will included photos.

IMG_4746.jpgIMG_4747.jpg


Graham - Welded from underneath. so it should be seamless, we will see Saturday.

Originally Posted by Oldbikerider

It looks like cast iron filler will be used. Thumbsucker, any more information on how this will be prepared and used as filler?

Yesterday I went to kwijibo99 (Greg) to repair the cast iron table and the foot of the drill press.

Here is a photoblog - I took over 150 photos but here are 14 to give you a taste.

This is what the table looked like before we started work.
IMG_4767.jpg

Here the table is attached to the milling machine and checked for level.

IMG_4773.jpg IMG_4776.jpg

The large oblong hole in the centre measured about30mm, so Greg used this special cutter head that cuts from the centre and can expand the hole to a perfect round. This hole was a stepped.

IMG_4780.jpg IMG_4795.jpg

Plugs were turned from cast iron. To an interference fit. Only one plug was welded in as it was a through hole, the others were blind or stepped holes.

IMG_4801.jpg IMG_4805.jpg

Here we are drilling out the smaller 1/4" holes & a 10mm hole.

IMG_4809.jpg IMG_4814.jpg

Here we have all the plugs inserted but not driven home.

IMG_4819.jpg

Next we used an end mill to full the extra plug material away.

IMG_4837.jpg

Then using the end mill Greg skimmed the top, to remove the dings and dents.

IMG_4841.jpg

Lastly we used the fly cutter to mill a flat surface.

IMG_4857.jpg

By this time it was late so we stopped.

We have decided to give the table top a light scrapping to true the surface more, to give a nice cross hatch pattern to the table and to further obscure the plugs.

The plugs are almost hidden, and you have to catch the light at the right angle to see them.

Greg's work was meticulous and precise. It looks so much better then if I had opted for the epoxy glue solution.

Greg and I will catch up sometime in the next week or two to repair the cast iron foot.

At which point the drill press will be ready for powder coating.

Looks like a job really well done.

Fantastic result thumbsucker!