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Discussion Starter · #261 ·
Firestopper - Just checking in with you to make sure you are ok. You either have your head down and creating more awesome stuff or the wife got after you for using her dinning room table for more projects. We all hope all is well and look forward to more of your posts.
Lil Brother Paco
Ditto to what Rusty said. Knew you had not bee around much, but also knew you and the wife needed some time.
Had been thinking of you.
Till L8R
Lil Brother :)
Howdy fellas,
Thanks for checking in on us. My lack of posting is due to several things but the main reason is my wife had back surgery last Tuesday. The neurosurgeon said all went well, that said I have complete duty of the household chores, shop work and of course taking care of Hercules and Valkyrie. I walk these two 3 miles every morning before 6 am. I will have to keep this up for seven weeks so posting will be limited but I should be able to post once a day without neglecting any duties at home.

I'm also awaiting the call from the place that provided cremation for Phalanx. I have had Gladius's remains for three weeks now and that really help me with some closure with her. Once I have both of my animals together I will be more at peace.
My wife's recent surgery has been a blessing in more ways than just providing her some pain relief, It has kept me very busy keeping me focused on moving forward. As you all have mentioned the hurt that comes with losing a pet is difficult let alone two of them.
Shop work has been full this week too. I built a large slide gate and pedestrian gate for the same home. Very heavy construction. I also built a custom ground mount stand for a large commercial evaporative cooler. I was able to deliver it yesterday. I will post up some on those projects in the future as I'm still sharing projects from the past.
Thanks again brothers!
God bless.
 

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FireStopper - thanks for the update. Sounds like your plate is full. Don't neglect those household duties as I am sure even with the back surgery your wife could whip out an $ss whoppin on you. Take care!
 

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2007 Chevrolet 3500 Silverado Classic LWB crew cab,dually, Kennedy dual pumps, , Donaldson filters
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Howdy fellas,
Thanks for checking in on us. My lack of posting is due to several things but the main reason is my wife had back surgery last Tuesday. The neurosurgeon said all went well, that said I have complete duty of the household chores, shop work and of course taking care of Hercules and Valkyrie. I walk these two 3 miles every morning before 6 am. I will have to keep this up for seven weeks so posting will be limited but I should be able to post once a day without neglecting any duties at home.

I'm also awaiting the call from the place that provided cremation for Phalanx. I have had Gladius's remains for three weeks now and that really help me with some closure with her. Once I have both of my animals together I will be more at peace.
My wife's recent surgery has been a blessing in more ways than just providing her some pain relief, It has kept me very busy keeping me focused on moving forward. As you all have mentioned the hurt that comes with losing a pet is difficult let alone two of them.
Shop work has been full this week too. I built a large slide gate and pedestrian gate for the same home. Very heavy construction. I also built a custom ground mount stand for a large commercial evaporative cooler. I was able to deliver it yesterday. I will post up some on those projects in the future as I'm still sharing projects from the past.
Thanks again brothers!
God bless.
Brother Paco
You take care of family , and all the extra chores, that should keep you out of trouble for a while. We can all catch up later.
Make sure whatever you do, be sure to hide that can off as whip your wife has stored.
B safe, stay healthy.
Till L8R
 
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Discussion Starter · #264 ·
More on the finger break.
The parts have been cleaned from spatter that was original from the manufacturing process.
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The bushing bores are ready for the new Oilite bushings. The upper right bore shows some center punch marks.
This upsets the ID slightly for a tighter interference fit for the new bushings. Also notice the original ball oiler on top.
This will also be replaced with a new oiler.
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The new bushings are in a dry ice bath. This will contract the the overall diameter allowing for an easier press.


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The set up.
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The original ball oiler being removed.
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With the new bushing chilled, they were gently tapped in using the male side of the custom tool made previously.
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New bushing at home.
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And the top bushings.
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With the bushings installed and all spatter removed, it was time for a coat of paint.
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I liked the look and durability of the Rust-O-lium hammer tone paint I used on the Rockwell Delta finishing machine so much, I used it on this project.
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More tomorrow.
 

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Discussion Starter · #265 ·
Yesterday I picked up Phalanx's ashes so now both of our pups are home again. It weird how comforting this simple act can be.

Back to the break.
I really like the color combination.
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The top apron clamp. Yeah, you gotta love this little conduit folding horses.:oops:
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I reached out to Dreis & Krump for a new ID plate with my original numbers and they flat out refused. The old tag is has nostalgia I suppose.
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The links, block, lever, and adjuster.
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A nice detail was to paint the counter bore flat with some bright orange paint to hi light the ball oilers.
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The lower apron ball oiler also got the hi light.
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I failed to snap completed shots of this restoration but I think you guys can appreciate the details that went into this project.
It was also around this time I purchased a bigger lathe. I ordered it new from Acra in Rancho Cucamonga Ca.
The machine is a much finer made lathe than my 17 year old 1440. The new Acra (Taiwanese) is a 1640 with a spindle bore of 2-1/16" vs the 1.5" Birmingham (Chinese).
This will bring me into the next project. This will also be a longish post as it will include many custom modifications, some frustrations and an overall positive result.
Stay tuned...
Paco
 

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Discussion Starter · #266 · (Edited)
The back story on the Acra 1640TE lathe.
I ordered the machine from Acra in CA. It took almost 7 weeks to arrive in Long Beach and clear customs.
The machine is the same sold by Kent, Lagun and other well known brands offered in the USA. Made in Taiwan these machines are very well made with impeccable fit and finish. The shipping was a bundled deal for an additional $500 to my driveway.
Heres were the story took an ugly turn. I was dealing directly with Tom the owner of Acra, he was awesome to deal with and kept me informed every step of the way to include when the contract driver left his facility with my new machine.
Rancho Cucamonga CA is about 570 miles from my location so I figured two days max as the driver had other deliveries. Four days passed and no word. Tom also had no luck contacting the driver. The driver was an independent owner operator so no large freight company to reach out too. I did have this guys cell number but it would go into voice mail in Spanish. WTH? My messages started off polite and requesting a status report (in Spanish). I finally got a call back from this clown only to understand 1/2 of what he was saying. I did catch that he was in Phoenix and that he would arrive later that day. PHX is only 100 miles from Tucson so I certainly was expecting the delivery that day.
It took two more days before the 40' flat bed semi arrived. It was a flat bed with an elevated platform over the fifth wheel coupler. The lathe was loaded on this elevated platform of the bed with no access for me to purchase the 3700 lb. machine without the driver unhitching the tractor allowing me to stab the forks through the heavy pallet. I told the driver he would need to separate the tractor and trailer for me to pull the machine off. This dude had a cow and disconnected the tractor with a bad bad attitude. I'm a fairly patient man, but this guy was already on my crap list for taking six days to deliver an expensive machine from only 570 miles. Plus when he finally answered his phone and informed me he was in PHX and would be to my location that day. He lied and arrived two days later. The disturbing part was the way the machine was tarped and secured. This moron use a cheap harbor freight silver tarp that was shredded and flapping at highway speeds. He also chained around the base of the machine instead of the heavy pallet.
I could see areas that had rubbed through down to the machine finish. It was hard to tell the extent of the damage without unwrapping the machine. I driver left and I moved the new lathe into the center of a bay for good 360º access.

The rear of the head stock base. The plastic was torn from the failed tarp the knucklehead used.
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The back splash were the chain had contacted from poor securing.
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The tail stock end (front).
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The headstock front base.
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The first photo using a tape measure.
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Overall. You can see the ample options to chain down the unit at the pallet and not around the machine itself.
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The model.
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You fellas can imagine how upsetting this was to me. I have only purchased a handful of new machines over the years. most have been gently used or demo units so buying new took a chunk of change. I was sick and pissed.
I sent Tom some photos and he offed to refund me the $500 freight fee. I just couldn't live with the damage after spending that kind of money.
When he ordered this machine from Taiwan, he had five more units brought in as well. That said he had four more sitting in his warehouse. I told him I would be brining the machine back and to have another one ready for me to swap out. Tom does a complete operational/functional test run prior to releasing any machine to his customers so he would do the same with the replacement. I informed him it would be three days as I needed to get some things done prior to the delivery.
More to come...
 

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Discussion Starter · #267 ·
I had had issues with my filter head losing prime about a week prior so I needed to fix that before heading to Ca. I also wanted to repack the wheel bearings on the trailer as my plan was to do a redeye turn around. I also needed to properly protect the damaged lathe so Tom could see the damage was not caused by my negligence.

The trailer wheel bearings were repacked.
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The dust covers are always a PITA to reinstall without damaging them.
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I cut a small piece of aluminum pipe.
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Turned it on the old lathe to fit over the dustcover but engage the lip.
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A mallet made short work of pounding the cover back on without damage.
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Next up was to rebuild the filter head and replace both fuel filters and the spin on Allison filter.
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Rebuilding the filter head was uneventful and went smoothly.
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Now to wrap the machine properly. What you see here is moving quilts followed by shrink wrap. Back side.
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Front.
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I used a Harbor freight tarp too but it was secured with nylon banding. I was concerned of encountering rain.
EC728335-9836-4A3D-8F8A-B165FF50C587.jpeg
 

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Discussion Starter · #268 ·
Loaded up for a 1 am departure.
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Two spare trailer tires, two spare rig tires, and a floor jack just incase. My plan was to take off at 1 am putting me at Acra's warehouse by noon, them unload and reload new machine and return home by 11 pm.
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The Acra warehouse in Rancho Cucamonga was an impressive sight. Over 150,000 SF and full of beautiful machines of all kinds and sizes.
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A large lathe getting ready for an operational test run prior to delivery.
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After loading and securing the new lathe, I had a conversation with Tom about the delivery driver. He again asked me if I wanted a refund of the $500 I had paid for shipping. I said no...He looked confused and then asked if I was interested in anything else. I looked him straight in the eyes and said a taper attachment for the new lathe. This is a $1,500 option and I offered him another $500 over the shipping cost and we shook on it. My troubles got me a quality taper attachment for $1k.

Some numbers to digest. 1006.9 miles
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Redeye 17 hours, thirteen minutes and 56 seconds to complete the jurney. I did not stop to eat only to fuel.
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The fuel consumption. Not bad milage considering the load and 80-90 MPH.
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The crappy part, I had a 24 hour shift the next day.
Next up will be the unveiling of the new undamaged Acra 1640TE.
Stay tuned...
 

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Why do I log in each night hoping to find another interesting, no, fascinating story of your work and exploits? Thanks for the education and the incredible artistry!!

Very sorry for your pup loss - I currently have 2 cremains in my dresser that will always be with me so I completely understand and sympathize with your loss. The consolation we take is that we gave them the best life we could, and we all loved and enjoyed our time together!
 

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Discussion Starter · #270 · (Edited)
Why do I log in each night hoping to find another interesting, no, fascinating story of your work and exploits? Thanks for the education and the incredible artistry!!

Very sorry for your pup loss - I currently have 2 cremains in my dresser that will always be with me so I completely understand and sympathize with your loss. The consolation we take is that we gave them the best life we could, and we all loved and enjoyed our time together!
Top of the morning to you!
I'm happy to provide some entertainment, although not always peaches and cream. Life is real and how we deal with setbacks are just as important as our successes. It's always good when things turn out for the positive.

Thank you for the kind words brother.
We love our furry kiddos and take comfort in the memories we shared.
I keep their paw impressions near by so I understand how you feel.
tempImageRD7Wpp.png
 

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Discussion Starter · #271 · (Edited)
More on the Acra lathe.
With the cosmoline mostly off and the side cover removed, the headstock drive is exposed. The blue nylon gear is sacrificial in the event of a crash. Also visible is the larger 2-1/16" spindle bore and the triple belt drive.
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The 5 HP drive motor 230 AC 3 phase. Notice the brake mechanism connected to the foot bar.

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The electrical cabinet. This will be replaced prior to service. This machine will also be modified into a "smart lathe".
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The fit and finish is impeccable.
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The rear.
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The headstock and 8" 3 jaw scroll chuck. The larger lathe utilizes a D1-6 spindle.
The cross slide also has T-slots.
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The headstock gear selection. Those switches will also be upgraded.
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The carriage utilizes a one shot lubrication feature as well as reverse feed drive.
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The cross slide has a rotating bezel for metric readings. Shown here is SAE
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The dove tails and ground finish. Ball oilers located in convenient places.
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More to come...
 

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Discussion Starter · #272 ·
The tail stock is beefy and has a 4 M/T taper. crisp graduations both in metic and SAE on the spindle.
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The large acme lead screw measures 1" in diameter.
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The bed ways are inductive heat treated and precision ground.
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The rear of the tailstock has fine adjustment for alignment or taper cutting.
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The halogen lite was modified to LED.
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Beautiful precision grin on the exposed surfaces.
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The bed width of just over 10"
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Lookin towards the headstock.
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Overall. WD-40works well for cleaning the cosmoline.
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Stedy and follow rest with roller bearings.
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The machine weighs much more than the 1440. The cast iron is Meehanite.
More to follow...
 

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Discussion Starter · #273 · (Edited)
The taper attachment.
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4-way tool post, 10" independant 4 jaw chuck, and a Manuel in proper English.(y)
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The taper attachment cleaned off. Very nice quality, it glides in all intended directions. I've have a taper attachment on the smaller lathe since new (17 years), and only use it on rare occasions, but it's invaluable for longer tapers.
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The robust Gibbs, and fine angle adjustment.
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Installation will require drilling, reaming.
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The leveling bolts engage a cast disk on the floor. A dab of anti-seize is applied.
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The motor is of nice quality and heavy construction. Check out that frame mount.
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Both of my lathes came with a tolerance sheet from the quality control/ inspection phase.
The old Chinese lathe had a little extra backlash that was fine as long as the operator takes into account the allowances.
That machine produced many projects that fell within .0002" In 2001 the Birmingham 1440 was my reintroduction to machining after HS (20 years) and a little in the Navy. I was able to teach my son on that machine when he was 13. It's was only fitting I give it to him.
The new Acra's tolerants sheets had some impressive numbers. From the spindle total indicated runout (TIR) to each graduation dial. I decided to reconcile some numbers using the tolerance sheet.

Using a Noga magnetic base and a Brown & Sharp test indicator with a resolution of 0.0005".
The compound slide was check for backlash and accuracy.
Dial and indicator set to zero.
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The dial was turned one graduation (0.001") and the indicator reflex that (each tic mark is 0.0005").
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The dial at 0.005" and the indicator agrees.
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More to come...
 

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Discussion Starter · #274 · (Edited)
Verifying the cross slide. With the compound slide rotated 90º, I was able to set up the indicator in line with the dial.
Zero set.

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The dial rotated to 0.010" and the indicator reads 0.005". Why?, some of you might ask. This is because when you take a cut, your reading diameter vs radius. This makes it much easier to remember and work with. A Digital Read Out (DRO) has the ability to also convert if the machine's cross slide was set up in radius.
The bottom line she reads exactly as intended.
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The tail stock also proved to be well made.
Set to zero.
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rotated the crank 0.010" and the test indicator was co-witnessed.
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The set up for the tail stock check.
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The new DRO arrives. This unit is made by DRO Pro's and utilized magnetic scales and a touch srcreen readout.
Ita a 3 Axis unit. Very well packed.
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A close up of the feeds/speeds and thread pitches in both metric and SAE. The SAE range is wide from 72 threads per inch (TPI) to 2 TPI.
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The transmission for the feeds. These switches will be upgraded as will be the entire electrical prior to placing into service.
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This is the threading block dial and lever used to engage the lead screw when threading. The lever utilizes bronze 1/2 nuts to encapsulate the lead screw resulting in the carriage feed.
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The threading dial rotated/engaged to the lead screw.
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More to follow...
 

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Discussion Starter · #275 · (Edited)
I ordered an LED strip light from an Ebay seller. This one has a magnetic mount.
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Bench test .
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Fits nicely along the top portion of the back splash.
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Next up was to mock up the DRO readout screen.
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Trying to figure out the best location and height.
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Working on designing a robust base mount from an aluminum billet.
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Also installed an hour meter to track hours for Maintanace. You can also see the hall sensor for the future tachometer.
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The carriage micro stop was also modified with a hall sensor for the upgraded control system. This too has a back up micro switch in case the hall sensor fails. you can see the tip of the switch just to the right of the hall sensors face.
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The new low voltage electrical control system designed by a good friend. This modification will make the lathe into a smart lathe with features like on the fly speed control, jog fwd/reverse, auto carriage stop, carriage stop bypass, two stage motor braking and low voltage (24vdc) for controls and lighting. All the high voltage will be in a wall mount cabinet.
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The taper attachment installation. The four holes required drilling, tapping and partial reaming.
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A few more details to follow...
 

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Discussion Starter · #276 · (Edited)
The upgraded switches installed.
from the left; Two stage braking mini toggle, two stage coolant (lit switch) constant on or only when the spindle turns, pilot light and carriage feed micro stop by-pass, E-stop, and forward/ reverse Joy stick switch.
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The tachometer and surface feed combination. The housing was a box that the window for the readout was machined out, the two knob switches drilled as well.
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A close up of the custom tach box. It's made from aluminum and comes with a rear cover. Again the window was machined out.
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A look inside the Tachometer. This is a kit that requires soldering and of course mating into a housing.
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With the back splash removed it was time to design mounting systems for the X, Z, and ZZ axis DRO scales.
This translates to numerous holes drilled followed by tapping all done manually. The thread pitches will vary from 1/4-20 down to 8-32.
8082E004-482B-4687-A0EA-4130EEC9E6AB.jpeg

The first scale tackled was the X axis on the cross slide. The scales are customizable by simply using a sharp pair of HD scissors. The magnetic scales are made from a thin strip of stainless steel. The material resembles shim stock.
First of many holes drilled and tapped.
AED7EEA9-452B-4961-A9C7-F2BA24CFAFA6.jpeg

With the tail stock removed, I was able to position the carriage close to the end of the bed allowing me to come up with a tapping guide. A couple of pieces of 2x4's with painters tape worked great. This will mount the read head for the scale.
FB21AA8B-A990-4EE8-9D99-7E5436924702.jpeg

Another angle.
BBDDDE2C-8028-423F-847E-09B4AB198027.jpeg

Next up was to drill and tap for the scale itself. The read head will be fixed to the carriage while the scale glides over the read head when the cross slide is in motion. A precise alignment is crucial as is the "air gap" between the two.
This was a 8-32 tap. The holes for the read heads are supper critical so I drilled/tapped one at a time then mounted the read head followed by a carful transfer punch to mark the second hole.
B31BAF39-1FC9-43A0-BAF8-3C6A1A9EC2E5.jpeg

I opted for all SS button head Allen fasteners.
340203AC-EA5D-40D7-99EE-1587B1C29D4D.jpeg

More to come...
 

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The upgraded switches installed.
from the left; Two stage braking mini toggle, two stage coolant (lit switch) constant on or only when the spindle turns, pilot light and carriage feed micro stop by-pass, E-stop, and forward/ reverse Joy stick switch.
View attachment 642138
The tachometer and surface feed combination. The housing was a box that the window for the readout was machined out, the two knob switches drilled as well.
View attachment 642139
A close up of the custom tach box. It's made from aluminum and comes with a rear cover. Again the window was machined out.
View attachment 642140
A look inside the Tachometer. This is a kit that requires soldering and of course mating into a housing.
View attachment 642148
With the back splash removed it was time to design mounting systems for the X, Y, and YY axis DRO scales.
This translates to numerous holes drilled followed by tapping all done manually. The thread pitches will vary from 1/4-20 down to 8-32.
View attachment 642141
The first scale tackled was the X axis on the cross slide. The scales are customizable by simply using a sharp pair of HD scissors. The magnetic scales are made from a thin strip of stainless steel. The material resembles shim stock.
First of many holes drilled and tapped.
View attachment 642142
With the tail stock removed, I was able to position the carriage close to the end of the bed allowing me to come up with a tapping guide. A couple of pieces of 2x4's with painters tape worked great. This will mount the read head for the scale.
View attachment 642143
Another angle.
View attachment 642144
Next up was to drill and tap for the scale itself. The read head will be fixed to the carriage while the scale glides over the read head when the cross slide is in motion. A precise alignment is crucial as is the "air gap" between the two.
This was a 8-32 tap. The holes for the read heads are supper critical so I drilled/tapped one at a time then mounted the read head followed by a carful transfer punch to mark the second hole.
View attachment 642145
I opted for all SS button head Allen fasteners.
View attachment 642146
More to come...
Paco
Thru the years I have heard numerous ways to describe a piece of wood.
Description of size could be 2x4, could be 2 by twice.
After all these years I have never heard of it being a tap guide. I guess I have just not been around the right crowd.
Hope all is well ! (y)
 
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Discussion Starter · #278 ·
Paco
Thru the years I have heard numerous ways to describe a piece of wood.
Description of size could be 2x4, could be 2 by twice.
After all these years I have never heard of it being a tap guide. I guess I have just not been around the right crowd.
Hope all is well ! (y)
A mans gotta do what a mans gotta do:ROFLMAO:.
 

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Discussion Starter · #279 ·
Drilling and tapping the second hole on the cross slide to mount the scale.
542290D9-15DE-4E90-B960-AA6A90ECEDBF.jpeg

Mounting the fixed read head for the X axis. That white shim stock is provided to set the correct air gap.
AAD6B778-A1F7-462D-A97E-E9D66C2E08C2.jpeg

The gauge is like 0.010".
8A8A2E20-5B6F-420C-8EDB-E7FF85AF05FA.jpeg

verifying the full travel of the cross slide ensuring the end mounting brackets clear. A good 1" remains.
The end mounting brackets that are secured to the cross slide have slotted holes (up/dwn) to provide fine adjustment.
E4310889-6C15-4169-9F80-1128B943C846.jpeg

The other direction of travel. Again the read head is fixed and the scale traverses back and forth.
8C21B900-9886-4BA1-85BD-B611DC158BA5.jpeg

The saddle has a nice machined groove for the DRO cable to nest in. Another hole drilled and tapped for the cable clamp.
8DE9634F-3174-4323-AE3F-58F62542E9DF.jpeg

The X axis is almost complete.
060696F1-F8B7-40E8-95C0-925255172D80_1_201_a.jpeg

Overall a clean look and smooth travel.
47D67CC7-7730-4F16-832A-6C69572861BA.jpeg

The chip cover cut to length and installed.
2265B424-5A16-4231-8783-F1B2B7E526D6.jpeg

We have an X axis reading!
8F82E70A-4733-40DE-B8C9-463859EBB1B4.jpeg

More to follow...
 

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Discussion Starter · #280 ·
With the X-Axis scale done, I takes the long Z scale.
F999A5AB-C433-4078-9459-B3506DA3B4ED.jpeg

The machine has a machined flat surface at the rear side just below the hardened ways. This should provide a perfect platform for the long scale. You can see the preliminary layout sharpie lines. Carful measurements in several directions prior to drilling.
6C110974-B3C9-448D-8E9C-66D7C3AEBDB4.jpeg

The scale was mounted. Now to come up with a read head mount.
58772681-4802-42FF-B320-94304380C2CA.jpeg

I milled an aluminum block to provide the correct height. Slotted holes provides in/out adjustment for the air gap.
CB1B0049-6492-4E06-A232-6E52EC6B19F1.jpeg

The last scale mounting hole was transferred punched and drilled/tapped.
B4C79FF2-8BE3-4020-985D-3797142EFD97.jpeg

A good example of the fine adjustment slot. You have to be close as not much adjustment is provided.
96F1817C-D644-4A0E-9FA3-0E64E028CE25.jpeg

Using the same Noga and test indicator to "sweep" the both faces of the scale right to left full travel.
38F9210E-7567-44FC-865A-5E9475956FAC.jpeg

Another angle. This measurement verifies the scale is parallel to the machine ways.
CD89EDA8-CDA6-4BEC-9215-B2D31A186386.jpeg

Sweeping towards the head stock. That dot you see in the middle/top of the scale is for a support clamp.
45E887E2-CE12-4A98-925F-98FB59B9144D.jpeg

The same instrument was used to sweep the top of the scale to ensure its level to the bed ways.
C762A757-1B6B-4D75-851E-A5873C47676A.jpeg

More to follow...
 
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