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  1. #31
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    Quote Originally Posted by Michael G View Post
    G'day Bob
    If you want to send the disc and hub for a holiday, my lathe can do 12"

    Michael
    Thank you for the kind offer Michael.

    Alan 'C-47' has a 13" swing Colchester Master 2500 which I used to face the little Tough drill's table a few years back. If I can't come up with a way of using my rotary table to aid in cleaning up the edge I will lean on Alan again for a favour. He is ten minutes away.

    Bob.

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  3. #32
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  4. #33
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    Quote Originally Posted by 62woollybugger View Post
    Looking good Bob. I had to hunt round town to find someone with a press, that would let me use it, to press everything off the shaft. The previous owner had used a 20mm bore saw blade on the 3/4" shaft, which had moved & damaged it so the inner blade washer wouldn't come off. The bearings, cutter head & pulley were all rusted in place.

    I can't recall having any problems fitting the bearings, they should only be a tight fit on one race & a slip fit on the other, but I can't remember which was which on mine. I normally put the bearing in the freezer & the housing out in the sun, then put the shaft in the freezer & the bearing/housing out in the sun.
    Thanks Mike,

    The bearings were tight on the spindle. I had to use a press to remove the saw end 6205 bearing because I couldn't reach with a three jaw puller. I made a couple of end caps to lessen the chance of mutilating the centre hole and the threaded grease nipple hole in the spidle while attempting to remove the bearings. Worth the effort.

    IMG_20200820_152451346 (Large).jpg IMG_20200820_154332854 (Large).jpg IMG_20200820_154353028 (Large).jpg

    Bob.

  5. #34
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    Being aluminium you can machine the disc with a router set up to cut a circle. Should be relatively straight foward as you have a lathe and can turn up a centre to fit the hole in the disc. Final polishing of the edge can be done when it is fitted on the Woodfast.

  6. #35
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    Quote Originally Posted by Bohdan View Post
    Being aluminium you can machine the disc with a router set up to cut a circle. Should be relatively straight foward as you have a lathe and can turn up a centre to fit the hole in the disc. Final polishing of the edge can be done when it is fitted on the Woodfast.
    Bohdan,

    My single experience with routing aluminium was roughly thirty years ago when I had the task of cleaning up several lineal metres of 6mm thick 5083 edge. The router released a shower of dart like splinters. With the correct setup it may have been controllable. I didn't have the correct setup so I resorted to filing and sanding those edges by hand.

    I will try my hand with the mill and rotary table. If that fails, it will be a job for the Colchester.

    Bob,

  7. #36
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    I gather that you don't have dust extraction on your router.

    I use a Festool and have little or no splinters coming off the ali but you do get a shower of flakes that are collected by the extractor.

  8. #37
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    Canberra
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    Its incredible to see such massive machines do their work.

    It must cost a fortune.

    Even more amazing is that they are all in someone's shed!

  9. #38
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    Quote Originally Posted by woodPixel View Post
    Its incredible to see such massive machines do their work.
    I've visited Bobs shed a few times.
    The machines are not really massive, especially compared to others I have seen.
    I think his biggest machine is 2HP?

    It must cost a fortune.
    I don't believe any of Bob's machine were bought new - as far as I know they were all more than a few decades old when he bought them. Bob is a just a wizard at getting hold of nice machines making them look good and work well!

    Even more amazing is that they are all in someone's shed!
    There would be a fair number of Metal work forum members with the similar level set ups in their sheds although perhaps not many with the level of meticulous attention to maintenance and detail.

  10. #39
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    Default Turning the Disc.

    Not an overly successful day.

    I think the Achilles heel in my attempt to acheive concentricity was a simple socket set screw. Woodfast cut a 12 degree angled flat on the spindle's spigot. A knurled cup point scoket set screw has minimal engagement if it is perendicular to the spindle's axis. The point can deform against the hardened spigot causing the screw to loosen or in the case of softer steel, deform the steel to the same effect.

    When I mounted the disc on the mill's horizontal spindle I used a short 5/8" dia. length of 1020 steel inserted into the hub and held in the spindle with an ER32 collet. The repeated shock of the interupted cut caused both the bar to move in the colet and the hub to move due to the loosening of the set screw. I did provide a flat on the bar at the screw location to facilitate the bar's removal but the choice of a cup nose screw was the wrong one. The screw should have been flat nosed. Live and learn.

    The spindle in the lathe setup was to enable the facing of the hub with the hub locked in place with a set screw, the nose of which had been turned to 12 degrees, a line of contact being better than a point to my thinking.

    The Colchester tomorrow...

    IMG_20200826_091838949 (Large).jpg IMG_20200826_091855594 (Large).jpg IMG_20200826_091941453 (Large).jpg IMG_20200826_095945662 (Large).jpg IMG_20200826_133329984 (Large).jpg IMG_20200826_133239081 (Large).jpg

    IMG_20200826_140742307 (1) (Large).jpg IMG_20200826_141547285 (Large).jpg

  11. #40
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    Quote Originally Posted by Anorak Bob View Post
    The Colchester tomorrow...
    Good move.

  12. #41
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    Quote Originally Posted by woodPixel View Post
    Its incredible to see such massive machines do their work.

    It must cost a fortune.

    Even more amazing is that they are all in someone's shed!
    In its day the grey milling machine cost enough for it to be only affordable by the likes of goverment departments and universities. It, a 1962 Swiss Schaublin 13, came from the Aeronautical Research Laboratories at the Weapons Research Establishment in Salisbury S.A, It has a work envelope about the size of a kid's shoe box. Certainly not massive, often frustratingly diminutive.

    The green lathe is a Hercus ARL manufactured in 1969. I used a Hercus when I was in high school. A touch more affordable than the 13!!

    Bob.

  13. #42
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    Default Ah well..

    So yesterday, filled with hope, I visited my friend Alan and mounted the assembled disc and spindle in the four jaw Burnerd chuck on his Colchester Master 2500 lathe. Using a 0.01mm dial test indicator with its stylus on the bearing journal, I centred the Woodfast spindle. The wobble remained.

    The Colchester's spindle was longer that the installed Woodfast's and with a torch illuminating the interior of the bore, I could see the Woodfast spindle wobbling. Not a lot but sufficient to induce a wobble in the disc.

    The overhang of the spindle behing the chuck jaws was the problem. To resolve the problem would require the making of a centring device to be installed inside the Colchester's spindle bore to support the Woodfast spindle along with a modification to the Woodfast spindle to accommodate that centring device. If the Colchester was mine, an easy enough task but alas, it isn't mine.

    Time to move onto the spindle moulder and its table....

    IMG_20200827_102423609 (Large).jpg

  14. #43
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    Default Spindle Bearings - Easing Their Installation

    In case Bob and Mike think I've been sitting on my fingers.

    I'm probably going against the grain but in my mind grease and sawdust aren't a great combination so I am going to instal sealed bearings rather than the single metal shield bearings Woodfast fitted.

    IMG_20200902_102631688 (Large).jpg IMG_20200902_103130960 (Large).jpg

    The original design of the bearing housing does not allow access to the the innner bearing race, requiring the bearing to be pressed onto the spindle prior to the installation of the bearing in the housing. If the housing was heated and the spindle mounted bearing cooled an easy fit might be achieved. Rather than the uncertainty of might I modified the housing to allow the bearing to be pressed into the housing then pressed onto the spindle.

    IMG_20200902_103940573 (Large).jpg

    The removable 4mm thick aluminium covers allow access for the sleeves required for pressing the bearings on via their inner races.

    IMG_20200902_112318966 (Large).jpg IMG_20200902_145227584 (Large).jpg IMG_20200902_145559099 (Large).jpg IMG_20200902_151126571 (Large).jpg IMG_20200903_154226073 (Large).jpg IMG_20200904_092812719 (Large).jpg

    IMG_20200904_091052140 (Large).jpg

    All that remains to be done is to reduce the length of the 3/16" BSW countersunk socket screws that will secure the covers then the spindle can be reassembled.

    IMG_20200904_142549650 (Large).jpg IMG_20200904_142730220 (Large).jpg IMG_20200904_142843016 (Large).jpg IMG_20200904_143951106 (Large).jpg IMG_20200904_144003179 (Large).jpg IMG_20200904_144041197 (Large).jpg

    IMG_20200904_144308296 (Large).jpg IMG_20200904_144441903 (Large).jpg

  15. #44
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    Lovely work Bob!

  16. #45
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    Default The Disc

    So with the spindle reassembled I mounted the sanding disc. It was immediately apparent there was a wobble in the disc. A 0.01mm dial indicator showed a wobble of roughly 0.2mm or 0.009". It also indicated that the aluminium plate had a 0.1mm kink in it, maybe the result of clamping while being cut from a larger sheet. I removed the disc from its hub and checked the hub for axial runout which was 0.02mm or just under one thou at the flange edge.

    In an attempt to improve the accuracy of the hub, I turned a 5/8" spigot on the lathe and mounted the hub, ensuring concentricity, then refaced the hub. With the disc attached to the hub and remounted on the Universal there was a whisker less wobble. My Price Ackling 'Multitool's 8" sanding disc has about 0.3mm wobble and functions well enough at 2850rpm on the end of my grinder, so tomorrow I will glue some cloth backed abrasive to the disc and give the thing a test run.....fingers crossed.

    Bob.

    IMG_20200907_160832483 (Large).jpg IMG_20200909_150851599 (Large).jpg IMG_20200907_161040547 (Large).jpg IMG_20200907_161607413 (Large).jpg

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