Spindles: Comprehensive Guide to Making Light Milling or Grinding

N02ïS10?FRA(1I(ESEZIESfrcm '.'kk .sr, .V' 1Interests ! o. 17 : 1. Hardenlz.g,Tempering and Treatment THeal ubalCain 2...

Author: Harprit Singh Sandhu

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N02ïS10?FRA(1I(ESEZIESfrcm '.'kk .sr, .V' 1Interests ! o.

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1. Hardenlz.g,Tempering and Treatment THeal ubalCain 2. VerticalM illl'nJ1'n the Hom e

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betw een inch and m etric dim ensions with the press ofabutt onl .Since lam not . used to metr i c di mensl ons, Iw as able to . conver tto Inches w heneverneeded. to . . conflrm that Iwas In the ballpark.ljust don't feel a.t hom e with. exactly how m uch 7mm Is but Iam qulte com fortable w ith 0 .2755 inches. r . ' .' . Bearings chosen ' '. , ' Nose end bearings ' : ' Ntlm berrequired 2 ' , lnsidediam eter 1.000 in (25m m ) Outsided' Iam eter 2.000in (5Om m ) i dth . 0.375 in (1Om m ) Seals Both sides Shields None . Type Deep grove bearings w ith axialand radial load capability A jternate AnguIarcontactbear. ra/ ?end,ear/ r?v

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back(double)orangularcontactbearings W ith seals w illbe the best bet.Special bearingsto beused backtobackaresold .n pairs and glound to be a perfect pair. I They are.how ever,more expensive and integralseals are often not avai lable. W e willuse the back bearing onl y to hold the back of the spindle in the m iddle ofthe 1es no cutt1ng load ax1ally hous1ng. It carr-

clam ping elements to assure ourselves thatthere w illbe no rubbing betw een the .ng seals.M ostbearclamps and the bearl .ng sealsare below the I I evelofthe races butwe m ustm ake sure. e also w.antt o m ake sure tha' t sw arf does not flnd . I ts w ay into the space created and eventually ruin the seals. . hen you . are . converting . from m e.trl .c to inch dl m ens l ons and vl ce ver s a, I t IS ... w ort.. n w r.lt.lng uow , n tne u. tnl u..rd and fOurth decim al places in the conversions because they give an indication Ofthe fi t that w e w illbe expecting.In close fits 0.0005 inches can m ake a big difference,Knowing w hetheri s itgoing to be loose ortight is a help. ' '' ' '?. . Spindle parts 11st The following items are needed for ' the spindle' . '

' a ce Of tbi slybea ing s freeng(but ight)t oI Fron'tbear. r' nove axi al inrt he i housi . Alt rnost aI lngs aear :he cuttl oad w1 lbe taken by the pal . bearing .ng l .l .r sRjj, . jtjje

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. ted in the selection consl derations resul bearings specified above. M any of thebear ings could have been used. Do other lability ofbearing putyou not jetthebavai off - anY earing that you can get your (json can be used. han nearings are m ade in m ore forms than you can jm agine. Ourinterestis in bear. thatare designed foraxialIoads and Ir1( )s lal loads. Axial Ioads are along the radaxis. ln otlrcase We m tlsthave sealed bearings to avo' ld having to fi t Seals. oeep groove bearings fitted blp back to

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, apforfron' tbear. lngs 1 : and. need no attention to any further c ' 1 pu r ch a s ed Iubrlcation. Flow ever.the seals rnust be xutforthe puIIey . Nuttocl an' 1pfron' tbearIngs 1 protected frorn swarfand d. Irt.

n , n t ' j t . ; t i ) ) i ) . : ) . b n tj t i , v : i y . ? yi y y . .y ,J t: g. ,t yp : ' s ! $ . : k k ?' $ q z) L ? t yy t l l; t kl y t : yi t ; ) ) ' k ( f : )y: jt ls ) ) kL s Sh. IeIds None .l v. , . ' t, ( J # : . ? . 4 j ) , ? . t k J J k k $ . J : '' y y L i / . J j n j j y y s y t ) y o e p g r o ove b e a r i ng Ta pe r b ear i n f)' #t ';. :r. t;, (y sè t y.: t.t' .;$k, .ys' y'' .;; .k ). y()@) rgj.àrT ? itj gsare bestforheavy Ioads !.è j . ; . t. 1/ -1 ; : ) . 4 E 5 , 1 : t . ) . t : t/ ' : àt?tkf tsLkjbî t) à q) j( ,, jL r :F t t$ Lk tj )! ? j y ? vî .t ) Ajternate standard Ioad bearing but are a bit m ore difficult to use in a K0X StOCQfOrptllley 1 brassscrap ' ?7l . ;' ): )J 'il, )(jJf &r tt : .jkJLtL .lt pta ik fmk tl .sql: i .j . : y y t j j j i q y t f . j l w b lq : r ' ) ) k . t $ j ' v ) F t x Va ' i u f . j ï . r i y y j â . , t r j y y w l s j ) j y c r . # p t y . yt i (Note:the axI ; .a1load on the bear. .s sp. . . j . jjoy,oap j . y j q h % o j % . ? 9 / t p & , 0 p i f , ' , t y : > l ; t . s u l t z j t y t ? s p l I t b u s y ' y j y j l j s f yi l ng l I nd I e t ha t 1 s bot h I n ex pe n s i ve a n d ea sy . , y tj j ; i : , qt J . /. 4 t . ? ': '9)j jL (; qs j. p t o jg ty / () bejt ' 1 purchased o t y y i à , / r : . ; : l jrwo . .; ,u ? ) . j j y j tobu1I d. Seal; Lp r : j ' ; y y y L ' ;u ' . é 1ng the bear1ngs 1 s the pr1r' ne r'V* . . 1 é F t ; ; j j , k ' J l k r . ' %h ' ; . Co )$' t . ? . f t' . t ) l . / j k t p . t j. . t ( ajl' rl()stzero) . . . . é; g k :ë . t) r;: J( ? t;' y' y?é jï : j rj ïq :î j.)y .k.): Tg? s; fê q k;t ' . ' J( p 't z : ' 6 . )i j C ht é t1 ? j . 7 . 1 p 7 k j . ) L s j g y , t t 7 j t ? y t / y ' ; l à j . t ; 7 : ) . C 1 5 4 ; ( E ) 1 L 4 : j 1 : E t l k r k / t t y j ; 1 2 , 1 2 1 I k ( : j l l l t ! i 1 t l : e l . l ( : 1 L I 4 : , ( 8 , ! ; , 1 1I -1j:h t) -1I1 5 ; ., ' q y ; : ) ' . ; . ) t : ; . 9 . ï ; y . . . r s # l : $ . . J p j . . j ? j j j ' ; .:yj' ;j.t / j6'T. js : :. j : ; ll p4 : )/ 1 : ;) l( :j e )r q j.j / t jk j: E ;4: ) 41k; jj : ; jj ay .1 :; j 4 aë !jj -jjlj gj:2 ;j k4 aj lç : jj kj : ; jj t ;j ( jj p 1! ' Ej it ,Jt 2 . : gj ( ;r # ., ;1, . ;jFbL . ,' -? . éF. 4$ l: ! !;.. :/q 1 .: .:...ty ,j, J 2 : . jyrjy:ljjr ëp t8 . .L .(( 'y y jy( k( -( k ;i qr t ,r h î3ïj L'L.. i4 t; . ' ,j :t ?) . y i . . ) : , . , j j . L , : ï t . . j : ) ; # y . : j ë t r ( i . : j t r j ' ; y j . tt jr cllk ji ls tt '. J ;h . . . ( y ( t ) t t' s.. ï:T. L(% (s..fJi.,r f).:.zo.. ).:tr 'tj:?1.fl: jy)) j j j l y . j j ( j j . ë j j y . j ( : j j : j j .j y .jj -jjjjy. jjt ;y j jy .jjj .jjtg jjr iëjty i jg jjtg yjj . jkj / . l k i L j . n t ( . àJ t j j s ' '. . : . ; ? t L ? :ya': , . ; y , ; ) j . j : , . : j . , y : k , j y . , 1 .iJ ,y j, near. .scussl .on . kj .; ( . (jl t ytî n t/ . x v) u )j 4 y); .. ? : #., ',. s. j , j ) . . g y. : : , . t ; k j : y . y. p y j j; jngs dj smallereasy to .

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y p:,. jry . ,;: ( ,, ryy ry.: j, y( ;r, :, -ë -:k(t.,y(ygjj yyg ty, ty j:, kyy yjy-yy,y ,j y: j)) ,jy-;jjj . ?: .. j : ; . , k y j s . , r y : r . , , .: -y.ky, . . y . y ; , ? j . y q E , L j . y j ;,'.u;iE .urL ':: :y Jg J, .! '.y :t :p .: .k r. :t ).p :;. . ..',, ... .g .L::) .;$'8 skj ) .j kj . .y $y .yk .g .. .. '. u: .j Cj ry

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Internalspindleassemblvofthebasic spindle.Note thebeanhgnutattherearof thefronttwtlbearings.The pullevnutis used tohold therearbearing tight.

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w ill be one that can be seated and unseated w ith lighttaps w ith a Iightplastic m allet.Bew are thatthis seating and unsequence of parts fabrication lt1sm uch eas1erto bu1Id thesp1ndIe 1fthe seating tends to Ioosen 'zonce firm 'fits. parts are m ade in the properorder - itis w e willnotbe using any adhesives (this easier to m ake the parts fit to one isapersonalrecom m endation). Buy the nutforthe pulley w hile you are another. W e w illm ake the partsin the following out Iooking for the bearings. This is a order: % -16 (seeAppendix2forUKequivalent) nut preferably of unplated, unhardened steel. 1. Buying the bearings. W hen testing tight fits it is important 2. The nut that clam ps the tw o front bearingsonto the spindle. thatthe bearings go in straightand that 3. The spindle itself (the part that 9ou have a w ay ofgetting them backout. This is one ofthe conditions thatdictates spins). thepart- making sequence. 4. Cutting the threads. 5. The spindle housing. . 6. Split collet for holding the bearing 2. The nutthatclamps the fronttw o bearingsonto the spindle cap. Here isthe machining sequence thatwe 7. The spindle frontcap. willfollow : 8. The drive pulley. 9. Cutting the keyway in the pulley. 10.M odifying the pulley nut. * Hold the blankinthe3-jaw . . Face and cham ferexposed face 11.Cutting the keyslot in the spindle . . Reverse in chuck shaft. . . Face to size and chamferagain. 12.Preliminary assem bly. * Drill through hole and open up to 13.M achining the N o 2 MT in the nose. 0.955 i 14.Cutting the spanner notches in the nch (adjust formetric beari cap and bearing nut. ngs). 16

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i!

Clearance recess 0,975diameter 0.905diameter

1. Buying the bearings Since everything depends on the bearings that w e willbe using,buy the bearingsfirst.Thisis criticalbecausethe fitof the bearingsto the spindlecom ponents is critical.If we have the bearings athand, w e can use them to check on the fits as w e m achine them .AIIfits are to be m ade as stiff,push-fits.The stiffer the better butusing force is notpermitted.Both the innerrace and the outerrace ofthe front bearings w illbe clam ped so the fit does

n ot have to be as ti ghtas you find on some commercialproducts.The bestfi t M aking the spindle

OD 1.50inches

Thissideisthe trueside 24 TPI Recessis 1/8 inchesdeep

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-0.312' ;

'.7'' ')'' /. t '

1/8inchsl ot1/8deep t'$!

squre a.t

Frontbeari ngs,onerrace,clampingnut.

* Cutrecess. * Cutthreads. * ChamferaIIedges and threads, * Rem ove from chuck and set aside. Generally,ifyou have to cut a m atching internaland externalthread,itiseasi erto Set a good fit if you make the internal threads first and then cut the external threads to m atch.It is easierto machine the Spindle to m atch the nutbecause you

can see w hatyou are doing on the out-

ueari ngseat n readsmustalowbeari ngstopass . z''overthem

1s h aqmustbesmall ughto all ownuttopasso jt eno vor

Figure3.5 Thread/shaftrelationshlps.

side of a spindle as com pared to the

insideofanutasyoutrytofitthethreads enough to allow the front bearinjs to One to the other.This being the case,the first thing we need to m ake is the nut thatw illclam p the innerrace ofthe front two bearings to the spindle. criticalitem s on this nut are that thThe e threads and the face that w illclam p to the innerraces ofthe bearings. These tw o m ustbe cutatone setting - this will ORSLIKe thatthey are true to one another. W l nave to m ake sure that the . yreeaadlso tj diameter that we pick is sm all

pass over the threads on the splndle w ithoutinterference. (W e w illbe cutting the spindle threads Iater but we need to plan ahead and thinkabouttheirdiam eter now .) The inside diam eter ofthe front bearings is 1.000 inch. W e w ill m ake the thread diam eteron ournut0.020 inches Iess than that. 1'ooo - (0.0:o x 2)= o.:8o 17

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Let us settle on 0.976 inches because this is an even fullturn on the average m icrom eterand thus easierto read. W e have a choice of selecting ei ther 24 tpior32 tpiforthe threads but Irecomm end 24 tpiforthe beginneras being slightly easier to cut. The finer the threads are,the more criticaleven very

the outsi de diam eterto 1.500 inches or 0.500 inches m ore than the ID of the bearings. Cham fer the outside edge 0.030 inches - that m eans the face of the cham fer is 0.030 inches w ide. W e specify i t in thatw ay because thatis the dimension that w e can see on the part being m achined.

small mistakes become. We want to

Turn the nutaround in the 3-jaw and

choose a m ultiple of8 forourthreads so face itagain.Bore a 0.903 inch diam eter thatw e can drop the halfnutatany Ioca- hole in the nut. Bore a recess 1.002 tion (on most Iathes) w hen w e cut the inches in diameter and 0.125 inches

7.000inches overall.Checkonyourspindle

p jj.! k

' c.a75 in thruhole

.

'x 0.750by 16 tpi

,2MorseTaper c.875in

BearingIDby24tpi

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0 042 x 0.866 = 0.036 . 0 .036 x 2= 0.072

(mul tiplyby2tocorrectfordiameter)

,

* M achine the exposed end carefully.

Clean up the crowns ofthe threads w ith . some emery paperto get aIIthe burrs off Nose notes and hen som e.Take a very slightfinish- Firstgetapiece ofpaperand m ake a note ing ctut on the face ofthe nut.This isthe of exactly how the collet closer fits on

* Put a large cenlre on the m achined end. @ Drilla W inch hole as faras you can into the spindle.

facethatmustbe used toclamptothe thenoseofyourparticularlatheso that

* Increase hole diameter to F8 inch

Iessthan the outsidediameterwhich isto the threads. tant part is to know how far the closer be o.97s inches. cham ferthe Iast thread on each side, Seats on the threads w hen closing on a The threads should always be cham fered No 2 M T collet.Itiscriticalthatthecloser o ,a7s - 0. does notbottom outbefore the collethas di072 = o.aoa inches internal with the thread-cutting tool. ameter(theoretical) Rem ove from chuck and setaside.w e cjbsed firm ly on the part being held. It

(Iaterto % ). * Nextw ork betw een the chuck and a tailstock centre. * M achine the outside of the spindle nose form compl etely. Check w i th a chuck and the collet closer. This m ustbe perfectatthis point.

placethe blankforthe nutinthe3-jaw willcut the two ! /8 inch slots, on the Would be appropriate to try more than andfaceitonone sideinthe a-jaw.Turn perimeter,forthespannerwrench,Iater. One colletalthough the ones forb inch

* Mounta largeface plate on Iathe. * Boltanotherface plate to it,face to

a Thespindle itself(the partthatspins) ltis worth noting thataIIcollets are not

@ clean and oiIthe spindle nose just

and yi inch rods are the m ostim portant.

.

Next we w ill m ake the spindle shaft sAurAxoues itself. This is the m ostcri ticalpartofthe xdxr ees device and so should be made as early in wsdegr ees the process as possible. I am from the dow nhillschool- getthe hard partdone firstand then it's dow nhillfrom there on. Figure 3.6 55and 60 degree threads.The Ifyou cannotgetthe hard partdone,yobl top ofthe triangle /à thethreadpl' tch. w' lIInot have w asted a Iot of time and E E . E ' :

'

the4-jaw chuck.

clean it up untilthe threads are right. Iocomotivecylindersfirst).

This m eans thatthe internaldiameter bearings and w e need itto be true.The you can dupllcatethatfiton the spindle of our threads has to be 0.072 inches otherface isnotguaranteed to be true to Y0u are about to m ake.The mostimpor-

.

1.250india

bearings to rest on un-m achlned stock. Bearing ID '. '' See assem bly drawings. Cham fer aII 1.125 by12tpi ? . ; inside and outside edges 0.030 inches. ' ', ' ,' .' Thread the bored hole at24 tpi.The toFigure 3.7 Seçtion al ong thespl hdle. ' ', ,. taI Iength of the thread flank is 0.041 . ' . , - '. ' ' i (the sam e as the pitch on 6Odnches . Hold the spindle blank accurately in egree threads)so you w illhave to make money on the easy parts no m atterjjow

(this willbe slightly deeperfor27.5 de- 8 passes at0.005 inches each and then much fun itwas (notunlike building the greesl

c.x cc.x c

Key

threads.The pitch ofa 24 tpithread is deep inthering.Thi srecessjermitsthe 0.042 inches. : ' '' 1/24 = 0.042 W ith a 6o-degree thread form , these threads have a depth of0.036 inches. 0.042 x Cos(3O)

()a1z i . n

2.000 i n

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the sam e and neitherare al1tapers. Here l do notm ean the actualtaperangle on the parts butratherthe otherrelative dimenSions.This is because differentmanufacturers follow slightly di fferentstandards. H ere is the m achining sequence w e w ill follow : ,

face.

m ade. * Screw new spindle into second face plate, aIIthe w ay. * Set it to run absolutely true. AbsoIutely true, no matter how Iong it takes! * Tighten the two face plates one to tj ae other. ! '

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i uacsneto1.z4c-uia

@ Using very smallcuts,w ith a sharp there is nothing m ore accurate than w ork

tool,facetheend.

donecarefullybetweencentresinalathe

j zsowqtomatch G

awd c cys @ PutasmallandthenIargecentreon with a properly aligned headstock anclp . z 4sjg i ahura t ock In

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the farend. tailstock. In our case w e are using the . Drilla r /'ainch hole to m eet the hole second face plate as one fixing but the on the otherside. effect is the same.W e can rem ove anu replace the spindle with ease w ithoutIos. cleanupthecentreonthissi de. . w orkbetw een theface plate and the ing accuracy.AIIaccurate Iathe w ork is

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tail stockcentre. * M achinelhe res' tof1he spindle body. . cut the threads for the front bearinas clam n nut. * Cutm ounting forthe frontbearings. @ Cut m ounting forthe rearbearing. . cutthreads forthe pulley nut. * M ake a spacerto take place of pul-

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Iey. * Test mount front and rear bearings

:

* Keyway is to be cutIater. * Rem ove spindle.

andclamp onto spindle wi th nut.

W e have ' to m ake ' the spindle first because we w illneed to have a way to getthe bearings outofthe housing w hen w e make the housing.The spindle willbe ourarborand handle,Itw illalso serve to

Roughturn0.950inchesofthespindle

to 1.300 inchesindiameter.Thisisthe

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- - - -

- - -

1.125Xlztpi section W e W ill form the M yford nose register and threads onto. Now finish yail stock turning this to 1.250 inches in diam eter and 1.ooo inch long. M achine the first 0.500 inches of this to 1.125 inches in

done between centres.The 3-jaw chuck

diameter.Machinearecess0.090 inches

can neverbe trusted to w ork w ith absoIute accuracy. Any part that has to be 0. 410. ''''' removed from the Iathe to be checked for Arbi tcar yclearance,, oow, any reason,m ustbe made betw een cencaj2. asx' ' tres. Any part that m ight have to be m odified at som e Iater date m ust be sexue. a.8 w ork retw pe,atthe nose o/'the m ade between centres. Any partthathas sn't r' ndle.

w ide ' to cleer the threading tool. This recess starts 0.410 inches from the end ofthe nose.Itis to be cutin the threaded halfinch and notin the un-threaded registerpartofthe nose.

it for later m achining m ust be m ade 0.500 inch hol e 3.000 inches into the

coarse thread. It is easierto cuta thread

to have anotherpartmounted exactly to ' -

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nsot psol e-- -Y=-- -

juckpl ae

thou atthisdimension.

4. cutting the threads

Twelve threads per inch is a pretty

between centres.The 4-jaw is a very blank.This hole has to meetthe 0.375 this deep in two sets of passes - this helpfuldevice and does w onderfulthings inch hole that w ill be drilled from the butdoesnotreplace doing w ork between otherside.This side w illbe opened up to centres.These are basic Iathe facts that a No 2 M T in the future. If the drilling are to be accepted as gospel by anv m ars the centre, remake the centre by aspiring turner. turning it. M ake sure that the tailstock centre on Place a ball bearing centre in the yourIathe is aligned correctly.The accu- tailstock and m ove the centre up to the racy of the w ork done depends on this. partbeing m achined. Thereisa section in Chapter16 thatdis- Try to avoid using a pair ofcalipers. cussesthisandyou w illfind this helpfulif Measure the diam eterof the registeron you have neverdone this before. Your Iathe w ith your 1-2 inch m icrom eter.w e w illm ake the diameteron our Note . nose register m atch this wlth this sam e lfyou are tem pted to hold the nose regis- m icrom eter.This w illm ake surethatboth

reduces the Iength ofthe flank that the toolhas to cutin half.Cutthe threads at the Iowestspeed at w hich yourIathe w ill run,in back gear.W e are cutting only 6 threads so it goes quite fast. Com pensate forthe Iarge threads by taking only sm allcuts and by using a very sharp tool. There is a section in Chapter 16 on cutting Iargethreadsintw o orm ore sets of passes. Clean aIIthe threads on a chuck orface plate thoroughly and use this as a gauge to testthe ' threadsthatyou have cut.ltis im portantto realisethateven the threads

'

guidethebearingsaccurately (w hensupported by thetailstock)w hen w etestthe

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fi tofthe bearings in the housing. The mostcriticalpartofthe entire spindle assem bly isthe partthatspins.lthas to be true to the axis of rotation in every

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way.Ifwe getthis right,we willhave a terin your4-jaw,do notdo it.l twillmar fefistersturnouttobethesamediameter cutby the factory willnotalIbe exactly

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goodchanceofhavingm adean accurate theregisterand you m ayneedto rem ove even if our microm eteris off by a few

spindle. Getti ngthisrightisprettymuch thespindl efrom theIathemanytimesto a matterofbuilding itin the rightway. check it.Thisis nota 4-jaw chuckappliand the centre and to turn the internal Start w ith a 1.760 inch diam eter bY M orse taperin the actualbearings, i.e.in 6.376 inch Iong piece offree m achining

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situ. '.:', ,.., - -,. . ., ? ,;r, )r.k .,

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Notematterwhatanyonelellsyouand f ta rucee.TCenl aking i ghiltlc ts, facewtih t sid e reI dr 1u he face le ho au lar ge

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steel.Placethespindle blankinthe4-jawj

chuckandadjusti ttorunthe outeren .

underw hat circum stances,in yourshop centre drill.Drilla 0.250 inch and then a

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The mostimportantthing isto turn aII cationandcannotbedoneproperlywith outside surfaces between the face pl ate a4-jaw chuck.

identicaland you w illfind thatthe nose

Figure3.9 work doneatthisstage.

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that you have machined is tighter on andchecki tout.lfyourlathespindleisnol and wejustdrilled a centre atthe other These threads are to match the threads som e ofyourchucks and plates than itis

running truly,itm ust be fixed before we end that is at the centre point. Things on the nut we made.Their crow n diameteristo bejustafew thou (0.025)Iess chucks and plates thatyou have in your ponents since repairing them is quite place a ball bearing centre in the than the ID ofthefrontbearings.See Figshop. beyond ourskills.Turning the plate to run tail stock again and m ove the tailstock ure 3,5,

on others.This is normal. Try aIlthe canproceed.Replacethenecessary com- should beright. '

Adjustthe threads and the registerto truei sasolutionbutthisplatecannotthen centre up to the partbeing machined.In

There are to be no threads underthe

@ emttfhitetf i tvou want.You should have a beused onanyotherIathe.Donotdoit. this set up,the spindbs le face and nose beari ngs.The clearance recess for the .r fl hat'can be pulled up onto thereg W e need two face plates forthe nexl should be running a olutely true as threading tool is to be right where the -

ister with the threads w ithout difficulty. It is very im portant that there is no play ofthe chuck back plate on the register. M achine a 0.030 inch cham feron the flange and register.Chamferthe threads with the thread-cutting tool. lf you m ake a m istake while m aking the first nose on your spindle,aIIis not

step.You can use the 7.000 inch plate should the tailstock end. W e are now and the dog driving plate thatcam e w ith ready to m achine the restofthe spindle. the lathe.If you do not have two plates Ifyou are using a solid centre instead you need to m ake arrangem ents to bor- of a ballbearing centre in the tailstock, row a plate or two from a friend. M ake you w illhave to w ork m ore carefully and sure that the threads on yourIathe nose atIow erspeedsto m ake sure you do not and the threads on both plates are abso- overheat,expand,and score the centre. Iutely clean. M ake sure that both the Pay attention and keep the centre oiled

bearings end.W e need one fullthread of unused threaded Iength and at Ieast 0.375 inchesofthreadsforthe nutto rest on.So m achine 0.500 inches ofthreads. Cham fer both sides with the threading tool,and cut 24 tpion this section ofthe shaft.Keep testing w ith the nut as you cutthe threads.If you over-cut,you will

Iost.Abandonworkonthisside,turnthe plates run absolutely true.Check them. and adjusted.Even a ballbearing centre havetostartoveragain,so becareful. part around and make the nose on the other side. The bad side will aII be machined aw ay and no-one w illbe any the w i ser. w e are going to m ake the reasonable assum ption thatthe Iathe spindle is true

Do nottake anyone's w ord forit. w illgettightso keep an eye on i t.There M ountthe Iargerplate to the Iathe and is a lotofm aterialto remove. Iightly bolt the sm all er plate to the First rough m achine the body of the m ounted plate as show n in the figure. spindle.Rough m achining m eans Ieaving Screw the spindle that you are w orking about 0.050 inches on aIIshoulders and on into the second plate.M akeabsolutely 0.100 inches on diam eters for finishing

Put the nut on the threads and m ake sure thatitruns aIIthe w ay pastthe Iast thread w ithout binding.This nut has to hold the innerraces ofthe bearing tight. Now thatw e can bring the bearings up to their seating Iocation, w e can finish

.

and tha t the face plates run absolutely sure thatthe spindle thatyou have just cuts.Thi s isenough fortwo orthreefin- machi ning the seat. W ork carefullv to true. I f there is a question in your m ind m achined runsabsolutely true in the face ishing cuts in the hom e shop. m ake sure that the surface does not'aet '' '

' tjle slow est Speed YOUrIathe W illperm it Ptlsh-fit for the bearings. Leave this '' . . I ustec . ., à. under power.W hen you Stop the Iathe, djm ension a Iittle bitoversize fornow . I . : ti ae spindle willtend to sink tow ards tiae M akethe calculationsand allow forthe ' , centre of the earth (0.0005 inches to Iength of the tw o bearings and the ' threads.Turn therestoftheshaftdown uvqs - - - - - - - - - - - - - -Tmusyocx 0.00 15inches). 1 0 Zhe root diam eter of the nut threads sl x soE Takinc I i aht cut s wi t h a shar p t ool 1 ,' 'l

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i nthe4-jaw cuuckand getitrunning handletopulli toutwith.Guideitinwith tFtle.Centre the part at the chuck end the tailstock centre so that it goes

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firstand then use a S0ft mallet to move theOuterend to thecentre OfthespindIe.

straight into the recess. Bore the recess

Slowly,gently-manysmallblowsmake T an igdhtcehrei c skbe wi ttte hrtha enbI eoaors inegrbau stynooutt gooo.

W orked betW oon the faCe plate and the Figure 3.12 Centreb0th endsofthesplhdle Lll ; One big bIow . Then re-check the part tight.There are no threads on the hous-

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Release the body housing from the chuck and turn itaround end forend.

* Bore the clearance forthe nut. * Bore forbearing seating.

on this end Ofthe housing.

* Rem ove bodY from chuck.

(a) SizethehousingforIength.

The criticalpartofm akingthe housing

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gj ure 3.14 Partlàlsectionshowing how thefrontbeanbgsareheld. V

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Threads like these are best cut w hile rotating the spindle m anually.Rem em ber thatthere are only three threads to cut.I

* Chamferthreads and aIIedges.

leave the hal f nut engaged allthe time and use the handle on the spindle to do aIIthe w ork manually.Actually there is no choice in the m atter- iti s aboutthe

bearings at the ends of the housing Iine tighten dow n on the bearings. (c) cut the recess to clearthe nut that up properly. This m eans that the tw o the recess for the nut behind the bearclam ps the bearings to the spindle. recesses are on one and the same axis - ings. since you already have the spindle

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e hole for the two bearings - notjustboth atthecentreofthehousing bearingsand nutin hand, youshouldget (d) Bor m ust be done Iast. but both on one and the sam e axis. Itthe dim ensions from them

only way you cangetthejob doneright. w e stillhave to pullthe toolback out of the threads before w e back the carriage up butthe technique saves a Iotoftim e.

Checkthe threads with amagnifying

. Thesequence fordoing this isasfollows: prehend w hatis required.So think aboutspindle housing. These threads are for to m ake sure that you have fulldept h, itand get yourplans firm ly in m ind.See the cap thatw illclam p the outerraces of clean threads w ith clean crow ns and gul. Hold the spindle body accurately in Figure 3.15. the two frontbearings. Thethreads need yace 1hehousing and' turn i' tdow n to its to clear the 2.000 inch bearing OD by , ' o.o t h e 4 j a w c h u c k . 4oi nch ' . Face outerend and size housing for properIength.Itneedsto be 4.250 inches about0.005 inches so w e willm ake the , . . Iength. Iong.Centre drillit.Drillthrough as faras recess 2.01o inches in diam eter and ' ' - 2. 250i nch . centre drill. you can with a yk inch drilland then open o.12s inches deep. At24 tpithis w illgive 2'010i nch

.orillyzinchholetomeetexisting lhisouttol /zinch.Nextboreinhajfwayofus' three' threadsofengagementwiththe holefrom otherside.

andisnotcriticalbutitisagoodideatobecutting tooljustpa;Clhe'-' 0.11sW-inW cM h ' ''

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. Bore rough outline for nul,bearings precise in alIthings #ou do. m ark.11takes another0.040 inchesto do Figure 3.16 Detal ïofthreadsatthe front Rough bore out the entire recessthis. and threads. beanhg outerrace. * Cutthreads. . r';... ) ..; . before you do anything else.Rough bore ' k

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hole. more to meet what was bored from the cap.since this is barely enough, w e w ill . Bore outto 1.250 inch hol e to meet otherside.This js a clearance dim ension form the clearance renoqs fnr#HO tl arona

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needssomethinkingaboutlofullycom' Nextw ew illaddressthethreadsinthe g lassasyougo.About7xto1OxIsa good magnificationfora shop glass Look

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t.! Iies.W e W illm ake the m ale threads to fit .. . , these so the exact dlam eter OT tnese threads iS nOt as criticalas getting good

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t he bear ings,cleanIIup=and pol ish alIsur. 8f1d about 0.375 inches thick (orIong). r ,.xn. z = .n...,.= Taces. Lnam ler aII OIJgOS anu klll=uus. This willclean Up nicely to form a collet Rem em ber that the threads are always ().25c to 0.312 inches thick.

threadform. chamferedwiththethreadingtool.Mako jjold the work in the 3-jaw with the Oncethethreadshave beencutinthe sure thatthe bearings are actually seat- jaWsreversed.Boreoutthecolletsothat

clearance recess gives us clearance pastthethreads. ,, ,

. . The following notes are applicable to

housing it is tim e to bore the recess for ing aIIthe way into the recess.This can tjae internal diam eter is about 0.250 aIIthread cutting but especially so to the the nutthatholdsthetw o frontbearings. be confirm ed by taking accurate m eas. incj aes Iess than the outside diam eterof finer threads: w hen cutting the finer check dim ensions from the nut at hand urem ents from the frontface ofthe hous. tjae partto be held.In ourcasethis willbe threads,the profile ofthe thread-cutting

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willrun into one anotherand wewill Examine the work afterthe firstcut to

A m icrom eter stop is the ideal, but an ordinary stop w illdo ata pinch.Having a stop gives you one Iess thing to w orry about w hen you are doing a close toler-

and accurately. In general split collets need to be m ade ofm aterialthatis0.25C inches in diam eter larger than the part thatyou are trying to hold.Since w e are

not be able to hol d anything! W e m ake sure thatthe toolis cutting clean. haveto keep this in m ind w hen m akW e need to clam p at Ieast ?/a2 inch of ing the split collet and w e have to the rim ofthe bearings.AlIshoulders that Ieave a Iittle m aterialhere and there meetthe bearings should be atIeastthat

ancejob.

going to hold a2.250 inch part,weneed

to hold everything together. It is high.Ifmore materialcan be provided,

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Figure3.17 W i ththeexceptionofthe2.250 inchholding dimension,the dimensi ons ofthespli tcolletare notcritical.

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iame .s eerkFi e .1 .ofchuck b ri h.isNeap oy, thininn ercaan (b1d Be j surt ee tr o ma tg hu er lo3 ca ti7 on oe ua te rng ra. cT es ep dl li ee ss st to ob sa no sd e aw num berone on the collet before should the clam ping surfaces touch the you remove itfrom the chuck.Also mark the identification num ber of the Chuck on the collet.The split in the collet should be between tw o

seals on the bearinas.On m ost bearinas the innerrace rotat-es in the sealand the outerrace is fixed to the seal. On m ost sealed bearings the seals w ill be below

goodonl forholdingthisonediam- thattheyactuallyare. ,.,. (-) w - n--d at lea-t t' ---e t, ----d- to ,. vhespi-dl-f---t-ap assure oursel ves that w e will get Now that w e have a w ay ofholding the

proper engagement. Theoretically, Onethread could be sufficientbutwe need tw o to m ake sure that we get Contact aIlthe way around and w e need the third thread because w e m ay Ieave one thread un-threaded to gtlarantee that clam ping is actually

spindle cap,w e can m achine i t. You will need one piece of 2W inch diameter free m achining steel 0.375 + inches Iong for the front cap for the housing.This is the same m aterialthat the spindle housing and the pulley are m ade of.

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easiestto m ake itsothatthe register the contact area or shoulder should be diam eter is Iarger than the recess m ade the sam e size as the race of the

jawsand notatajaw.Thiscolletis thebearingracesbutwe mustmakesure

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fections in the profile w illlead to im perfectthreads and on sm allthreads w e do not have a Iot to play w i th. It is also essentialthat the toolbe m ounted to m eetthe work atthe rightangle. Honing the thread-cutting toolon alIcutting surfaces is recom m ended.A sharp toolw ill form cleanerthreads,a dulltoolw illtend to tearthe work.This can be seen quite clearly under a 1O power m agnifier.

ifyou can setup astop forthe carriage. to holdthin partsin a3-jaw chuckfirmly

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ginches.Thisisnotacriticaldimension. toolbecomescriticalbecauseanyimper-

Take the houslng out of 1he chuck. Now you can putthe back bearing in the Notes: , . ' ' back recessand putthe spindle and bear. ings into the housing from the front.It (a) w e need a0.125 inch orlongerregshould run sm oothly and w ithoutbinding isterto hold the collet adequately in or friction if you have done your w ork the chuck. W e need a recess of right. ' about 0.125 inches to hold the part . . in the collet. Unfortunately 0.125 6. Splitcolletforholding the bearing cap and 0.125 m akes 0.250 so ifwe are Hom e-m ade split collets are a good w ay not careful, the register and recess

Once you are satisfied with the fit of a blank about 2.500 inches in diameter

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ingwithadepthjauge.

Now the criticalpart.The bearings are each 0.600 inchesthick so they willtake up 1.000 inch. Added to this we need 0.125 inchesforthethreadsforthecap so that the totaldepth ofthe recess for the bearings is 1.125 inches from the face ofthehousing. dediameter ''' The outsi ofthe bearings is 2.000 inches.W e need the bearingsto be apush-fi tin therecess. W hen boring to a fixed depth,itis best

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putthe m ateria!in the split coliel and face it. If the blank you got is not cut square to the axis ofthe rod orifthere is a rough saw cut,take these into account w hen clam ping the part so that it w ill face true.Clean up the face.Put a slight chamfer on the outside edge, about

o o3o incheswide.

1he toolnose slightly.The pum ose oj u round nose is to give you a finer finish, Generally, the larger the tool nose the sm oother the finish (w ithin Iim its of coursel. W hen cutting anything over 20 threads per inch, be particularly careful to m ake sure that the thread crow ns do

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inchessowehavetostartatadi ameter notthetimetomakeamess!

Bore0th 3e 2h inocle hg inap th.ecapoutto1

shoulderto clearthethread-cuttingtool spindle.YouwiIIrecallthatthesewereto the threading setting to be comjletely at the end of the cut. This should be about 0.030 inches wide and 0.040 inches deep (radius). M ake sure thatthe blank actuallyseats firm ly in the split collet.Take light cuts with a sharp toolwhen working with a

have an inside diam eterof 2.01O inches but it is w orthw hile checking this again before starting. W e need a registerthatis 2.100 inches in diam eterand O.157 inches Iong forthe threaded portion ofthe cap.On this we

clampallowsustohavethesmallest

' true to the thread axis. W e are sooklng for a hole that is 0 .004 inches Iarger than the spindle flange i.e.0.002 inches clear allthe w ay around. Now place the bearings on the spindle and put the w orks in the body.

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possible oulside diam eter for 1he housing.In this case the housing w ill be 0.250 inches largerthan the Iargestbearing (in diam eter).This gives 0.125 inch of w allon either side.If

Tcig l argepieceinasplitcollet.Useahoneto willcutO.125 inchesofthreadsand thecapontothebodyand che kht te hn e getthe bestedge thatyou can and round allow 0.032 inches forthe recess on the clearance betw een the cap and the body

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we edutl o thaetble ng on,wa went wo dbnoelt ed ea ar si t 5 /!c sla inmp ch '

on each si de and m aybe m ore.Bol ting down is also m ore w ork. wecancut3threadsat24tqionaregis- inches.Ifitis not,you can adjustitby (b) When a milling cuttercuts, it pulls ter0.125 inches long.W e wlllcut these m achining the cap at the appropriate the sw arfoutofthe cut. This in turn threads by turning the spindle by hand, Iocation. pul lsthe cutterinto the cut.This pull era1Iedges and threads and set has to be taken up by the frontbearAfter each pass check the fit of the tjaeChamf ca threads w ith the body of the spindle. p aside. w e w ill cut the 6 ings and these are held in w ith the stop cutting and clean up your work a5 Castellations forthe spannerwrench in it cap w e are machining.So itisim porsoon as the threads start to engage, lateron afterw e set up to do aIIthis and tant that these threads fit w elland 5m 00th down the crow ns and cut the Similarwork,atone time, in the Iathe. seat as perfectly as possible. Full threads 0.001 inches at a tim e untilyotl threadsthatengage fully are needed. .

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.o on the nut.Ifyou startgetting a point at ou tsiuediameterofthe the thread crow ns w hen cutting the ' beari ngs : threads, file them down imm ediately or you are Iiable to get an erroneous fit. Threadi ngtool ' , Gl earance . . . '. .'' (This condition m akes the nut seem f, ' tighterthan it really is.) BearingNut colszinr.h ' '' ' Once the fit gets close: take two -'' . . .001 s gure a.1: secgon across t:ebearing nut(cap)penw eter. )., incheson each setting.File thecrow nsof i nches so t ha t we woul d t he t hr e ads down as t hey ar e cr ea t ed . Tr y ' . . t hisor2.010 ,.. ' not disturb the bearing seat.Threads at the nut after every pass. Check the the bearings there in place there should Notes.. 24 tpi have a double depth of 0.084 thread crow ns after each pass. Now i s be a 0. .375 (a) The ring clam p is threaded into the slightly over 2.100 inches and w ork Thethreadsthatthis cap hasto fithave inches in diameterbefore rem oving from housing to hold the bearing outer ' down from there. Cut a recess at the already been cut in the housing forthe the coll et. This hole should be bored at race because this form of bearing

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2.2soinchdiameter

portion thatIsgoing to be threaded to the right diam eter.The diam eter should be o 08O inches greater than the inside diam eter of the part that is going to fit these threads, in this case the body of the spindle housing.The bore ofthe spindle housing forthe bearings w as 2.000 inches. the threads 0.01O inches greater than

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inboard side to cl ear the threading tool, It should be betw een 0 .030 and 0.035

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bearings in the housing,the cap shoulg thread aIIthe w ay into the housing.W ith

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N owisthetimetodecidewuatk indof standardpulleyforthisspindleandis pulleys you are going to use to dri ve this suitable for most m illing applications. l t ence with the back bearing and housing. spindle. M ake the back ofthe spindle to suit your particular needs.The description covers the standard forpulleys with a 0.750 inch hole and an O.125 inch

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diameterand1.000inchIong.Thisis chuckyouareusinghasalotofeffecton

Theintentofthedesignistoallowany The0.750inchshaftforthepulleyis

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Firsthold the pulley stock in a 4-jaw chuck and m achine one face of the pulIey.Holding the stock deep in the chuck w illensure that the body ofthe m ateri al is held accurately in the chuck so that it gets faced atright anglesto the axis. Drilla 0.500 inch hole in the pulley and bore this out to 0.740 inches and then ream to 0.750 inches.W e w illcut the pulley groove between centres after m ounting the pulley on the spindl e. lt cannot be done atthis tim e because we stillneed the blank to drive the spindle

can be replaced with ease so you can selecta pulley w i th a keyw ay ratherthan change your mind Iater if you Iike.Note one needing a flatfora setscrew . that even keyed pulleys have to be Ihave designed the pulley so thatit is nutted dow n because the back bearing the same diam eter as the spindle houssquare key (as found in m osthardw are on this spindle (w hich bears no axial ing,Itis bettertodoitthisw ay because a storesin the USA). Ioad)ishel d w iththisnut.Do notusethe Iargerpulley tendsto getin the w ay m ost The pulley should be cutto m atch the setscrew in these pulleys. of the tim e and is not needed for the beltthatyou are going to use.The draw Firstm ount the blank accurately,cen. high-speed w ork this spindle w illbe used ings show a pulley that willwork with tred in a 4-jaw chuck.Lightly face the form ostofthe time. Thesequence ofoperations form aking estpartofthebelt.The narrowerbeltis ''Mount parts accurately in the 4-jaw the pulley is as follows: when wemachinetheMorsetaqer.The easierto use and is m ore than adequate and centre them ''m eans that the total forces required to do thi s are qul te Iarge foreverything you w illwantto do w ith a outofround from side to side on the dial @ De-burr1he blank. and w ould ruin a fini shed pulley.M ore on s indle Iikethis.Itisalso more flexible. indicatoris Iessthan 0.001 inches not . Hold the stock in the 4-jaw chuck this later. Bp uy your belt first and then w ork to it. counting the blips caused by scratches and centre with W inch sticking out. lhave selected bearings w ith integral, Thebelttopshouldbeevenwiththeout- and imperfections on the surface.The * Face 1he stock. double seals.W hen clam ping the inner side ofthe pulley w hen itisseating ri ght. part should be checked for ''on centre'' @ Turn a boss : 9 6inch Iong and 1.375 and outerraces ofthese bearings itis im inches in diameteron face. portantthat the seals not be touched by The pulleyis madefrom a piece offree on each end ifitsticks outofthe 4-jaw m achining bar stock 2.250 inches in over2.000 inches.The condition of the * Centre drilland drillou1tol/z inch. the clamping faces.To ensure this you @ Bore outto 0.740 inches. should turn aw ay about0.010 inches on m ade of the sam e stock as the housing alignment.W orn and abused chucks are * Ream orbore to 0.750 inches fora the entire face ofthe pulley boss except and cap. harderto use. Iightpush-fiton 1he 0.750 inch spin- forthe partthatis going to clam p to the dIe shaft. innerrace.Take a close Iook atthe bearstandard run-of-the-m illpulley w ith a : /4 intended to be long enough to allow you * Hold in4-jaw chuckbytheregister. ing seals lo see w hatyou need to do. inch bore and a key slotto drive this spin- to m ount standard pulleys on it. There * Check centring and axialalignm ent with the back of the spindle in the 9.Cutting the keyw ay in the pulley bore and a centre suqporting the The keyw ay in the pulley can be cut by 0 187'' 0.375.' spindle head from the tallstock. using the lathe as a shaper.The pulley is .093 * Tighten dow n the chuck as you cen- held square in &he chuck and a keytre the pulley, shaped cutter is held dead on centre 40degincl h * Remove spindle. height in a boring bar in the toolholder. angle 1.250'' * Face pulley to correctthickness. The lathe chuck is held firm by som e * Cut keyw ay. m ethod and the key cutter is m oved * The belt groove will be m achined across the pulley bore m anually by traIater after m ounting to the spindle versing the carriage.Itis possible ' to take Shaf' tto guarantee absolute concen- cuts of about 0.005 inches w ith each tricity. pass. Depending on how carefully the cutter ' '...' . . . ,.. . .,t ,l' lrecomm end a 2.250 inch diam eterdrive has been m ade, it m ay be necessary to . ' ., : '. : ; . . pulley asthis is tbe sam e size as the body m ake a holderthatw illallow the finished ; . Ofthe housing. lf you w ould Iike to fi t a keyw ay to be broached by a square tool Smaller or a larger pulley, that can be of the right size.The holder is a 0.750 d one. oss rhep,,,epzrw/epslwen . , .ao secpvn acr inch shaftw hich hashad halfthe keyw ay

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Y be a need forsom e modifi cation ofa dIe.ysea.csoincupuIjeysbownisti,s ma comm ercial pulley to prevent interfer-

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illed into it m k e ywayi si ntl a T ehp eul oe ty her Thh ea l f too olfisthae wo gourg ke .At h pe lai s nu rfasce wa bea rg ma ain ys t bew ma hi c dh eu th pe y i fc naespus t ceaéhlr a ettfiheu ol nt .h atyoudonotdamagethe scpaindr le emoo nv e thet hle atb teapaesrsahnodwnmo inu n Ft i gu th re e spindle in from the front.The 3.23. standard o 125 by o.125 inch turning you like. .

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toolthat is ground completely flat and

installed back bearing willhold the spin-

o:inthe spindle sharp at the cutting face. It can be 11. cuttinqthekeysl

dIe at centre and make iteasierto Iine Iey held in the 4-jaw and support the

ressed throuqh with thetailstockforthe shaft

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things up.

f Fl.nalpass.Ifyou have a Iargerdrillpress Use yourverticalslideand asmallangle this can also be done in the drillpress.

W e willdrivethe spindle with the:ul-

nose end in a fixed steady. w e w illdo

screw inthe frontcap and tighten it thisaftercentring andaligningthework

or vice to hold the spindle at the righ! down good and tightbutagain be careful as perfectlv as w e nossihlu r-nn

carefulfilinucanalsobeusedtofinish heighttocuttheslotforthekey.Itisalso thatyotldonOtdamagethecastellation. Holdthe' pulleyeJdoft ' -h'' eW sn Wi 'J 'dleinthe thekeyway.possibletoclamptheshafttothelathe Installthekeyonthebackofthespin- 4-jaw chuckand supporttU' e nose end cross slide w iththe rightam ountofpact dle and push the pulley onto the spindle. w ith a centre in the tailstock.Adiust the 10 uodifyinqthepulleynut ingunderi ttodothis. Installthenutonthebackofthespin- 4-jaw untilthespindleisperfecllycenvou willneed to purchase a : y4-16 (see

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cutthe slot 0.063 inches deep w i th a dIe and tighten it.IfaIIis wellwe are now

tred.Usino the tailstock koonq tl a=e orx'l

Appendix2forUKequivalent)unplated 0.125inchdiametermillingcutter.Two readytomachinetheMorsetaperinthe aligned.Ti lhtendownsnun -'0M n'-tHWo ''Qn *VY' lll' l nutandmodifyit.seethedrawingfor orthreepassesshouldbesufficienttc nose.Wewillmachinethepull eygroove -wewillbetakinasomehJ 'avur tYP J* w''/ +1 themodificationsrequired. getthedepthyouneed.Theslotshoult Iater.Rightnow weneedthepulleyasit thereamerandwW eneedtoho' ld-z' a olZU'/'

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unfortunately large, unplated, com- goalmosttotheshoul derforthebearing. is to hold it in the 4-jaw as ourdriver. W hile stillin this nosi tion.nosito ioW nxo 'thY e'

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cially m ade nuts are not quaranteed It does not have to be cut across the Take itaIIapart. fixed steady on th' e spindl' e 'at the nose to havethethreadseitherinthecentreof threads and a shortslot (0.500 inches) bearing to supoortitfirm lv. thfetn u t o r pa r t i c u l a r l y i n I i n e wi t h t h e a x i s j u s t un d e r t h e pu l l e y i s OK. 1 3. Ma c h i n i n g t h e No 2 MT i n t h e n os e Thesecuenc'efordoinz# laowzxrl e;0ao he nut. Iw as surprised to discover Clean up yourw ork with a sm ooth file. First we need to set up the com pound follow s: O * W''W, 0 W ''h .'* V'C' o this (orlm ay have got m y hands on a slide atthe M orse taperangle.W e can , .

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Particularlybadnut).Thisbeingthecase, 12.preliminaq assembly

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useaNo2MTplugtohelpus.SeeFigure

h ide ofthe nutshould be re-faced A word ofcautlon here - donotusie any 3.22.Itis preferable to have a '.steeper eac s ul .. . 1

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after it has been m ounted on straight, Iathe cut threads. I used a Y.-16 (see Appendix 2 forUK equivalent)nut and m achined it dow n to about 0.376 inch.

m ore ofthe shaftto be available as seat- used on the inner races of the double

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ing for the pulley. Do not use a Iock bearings only and now here el se.Do not w asher under this nut as these tend to do it. First, clean everything, especially al l .

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jaw chuck bythespindlepulley.

. putthe tailstock centre in the centre in the nose.

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Turndownt o 0.375'1thick

Iightly oiIorgrease (w hlte Iithium )every' thinc for rust Drevention and ease Of assem blY. Push the back bearing into its recess.It hhastoindl beeab let e ne, thi sore es ads war mosmo upvi ni us s itcsi as oul t e Sp not be glued under any conditions. Dû not allow this bearing to faIIout as yot proceed With assem bjy. ..uttne F , tW O î .ronl .Dear . l .ngs On I .ne ,.. Spl -!l .mr .

dIe and nutthem dow nastightaspossi ' Figure3.21 Modlficatlonofacommerclal 4-lsnut. t.. . .., ., ,..1 ; . 2., à. . r??.)?, bIe with the nutthathol dsthem in place' .y '

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adhesives,anyw here,i f at allposs e,if tzhan needed'' taper as opposed to a you ever w ant to take any part of thi s shallowerthan needed''taper. i ndl e a pa r t . The de si gn does not I end Once the compound is adjusted we sp itself to disassem bly if things are glued

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p.9klFe 3.22 How tosetup the taperangle on thecompound slide. M ountthe d i&JP lindicator/ W compoundandaëbstuntlcompoundp : spara//e/tothetaper DO . X st eepertaper/spreferred.

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Since no-one l know has drills over

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willhaveto boremostoftheholeforthe

Thetaperreamerscomeintwoforms, Morsetaper(No 2).Firstbore in about

a roughing ream erand a finishing ream er. 0.062 inches at0.685 inch diam eteras a YOU CZR dO W itjjOtltthe roughing reamer m arker.M ake the bore so thatit is tight but you do need the finishing ream er. on a taperatthe inside end and loose on

The roughing reamerIooks justIike the theoutsideandnottheotherwayaround

Figurea.2a How tosetuptornac/wy?,theNoJMT..

jjnjshjng ream erexcept thatit has som e tiny scallops cutinto each ofthe cutters to break up tlae chips. . setspindle to run absolutely true at accurate M orse taper hole is w ith a Ifyou have a choice,geta ream erw ith .

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thjetre akes meraouM6 tify ouhhol aveetota inch to start the

s pendyourmoneyandtimebuyingor 0.500 inchesindiameterinhishome yorrowjng a taper attachment for this shop,we cannotstep-drillthe hole and 2

X Hol dinfi xedsteady

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!jathelikemySouthjBegnd, thejncj trav el incj (joc jes On and We need to bore aboutthree deep! so itw oujd take a m uch largerlatbeto do tjjejob.Rough bore in sections,use the reamerand tjaen scrape to fit i f need be.

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- w e w ant the taperto be bored stee?er than itneeds to be.w atching the outsl de end so that it does not get too Iarge is m ade easier by m aking the 0.685 inch

Morsetaperreamer.lfyou cannotafford aflatatthe endoftheMorsetapertang. section indicated above.W hen it gets

.

. M ountthe fixed steady atthe double a ream er,borrow one ori fthatis notpos. This i s very helpfulifyou m anage to get close, start using the ream er. Use the bearinss and set. sible, have a localm acl aine slnop do the the reamerstuck in the spîndle forany of slowest back geared speed on the lathe. . Rough bore tl ae M orse taper hole w ork foryou.The spindle can be held in a a num berof reasons.Ifthe ream er gets Be absolutely sure to putthe Fainch thru-

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withthecompoundslide. sc orIargercollettodotheworkfairly stuck,itwillcomelooseinthetailstock holeinthespindle,assuggestedabove, . Finishream theMorsetaperholeand quickly. t otgo andl nde. yolu wi lleha ve oflr ele astehe it b eforeayo uuck star .mTha hole llh lpyou fn rom tl ao ed) spi ft her is not at on knock st rt ea ert out ofwi the te aper adjustfordepth.

. Rem ove spindle.

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have neverdone anvthing Iike this before tang,and no hole in the spindle,you are now . M orse tapers are about o.sco in trouble because there is now no way itical inches per foot or 1 in 24.The various to get a wrench on the ream er.Discard becaus ' rhedeeip tho fthbe isMo rsett ap risMcr ford Morsetapers(No1toNo6)arenotaI1attbespindleanddiscardthereamerand t such te the i IIha cls osteopr oper ly wha hen the y collet the sam e taper.The fit to the taper is Startover. collets w closer is screw ed dow n on the nose very sensitive to the angle of the taper, Tlae reamers are to be used forthefinal ne bestw ay to m ake sure that There is no realistic possibility tbat w e sizin: oftlne taperonly. hreads. Tl t alonqtueream eris so long ThetIe of cuyt i an atgt ithis ver this w illindeed be the case is to have a m i qhtharden,tem perand then grind this I taper.Itis notin the cards to have equip. hard to hold the ream er in the tailstock c ll tanclo sera nel dyamhade alfin chound colleiftpos aon j- m entfike thatin the shops ofhobbvists wj jeomakin:thesecuts.workcarefully wo i t he accur at (gr sl nd use Iots of cutting oiIw hen m aking ble,useanoId x inchendmillshank)half and amateurs. w ith a Iittle care, ac a thes

As you proceed, check the depth of the reamed hole w ith the collet and the collet closer. It is im perative that this

doesnotbecometoodeep.Thespindl eis alm ostdone - now is notthe tim e forinattention to details.

ces. lean upove ,chfarmf and q isepar haIl siu rfac Rem omer chuck Inol pr at on forfinalassem bly.

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14. cutting the spannernotches in the

i nchrodinhandwhilethemachiningis unhardenedtaperwilltakeustotheenk d tslowl eycu to tsa .v Toaç k degveetr tylnIgi gh t cutsandwork capandbearingnut beingundertaken w e w illneed to have of ourdays.The bestw ay to ensure a fg in tjjq taper jjere agai tl aecutterstuck Beforewecangettofinalassembly,we n lcaution you not need to cutthe 0.125 inch wide notches a bouthal faturnIefttogo hto int nthe hecol collet l et. Misor by set t raper ialsa ream ndser cr .a l p ti nsgnot i aftpos erusi sbl inegto ttohespi startunless you laave tl ae I aole tl nrouqh in the nutforthe frontbearings and in the closerwhentheshaftistig ndje i .

The easiest and only w ay to make an bore a taper because even on a s.ooû

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n place so thatyou can knock front cap.w e willcut 2 notches in the

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bearingnutand6inthefrontcap.wedo way setthe com pound to -20 degreea .

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notactually need 6 but 6 look best.

and cutthe otherside.Finish the bottom

Usea0.125inchdiametercutterhel d ofthepulleygroove.Makesurethatboth

in a collet in the Iathe spindle to do the sides ofthe pulley are even.Cham feran4

cutting.Ifyou have made the George polishupyourwork.

Thom as dividing head,Ido not need to . '?' ,! tellyou how to cut the notches.If you 16. Finalassem bly have not, you should consider m aking Clean a1lparts and oilIightly. this excell ent tool.lwilldescribe how to Assem ble as before but this tim e do itw i t bout t he d i v i di n g head . t i ght en everything down forgood. Hold the nutand then the cap in the 3Happy m achining is around the corner.

p,/( i

spaced m arks on them respectively. A toolmounted at centre height w illallow you to engrave a diam eter accurately. You can engravethree equally spaced diam eters by indexing on each of the 3

Nextsetupasmal,ang'eplateonyour

nalnutofftk ae backoft' aesqindleJ

plate sothatyou can cuttheO.125 inch wideby0.125 inchdeep slotsin thenut

jaw chuck with soft copperor aluminium packingsand use an (adjustable crescent)w rench on thenut.

inches at a time w ithout difficulty.The cross slide and carriage are Iocked in place and the cuts are taken by m oving theverticalsl ideupand down.W orkcare-

* M ake the key forthe pulley of brass forease offiling.Brass is m ore than strong enough to carry the Ioad being transm itted.

fullysothatyougetanicelookingjob.

* Theholethroughthesqindlehasto

Deburrtheparts.

15. cuuing the beltgroove in the pulley Firstgetthe beltyou w illbe using - a K

ofthe Morse No 2 milling holders use this size to pullthe taper in. Since

wi llw ork too.The forces we intend to transmit w i th this belt are quite m odest. A sm allsection ism ore fl exible and easier to handle. Setthespindlew ith thepulley m ounted on it up between centres on the Iathe. The included angle in the pulley is 40 degrees(orto suityourbelt).Firstroughm achine thegroove w i th a parting tool.Next setthecom pound up atzodegreesto the crossslide,orto suityourbelt,and finish cut one side of the belt groove aIIthe

the shaft,this hole could be m ade li inch w ithoutencountering any difficulties.This would allow Iargerparts to be held through the spindle but can also cause out of balance of problems athigh speed ifeverything is notcentred in the spindle properly, Unless you have som e overw helming reasons, Ieave this at Ya inch at this time. In any case you sl aould avoid draw bolts as bad practice and usethe cotletcloserm ethod asbeing

inchwidebeltisfineandasmallerbelt

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m ake a close-fitting tube to space nutto bejlaced on thefrontbearand clamp the two bearings (as Ajso Itis easierifboth bearings w ould be needed in som e ofthe deings. not the sam e size because then si gns presented Iat are eron). , , . ' . : '' , 7).: : ' , '.'' ' . . ).,' '. ;t .'.' ''f, ;' ,... . t ' '

as soon as we can m ounti t.A sim ple but versatile m ount forthe verticalslide w ill be described in the nextchapter. ' Notes and com m ents

equaldivisions.

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tjj e most suitable for high-speed rk. W0 . vj je back bearing has to be sm aller tjjan the front bearing to allow the

jaw and mark outtwoand sixequally ThespindlewillbereadyforitsfirstjoL

jaws of the 3-jaw chuck.This gives 6

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Cutthe m aterialand then face one Iong

s ideoneachplatesothatyouhaveatrue surface to work from .File the burrs off the m achined sides. File aIl edges to remove aIIburrs.In these operations itis im portant thatthe m achined faces be at right anglesto the plate faces. Next m achine tbe side opposite the first side that you m achined.Again file

.D rillo neOneoft hetheWplinac holesinthe t ebu rr off.C he2. ck500 thatinches youhawve plaand tes face Of Of th es. th hat ar es exac tly ide @ use this hole as a guide to drillthe 4 thatthe sides are parallel.This is imporholes in the otherplate. tant.coat w ith Iayout blue and m ark up

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. clampthetwo pIatestogether.

the plates so you can see whatyou will

labur te.raj!jjoles. .p De

chin et th d sideso feea hpea lat e. yilMa e the bur rh se of fi .r M ake ur tc hat ch

. oriI1theotherthreeholesinthefirst bedoinginthenextsteps.

1(l. 'f

Introduction . '

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T e r elear umb edro s thheat rwo hev er t c a dtehamo ting npsii sdts f . olt p-la te ougcekth tlyk9 rece oare u- . sh pîi n d ce aa nn be use of nw tba eyI at ,baub ta ts hi jc s' t sp li tti p lalts el si tcu lan mp thc eos n leo in .B Mo ut nh te flt awo tin4 ja wccth ae nr d.centre. c go orn oe nr .i Is fneoxta ,c ma eo thd eea Je es ssb ae rf v d'iv u'o s t ndle isdifferent.since we have a full the posi ion desired. The mounting is * Bore out hole to accept spindle mentsand re-macbinetbeside.M 'achi ne

ffIlI

Partsneeded

s phespindlenoseonthisspindle,wecan lat

fairly sim ple and flexible. m ountchucks on it.This m eans that we To m ount the spindle to the vertical can actually hold thinqs in the Iittle spin- side,the follow ing items are needed.The

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through both plates. the finalside to m ake the plates to size. . Mark edge ofplates forthe four1764 File off allburrs on aIl12 edaes of each inch holes. plate.Atthis staoe the nlateW s should be

dIe and use the Iathespindl e to do the dimensionsgivenarethefinisheddimen- * Centredrillgn4 Iocationsfrom both to si ze and youihouldube able to nut machining.x wholemassofaccessories sionsoftheparts. sides(8locationstotal). them togetherinanvwavvouoleaseJnd come to mind - butnotnow and not * Drillykinchholefrom eachsideso notbeabletotellth' atth' er ' eislnydifferhere! The basic m ountings that com e to ' '

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ind im m ediately are: m

2 Pcs

steel,4.ooo inches x 2.500 inches.plates need to be

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4 pcs

steel,o.soo inches round x

.ton theverticalslide,b0thhorizonallyandvertically(oratanyangleif l a

2 .625inchesIongas spacers,

w ivelling slide), this 4 studs o.2so inches x 3.125 inches

thatthey meet. ence betw een the nlates. * Open holes outto :' y- inch and drill ne-blue one plate and m ark on i t one through. of the four17s. inch holes on the plate * Stam p num berstam ps to m atch the face.M ark this hole very accuratel y and

.un unib ts o. ltplates.

* Cutplates in two.

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you ave a sdard use. being t Iong w ith washers and * M illsaw n faces so aIlplates are the he stan . on thecrossslide atcentreheightfor nuts. sam e size. * File aIIedges. specialfunctions.cross drilling and 4 T nuts M aclained.M ake each from 0.750 inch diameterx * M ake the 4 optionalspacers. keyw ay cutting are obvious examples of often needed operations at 0.375 inches Iong shafting. The raw materialforthe plates is nominal centre height. .' . once we have the materials in hand,w e 0.500 inch mild stee! plate vou need . '

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we willworry aboutthe use ofthe spindle on the verticalslide and Iathe car-

riageonly.

arereadytobeginmachining.

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c heckyourwork.Firstmarkthe hol e . withaIIghtcentrepunch.'rhenIookatit . with a m agnifying glass.If itneeds to be moved overyou can do it w ith a heavier punch and a ham mer.Just ham m erthe centre punched hole over to where it needs to be.This hole willbe used as a guide to drill aIIthe other holes in the faces ofboth plates so it is im portant ' to get this right. centre drillthis hole and

e n000 oughinch stoby ck2to make two finished then drill it through :764 inch. Deburr 4. .500 i nch plates.Try to 9etthe m ostfree m achining m aterialthat YOu can find - itm akes it a 1oteasierto do the work. Life is too short to spend it

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b0th sides of the hole.Now clam p the two plates together four tim es in the . four possible orientations and drill through with this hole as a guide.Using

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the platesto clam p lent)foracap screw .

.se spindle withoutthe bolts binding in Make the washers out of machined çt le horl es.lt. alsogivesyoualittleadjust- 0.500 or 0.750 inch material, O.125 -j ent oom urryourwork.ll bolted tin ches thick with a 0.250 inch hole m w hile theDeb hrough them fora close fiton the studs. pjates are sti atjisry use yournklmber9UNCheSOra tog ' .. centre punch tO m ark a1lthe mating sur- M ounting the spindle on the faces that will be created when the verticalslide t. aisl llmake The two splitplates when assembl ed to plates areieSaWn rdurinagpa rera ss'r elmb ywi . the fourspacers w illprovide a footprint thkngseaS unboltthe plates and saw them in laalf that w illplace the m ounting studs on a I engthwise as shown on the drawings. 3! 4 inch by 314 inch grid.That is the putaIIfourhalvesinthe millorthe 4-jaw same as the standard spacing for the

chuck and m illdown the saw n surfaces forclean up.Remove aI lbolts and file alI ) ,,, : ,, surfaces and edges to rem ove allburrs. Check the dim ension to tbe edges and Itis wellworth the tim e to m ake the 4

slots on the vertical slide and on the cross slide table. The spindle can be mounted in either direction on each of these surfaces.

w e can now clamp the two plates make adjustments as necessary as the spacers thatwillhold the plates exactly

ThegoalinFigure4.2 isto have avery

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rem aining three boles in the firstplate.

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vjjendrillthroughateachofthe4holes aNo7drill5 /ainchdeepandtapeachend I k j j j a 1 y s 4 d r i l l . Th e s l i gh t l y I a r ge r d r i l l i s W -2 8 ( s e e Appendix2 forUK equivaW nere to allow oseded j

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together with four 1W inch Iong by 1 /0- w ork progresses.You should be able to 3ys inch apart on centres. ln the m ain, com pactm ountinq thatis as close to the 2o (see Appendix 2 for UK equivalent) putthe spindle into the bored holes w i th thespacers m ake iteasierto m ountthe m ountingsurface as possible forrigidity.

bolts.Mark the exactcentre ofthe hole theslightestbitofji ggling.Thefi tshould spindle.The spacersshould be made of Itis the intention ofthe design thatthe for the spindl e.This shoul d be done as accurately as possible and it is well worth the tim e to m ake a centring button and screw the button to thecentre w ith a 6-32 screw . The button can then be

be a close sliding fitso thatw hen you cut yz inch rod and should be exactly 25/8 clams be nearthe bearings form axim um the plates in tw o and re-bolt them inch Iong. Centre drilleach end,drillwith rigidity although that is, of course, not together,the spindle is held snugly and firm ly.W hen unclam ped w e w ant it to ; stuu !' :'. come loose with ease.W e need the hole Nut , y

adjusteduntilitisexactl y inthecentreof to be from 0.002 to 0.004 inches over-

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the tw o bolted plates.Chapter 16 contains instructions on how to m ake a set of centring buttons. These have also been described from time to time in M odelEngl beer.You may preferto usea published design. lt willbe well worth yourtim e to m ake a set of buttons. The two-plate assem bly is now

size. ln a design like this the clam ping hole should alw ays be slightly oversized sm aller holes w ould m ar the spindle at

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thejawseachtimeyou used them.

Rem ove the bolted assem bly from the chuck and re-blue the 4.000 inch by /2 inch si des. M ark the plates ' to drill the j

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Figure 4.2 crosssection ofsplhdlemounting. .

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holes are intended to m atch the slots in the M yford system .These slots are 1F:6 inches on centre,so the holes need to be 3:4 inch apart. M ark these holes from both sides and centre drillateach ofthe 8 locations. Drill to the centre of the plates from each side w ith a W inch drill, î

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mounted in a 4-jaw chuck.centre the four 76. inch clamping holes that go ates with the centring button which is through the width of the plates. The pI already atthe exact centre ofthe plates. Make sure that the plates are flat in the chuck. Rem ove the centring button and drilla sm allhole at the centre through both plates.Open this out to the Iargest drillin yourcollection and then bore itout so thatitis a nice fiton the spindle body.

Viasher

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bring the spindle centre to the exactIathe M achine off0.125 inches oras needed gure4.6 Tnuts formountlhg splhdle. centre height.Since each Iathe is sli ghtly Fi foryourslots from one side ofeacb nut. differentin this dimension,you willhave -rhe T nuts should be made to suitthe Set up again to m achine off another to determ ine the nronerthickness ofthe v ol.a's on vour Iatheo. The T nuts for 0.125 inches from the otherside.

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eterrod,First m achine 4 shortcylinders in the nutseach 0.375 inches tall.Drilland tap a W Driving the spindle is covered in Chap20 (see Appendix 2 forUK equivalent) ter14. .

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absolutely essential.Ifthe mounting isto e Verticalsîide,the studs should be kept as short as possible to avoid interference with the 'chuck end' 'parts ofthe Iathe. W hen m ounting to the verticalslide it is often necessary to make sure thatthe

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ence purqoses,the approximate thick- tomakefrom apieceof0.750inchdiam- eachcylinderinmind,machinethesteps

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spacerforyourpa-rtiJularIathe.Forrefer-m 'Ju '-ntingth' espindletoTslotsareeasy Now,keepingtheun-threadedendof ness ofthls spaceris 1.062 inches.

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way through the cylinder as discussed

spa'certhat mounts on the carriage. This

Figure 4.3 Frontview ofthem ountlhg. ''

thread in each cylinder but not all the .( ' ., 3 '' * ' '. .

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plished by confirming that the slide is actually parallelto the face ofthe chuck

Since the loads transm itted by the

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andparalleltothecrossslidebefore spindlecanbecontrolledwiththedepth m ounting the spindle. The cross slide should be m ade parallel to the chuck face by bringing itup to the chuck or a face plate as it is being m ounted.W hen the spindle is mounted to the vertical slide its face has to be m ade atrightangl es to the bed.Thi s can be done by using a m achinists square betw een itsface and the bed ofthelathe. W hen m ounting to a sw ivelling vertical slide itis bestto m ountat0 degrees with

t heswi velsetatOdegreesandthento adjustto the angle thatmay be desired with tbe swivel.

of cut thal is taken,it is possible to use four spacers instead of a block. These spacers can be 0.750 inches in diam eter with a l' Ji. inch hole in them . Longer studs w illhave to be m ade to allow the clam ps to be bolted dow n with the spacerin place. ,' '' ,'

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Tbe end oftbe stud thatfits into the :' ' ' . ,' . ' . . ' . : '' ' ' ' ' nuts shoul d be threaded so thatthe stui .M ounting on thhe cross sl ide w illnot go aIIthe w ay through the nut. . .'. ' , ': , .' ;' ' )'' M ounting att e cross sIide alm ostinvari- Thiskeepsthenutfrom breaking theslots 't ' ' , .. ; î ' . '' . ' . .. . , ' ably m eansthatw e are going to mountat in the table if over-tightened. I t is also ;i , ' ( the lathe centre height(ifnot,w e use the w orththetroubleto m akethenutssotha - . . * These ar e avai l verticalslide to attain the heightthat we a stud cannotbe threaded through them aam)utdor ablefrom varioussuppliers,ready madeorthreaded. A.J.Reeves& co tB-i need orto makea cutl. , .).;.kï. ,;. pastthebottom faceforthesam ereason,A.Marks(Modelog)aretwosuppli ers.

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ture.Tiaespindlefi tsina 2.ooo inch by

2.o oao ncar chts t eelba rhndl ouesing .cribed Tl ei ri dge spi des

in chaptera is a relatively large spindle for

u seonasmallIatheandcangetinitsown w ay w hen w orking in close quarters.A part of the problem are the clam shell s that m ount tl ae spindle,w hich althouah very versatile,do take up a Iotofroom .-ln this nextdesign,the m ounting is formed by the housing itself.Although the 2.2so inclaround housino is replaced by a2.ooo inch square l aousr lng, . the elim ination of

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Ifeltthatthis spindle design represented the smallest spindle thatone could m ake and stillpreserve the No 2 M T and thus

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are barm akes it easierto m ountthe that were used on the cartridge spindle and thus the outer dim ension of the ' ', . . housing is reduced. M ore im portantly, . the m ounting slots can now be m illed right into the spindle housing. ' r engineers find them selves dealing Elim inating the register for the chuck tetl also elim i nates the need for the flange thatthe chuck tightens up against.This .::. wit. too allow s the spindle to be made sm aller. However, w e stillhave to proleroverhang atthe frontofthe vide a shoulder for the bearings to use a sm al tighten up against and a sm aller flange face to protect the bearing seal s. The ;. ! outside diam eter of the bearings deteryhe general construction of the spindle mi nestheoutsidedimensionofthesqinthe m ounting m akes this effectively 2follows the construction ofthe cartridge dle.lfyou can find smallercross sectlon m uch sm allerdevice. soindle.The emphasis in these instruc- bearings,this outside dim ension can be This spindle issim ilarto the basic snin.ti ' ons i s on the differences between the reduced further.Ipicked the ''easiest to ind''bearings.W e willneed aboutO.125 dIebutomitstheabilitytomountachlckcartridgespindleandthesmallNo2MT finches ofm aterialpastthe outside ofthe onthespindlenose.Doinj thatallows8spindle. bearings on aII sides to allow for the getinto sm aller-tighterspaces. ofa No 2 MT, the taper is Iess than : /4 threads forthe bearing cap. The m aiorchance in the desinn ofthisinch in diameterand so can be m adeto fit The spindle cannot be m ade any shor ter because w e stillhave to be able s mallersp'indleisfheomissionJftherec .ina0.750inchshaft.ThereisnotaIotof isterthat centres the chuck on the snin W. m aterialIeft but there is enough for our to span the table that w e willm ountthe dle nose.This allow s us to reduce 'thiIight duty spindle. That dimension is the spindle to,on the verticalslide.One side outside diameter of the snindle frorrbasisforselecting the inside diam eterof has to clearthe cutterand the w ork and 2.250i nchesdowntoz.ooo-inches.Th6themainbearingstobe44inch.These the otherside has to clearthe driving pulspindle can be made eitherw ith a rountbearings are sm aller than the bearings ley. That pretty m uch sets the Iength. How ever,there m ay be an advantage in body thatis 2.ooo inches in diam eterol making the spindle longer - it w ould be housed within a square barw i th a sectior j st iffer.You m ay w antto considerthis on 2.ooo inches by 2.ooo inches.using thi l I 1 . ...j.... lI l yourspindle.You w illstillhave to design l ! ..'* ''- ) I forslots that are 1? /1e and 3% inches on ., I1 .tjj .I .. . .

s qud;etoftl attjsvursfa cesthathavethe spin jotscutinthem It is ford Stan jar vy jsoeasiertoclamparectangularsection a io aIIkinds ofstrange setups thatama-

El N o i mt ei natingonefrontbeari ngalowsusto s i n p gi nh d el ev a .v Th ci st u i s.desi rabl eforstabi li tydur-

smallerspindletobefabncatedthatcar About2.000inchesinfromthebigend

3.125inchesoncenters

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Figure 6.1 A smallerNo 2 Morse spindle housed?' >a2l ' hch square barhouslïw.

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Figure s.2 Frontvjew ot.spindle , .' ?thches sqsare '

centre.

W e w illm ake the com ponents of the spindle in the follow ing order:

1. Buying the bearings. 2. Front bearing, inner race clam ping nut.

3. The spindle itself (the part that spins). 4. Block style outerhousing. 5. Drive pulley. 6. Frontbearing cap. 47

46

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7. Cutting the pulley grooves. you can hold it squarely in the 3-jaw. 8. Cutting the notches in the bearing Face and cham fer one face. Reverse in the chuck and face and cham fer the cap and bearing nut. 9. Cutting the keyway in the shaftand otherface - this w illbe the truefacethat has to clamp up against the bearing.W e in the pulley. w illidentify thi s face by the step thatwill 10. M aking the No 2 MT. be m achined on to it.Drilla ? 4 inch hole 11. Finalassem bly. in the disk and open this hol e out to 0.700 inches in diam eter. 1. Buying 1he bearings Cutthreadsat24 tpiin the bore.These As usual, before you do anything else, buy the bearings. In this case the inner are to fit on the threads on the spindle diam eter of the bearings is critical shaft w hich w illbe at 24 tpion 0.74: because the dimensions are so tight.In a inches.Once the fullthreads have been w ay this is the squeezed version ofthe cutsm ooth dow n the inside crow ns w ith basic spindle in the previous chapters. some em ery paper m ake another pass Do not buy a bearing that has an ID of w ith the threading toolto clean up the less than 0.750 inches or an OD over threads again.Cham ferthe firstand last 1.850 inches.The bearingsthatwe need thread w ith the threading tool.M ark the true face w ith a Iine across a diameter. are as follows.

1.750 in (45mm ) 0.750 in (2Omm ) 0.437 in (12mm ) 80th sides Li ghtduty ordeep grOOVO

Rearbeanhg Outside diameter Inside diam eter Thickness Shield Type

250''dia. -

- .1 -

24 TP1 '

1.5OO in (38m m ) O.625 in (16m m ) 0.375 in (1Omm ) Both sides Lightduty ordeep

0 1250by 0.125''

SYx j 7 ..

Holdtheblank accurately inthezbjaw.

Besure thatboth ends are running true i ti s im portantthatboth centres be in line atboth ends ofthe spindle.Face the part and drilla centre in it.This centre has to be Iarge enough to alIow a 34 inch hole to be drilled into the centre and stillhave some centre I eft. If you do not have a Iargeenough centre,turn the centre.Drill a W inch hole in the spindle as far as it willgo,open this outto 0.375 inches in stages and m ake it 3.500 inches deep. Thishole m ustmeetthe M orse tapefand hole putin from the otherside.

thetaperinthespindlenose.Placeacen-

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tre in the lathe nose.M ountthe dog drivingface plate onthespindleand getasuitQble dOg m ounted to the spindle blank (if YOu do not have a targe dog,you may

l

Spannerslot

Figure6.3 Frontbearl hg,innerrace

havetofabricateoneforthisjob).Placea

clampl hg nut.

groove

2. Frontbearing,innerrace clamping nut The firstthing we need to make isthe nut that clam ps the inner race of the front bearing. The nut is m ade from a slice of free machining steel1.250 inches in diameter and 0.375 inches long.Itcan be m ade in

3.The spindleitself(thepartthatspins)

The spindle proper is m ade from a piece 7 of free m achining steel 1.500 inches ir diameterand 6.500 inches Iong. Unfortunately one end of this spindle cannot be held with a face plate,as w aS done w ith the firstspindle,because this the 3-jaw chuck.File the edges so that spindle does not have the full Myford

48

/ 1. 125by12tpi

again once you rem ove this firstsetting.

cut the tw o spanner notches Iater on formed.W hen facing faraw ay from the w hen w ehave the verticalslidesetup for chuck it is necessary to use very Iight al1ourslide w ork. cuts and sharp tools. lf an appropriate steady restis available,itshould be used. o. 2s0' W e now have a 1.375 inch diameter 0. 812.di a I shaft with a 0.375 inch hole in it w i th . - ,r .. x.x -X 0.740.,dia Cenlres On b0th Sides. =0704'di a ;' I & Rem ovethe4-jaW andthoroughl 1 yclean .

Diametertobe0.004inchIess thantheID ofthebearingcap.

Matchbearing 0.375* N

jaw fora while.Do not use the 4-jaw

Thiscan be done with a cutting toolset Turn the spindle around in the zpjaw at dead centre.W e willuse this Iine to and repeat the operations just per-

Bearing dim ensions Frontbeanbg Outside diam eter lnside diam eter Thickness Shield Type

nose On it.So aIIfinished w ork hasto be dOne with centres at both ends. However, you can hold the one end in the 4-

ballbearingcentre inthetailstock. W ew ill dothe restofthe w ork betw een centres. Bring up the tailstock w ith a running Dentre in i t to support the w ork. Turn 0.625 inches ofthe shaftdow n to 1.125 i nches in diameter. Cuta groove I /ainch Wideand J40inch deep 0.437 inches from the end as a clearance forthe threading tool.Threadthe restofthe turned section to1.125 x 12 tpi.M atch thesethreads to Vour collet closer. W hen cutting such

24tpiby0.740..

0. Q31. '1 1. aezs' 0312'' .

Figure 5.4 Splhdlenosedlïnensions- there isno allow ance form ountlhg a chuck.

Iarge threads it is necessary that the threading toolbe very sharp because the flank ofthe threadsgets ratherIarge.Itis also possible to cut the threads in tw o sets of passes so that the flank rem ains halfas w ide.The thread is cutto half i ts depth,the toolis then m oved overhalfa thread pitch and the other half of the thread is cut.Use yourcollet closeras s a gauge for these threads.These threads w illneverm ount a chuck so their fitting accurately to a chuck back plate is not relevant.Chamfer the threads w i th the threading tool.Thereis a section in Chapter16 on cutting coarse threads w ith tw o setsofpasses. Turn the next0.375 inches ofthe spindIedow n to a 1.375 inch diam etershoulder.Turn the shoulderinto a 0.312 inch w ide flange and cham fer both sides. Polish clean. This com pletes w ork on this end ofthe spindle fornow .Turn the spindle around between centres and rem ountthe dog to the spindle,m aking sure thatyou protect the threads already cut w ith appropriate softm aterials. The frontbearingshave an inside diam eter of 0.750 inch so we can turn the entire shaftdow n to 0.760 inches aIIthe

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The threads are to be cut at 24 tpi.As always,go slow ly untilyou get the nut started on the threads.On fine threads,a couple oftbousandths orso can m ake a big difference - we w antasnug fiton the threads. W e need a m inim um of about three threads or I /s inch of threads to engage. cut a recess at this point to accom modate the threading tool- this willalso form the clearance forthe nut.

dow n to 0.680 inches - this willform the pastthe bearing seat.Itshould be barely

these threads to the nut purchased to

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way to the shoulderbehind the threaded nose.Leave about 0.030 inches on the shoulderforthe finalfinish cuts. The frontbearing is 0.375 inches thick and we need a 0.250 inch space forthe nutto hold the bearings so w e can turn aIIbutthe0.625inches(0.375 + 0.250) nextto the shoulderdown to the rootdiam eterofthe bearing nutthreads.At24 tpi,the double depth of the threads is

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ing has an inside diam eter of 0.625 inches.W e willcut the shoulderforthe sm allerbearing Iater.Rightnow ourinterest is in fitting the front bearing and its clam ping nut. W e can now fittbe frontbearing.Turn the bearing seatdow n to 0.750 inchesto

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Thls com pletes the outsi de ofthe spindle excep' tforthe keyw ay.W e stillalso need to m achine the No 2 MT in the spindle.W e willdo lhatin si' tu afterthe spindIe has been assem bled to ensure that tbe M orse taperand the spindle axis are Dom pletely co-linear.

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makea bearing apush-fitonto theshaft,

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do this.This is criticalon Iarge parts but even on relatively sm allparts like these there is a noticeable difference. Before we cutthe threads,we need to havethe nutthey willfitto athand.That w as the reason that the nut was m ade first.

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smallsquare

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nextin greatdetailis the preferred housï ' ing forthis spindle. 'i Taking thetim eto m akethe blockstyle '' : body for this spindle will give you an . easierto m ountspindle.This applies to ''' allkinds ofm ountings w hetherthey be to ' .. a table,to a slide,to a toolpostorsom e . , Iash up you have to use for a special . ,'E

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2.000 inches x 5.250 inches Iong.These are 1he finished dim ensions. Do notfinish face the tw o ends ofthe block yet.W e do no1w antto do lhis in a m illeither- w e want to use this operation to confirm thatthe block is m ounted accurately in the chuck.First m ount the

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roundhousingbecause,forotherthanits thecentreofrotationand useamachin-

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s gure s.6 Detailatthenutthatclamps the ynerrace o/'the frontbearing. Note how t/)a clearanceforthe êhraaJfn.qtoolextendsto justunderthe:ear/hvandhow thecrownsof thethreadsarejustabitsmallerthan the beanhg ID.

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The raw m aterialforthe body isa piece

dim ensions,i t is identicalto the m achin- ist's square Iaid on the Iathe shears to ing ofthe basic spindle housing. m ake sure thateach face is perfectly verjt is easierto m ake the round housing ticalw hen you take yourm easurem ents. o an jtjsto m ake the block style housing Once you are satisfied with the setup, ,

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piece in the 4-jaw as accurately as you

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0.070 inches.So we can turn the shaft The leftedge oflhisrecess is to bejust P8Stthe seating forthe bearing.Match project.

shoulderforthebackbearing.Thisbear- wide enough to accommodate the dam?thepulleyand1hebackbearing.

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t jgggs w jjen you cut the threads, their

threads On 1he nutlhatYou m ade. Theshoulderto clam p the back bearing i s4.250 inchesfrom 1he shoulderforthe f ont bearings.Check the drawinqs and 'r c'heck again-against your work.M''''easuring from the front ofthe frontbearing to the front ofthe back bearing.The shaft Should be m achined dow n to 0.625 incbes in diameterpast this pointw ith a Straight shoulder for the back bearing. This Should be a push-fit for the back bearingandforthedrivepulleywhichwill have a 0.625 inch ream ed hole in it. Ctlt 5/8-18 (see Appendix 2 for UK eqtlivalent)threads on the spindle shaft

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andcangodaheut adia ndfacethecentreof we can centre on if we ever need to n a centre

.j1surfaces with some 40O gritemery Boreouttherecessfortheclampforthe

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tentcutthatmightmovethe partin the ing centre is notqui te as precise asis a jaws,Oncethecentreisinplace,you can fi xed type, but for our purposes, promaketheintermittentcut.)lfnot,adjust vided therotating centre isofgood qual-

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the partand take anotherlightcutto see if the centre is right.You have to be in the centre from allfoursides.There is 1 /$6 inch orso ofextra Iength on each side to play w ith. Keep in m ind thatthe finished s ock is to be 5.062 inches long.

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i ty, it is more than adequate.To some extentthis type is betterable to take up forces engendered by expansion of the work as it heats up than are fixed centres. Rem ove the centre and drilla /2 inch

body should be 5.062 inches.W e need theunturned portion ofthe blockto be at Ieast 3-% inches Iong to allow hold down bolt slots that are 3/8 inches on

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tionsofthebearings - studythedraw- bearingsarenotinthehousingwhenyou ingsto getthe design firmly in m ind. Drill a ! 4 inch hose to m eet the hote

intermlttent cuts and these have a ham - is a tight push-fit on the bearing . This m ering action thattendsto m ovethe part recess should be % inch deep orabout !4 in the chuck.The solution p: snotto over- inch deeperthatthe bearing is thick. The

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partto m eetthe hole from the otherside. the tailstock to keep the axes aligned. There are three distinct recesses that Using the front bearings as a guide, have to be m ade on the frontend ofthe bore a recess that is a ti ght push-fit on

tlk qhten thetc huck (and thus rts' b the spindle isdesi gnedtoallow the bearing ure work)butto use a cen- to m ove in this recess (there willnot be

h ousing:(1)Therecess forthe bearing the bearings.This recess should be /8 cap

2.000 inches in diam eter. Cham ferthe side,allis notIost, you can open itup for corners ofthe block.W e w illneed this 3 /8 the Iargerbearing atthe frontofthespininch asa surface forthe fixed steady dur- dle housing.

holds the bearings. Firstrough bore the front ofthe housing forthese three recesses, then finish the recesses in the order described bel ow .

chuckforfu treanddo,fnk qht. much movement)butthe fitshould be a Turn down 3/a inch of the block to very firm push-fi t. If you overbore this

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Backbearingrecess Nutclearanc --- ---- ---- --- --- -

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Q.187 inches deep.Cut a threading tool clearance recess atthe innerend ofthe 0.187 inch bore and thread the outerpart ofthis bore to 24 tpi.W e w illcutthe cap

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T hethreadofsoerm iscriticalandshouldbe inchwide by 0.406 inchdeep and31 4 made ascl to perfectas possible.w e inches aparton theircentres.

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Thishousingistobe made of2.0inchby2.0inchbarstock.

Cut this recess and the threads first so Go over the entire housing w ith a thatthe seatings ofthe bearings willnot smooth file and emery paperand clean it bedisturbed once they have been cut. up.Use the file to cham feralledges. . . o This compl etesthe outerhousing. . . .

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Figure s.8 Detalïs o/'hotzs/bv.

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machlne.Firstm ark the locations ofthe 4 slots that you are about to mill. Then check them against the surfaces on w hich you are going to mount the spin-

t hreadstofitthisthreadssot hefinished dle.Onlythen,cutthe4 slotsforthe diameter of the threads i not critical. mounting bolts.The slots are to be W +

Yo2scinwide slots

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Lightly cham feralIedges and go overaII Surfaces lightly W ith som e 4OO grit em ery paper.

thantheouterrace ofthe bearingsand and qrepare to take it to the milling

Bearing

1.062inch hole inhousing

recess.Ifyou overbore this side,you w ill have to startagain,so be very careful.

(a)Threads This com pletes the lathe w ork on the The dîam eter of 1he bore for ' the cap housing. threads should be o .oo5 inches Iarger Remove the housing from the 4-jaw

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(2)the recessforthe bearingsthem- inchdeeperthanthe bearingisthick.The

selvesand (3)therecessforthenutthat bearingouterraceswillbeclampedinthis

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do this so thatthey do notget contaminated w i' th sw arf. Be sure to use the

ffom the otherside.Bore this out to spindleasaholderandguideforthebear1.000 inch diameter halfway into the ingswhenyouaretestfitting them.Use

tre suqportbecause you willbe taking rearbearingasaguide,borearecessthat

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(c)Beanhg recess W hen using the bearingsas aguide in the nextstep,make sure thatyou do notget them stuck in the recess because you

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centre to be cut into the block. These have a Iot of m achining to do aftercutslots m ust not interfere w ith the loca- ting the bearing seats. lt is best if the

Onceyouhavethecentredrilledinthe hole atIeasthalfway orasfarinto the

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bearing innerraces.This is a clearance

dotheothersidejustasyoudid the first sions.Theaim isto clearthenutbyabout gde, keeping in m ind the changes in the 0.050 inches orso on aIIsides. dimensions.The finished length ofthe '

body,put in a ballbearing centre in the blockasyourequipmentw illallow you to tailstock,to supportthe farend and face go.Bore this outto 1.000 inch diam eler the part.Again,you need to use the cen- halfway into the part. Next,usi ng the

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As stated before,the m achining ofthe needed. Provide a threading clearance round housing is sim ilar except that no after the $4 inch for the threads. M ake

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he housing straight and to m ake sure forces are higherw hen using a Iarge pultpatvou can getitback outagain. Iey so this should be taken into consid-

mountingslots willbe needed.Please re- this0.062 incheswideand 0.036 inches

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ferto the detailed descriptions in Chapter deep. Drilla ! 4 inch hole through the partand 3 onthe basic spindle fordetails. bore this outto 1.127 inches.Check this 5 Drive pulley against the spindle nose - this hole Axpulley 2.000 inches in diameter is should be 0.002 inches Iarger than the shown in the drawings. The pulley spindle atthe bearing shoul der.Itshould

jaere should be about 0 030 inches t tween the cap and the. housing. If be there is too m uch, m achine the front on tj ae cap w here it touches the outerrace ofthe bearing.Ifthere is notenough turn backthe shoulderuntilyou getitthe w ay

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s ldbe madfe tohi ssuit thndl euesesintended justbarely clearthe spindle sothatthe bh the user or spi you

vou want it. Chamfer aII edges and

Since the tw o do nottouch w hen the spindle isrun-

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pulley arrangem ent m ay be in order for dirtso keep itassm allaspossible.Do not som e users. chamfer the edges on this hole. Polish , ' . the surfaces but keep the edges sharp.

6.Frontbearing cap

polish.

Cut24 tpithreads on the section just

The bearing cap is m ade outofa slice of m achined. W hen cutting relatively fine free m achining steel 2.000 inches in threads, there is a problem with the diameterand 0.375inchesthick.Thisis threads suddenty becoming Ioose. Fine m ore than we need but we w illm achine threads are ready w hen they go on but the excess aw ay afteritis rem oved from they are stillrelatively tight.By the tim e the Iathe.The threads are cut to m atch you sm ooth the crow ns and clean them the housing threads and are at24 tpi. up,thefitw illbe perfect.Thatisw hatwe

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Turn ? /$einch ofthe partto 1.850 inches Test the cap on the housing with the in diameter(0.100 in diameterm orethan bearing in place. The bearing m ust be the OD ofthe bearing).This w il provide m ounted on the spindle w ith the back enough m aterial to cut the threads bearing in place to m ake sure that itis in

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w hen the bearings are clamped tight, eration.

'oli sh. p Now hold the housing inthe4 jaw and getitrunning exactly true. Turn the face ofthe cap dow n untilyou have ? 4 inch exposure atthe outeredge.Chamferand

spindleiscapableofheavy work,a Iarger ning.Any space we allow is a doorfor

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W e w illcut the notches for the spannerIaterw hen w e have the verticalslide se1up. . ' 7. Cutting the pulley groove The pulley groove is to be cut w ith the pulley mounted to the spindle and the

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helpfulto have the beltthatyou are going to use in hand w hen doing this work. The design calls for belts that are 3/8 inches w ide as the w ide end ofthe 'V'' Ifsuch > bel tsare notavailable to you,you m ight

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overto give a zo-degree cut and cut one side on one groove.Then cut the other side with a -2O degree cut.W iden the

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t' ight. l the nlg oto tooves henexattgonce, rooveyou -if you trOn y toydo aI the gr are m ore Iikely to m ake am istake. Once the groove is right, cham fer aII edges and polish the entire pulley w ith 4OO gritemery paper. ''

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groove slowly untilthe belt seating i s

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cap and bearing nut , , Set up the vertical slide w ith an angle .. plate on itand cutthe tw o spannerslots '! on the bearing nut you m ade. The '' . notches should be /8 inch w i de and /8 ,

want to consider changing the dimen- inch deep.Make the cutsby moving the

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sions so that they fit the belt that you verticalslide up and down. File off the . ' intendtouse. burrs. uountthe back bearing and the back Usingthesame setup, cutthe six slots pul ley to the spindl e and ti ghten w i th the in thebearing cap.These slotstoo should ' ' pulley nut - this should be done only be /8inch wide and /8inch deep. after the ke9way has been cut in the . , shaft.W e need to use the key to m ake 9. Cutting the keyw ay in the shaftand Stlre thatthe pulley does not slip on and in the pulley '. score tjje shaft w hen we start the ma- Detailed instructions for cutting the

keyway in the shaftand in the pulleys

10.M aking theNo 2M T Spindle should be assem bled with the Next drilla /2 inch hole 3.500 inches Iarge pulley next to the bearing.) The deeptoclearaNo2M T,Youdo notneed

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included angle.Then setthe compound '

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groove.The included angle ofthe groove should be 40 degreesandthe w idth ofthe groove should be such thatthe top ofthe beltssits even with the pulley flange.

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Setup the Iathe to turn betw een cen- are given in the Chapter 3 on the baslc tres.Be sure to protectthe spindle from spindle.

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pulley and then machine the pulley

work willbe done between centres.Iti s 8.Cuttingthenotchesinthe bearing

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to drillaIIthe way through - aIIyou need

the clam ping nutonto the spindle. Put the back bearing in the housing. Rough bore this outto accom m odate a Putthe spindle through to the front and No 2 M T and ream itforthe rightdepth the back bearing from the front and put for a No 2 M T collet. Detailed instruc- the pulley on the spindle. Place the nut tions fordoing this are provided in Chap- on the shaft to hold everything toter3. gether. Put the front bearing cap on the front 11. Finalassem bly threads and tighten down. Tighten the Clean and Iightly oiIalIthe parts.Sl ip the back nuton the spindle. frontbearing onto thespindleand tighten The spindle is ready foruse. ': .

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and OthertOOIS Iike it on a Iathe toolpost with any rigidity and repeatability. Added to this is the problem of a rather large amount of axialplay in the spindles of these high-speed m otorised tools that

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Three-quarterlàchspindle mountedl ' h Thomasdividing head.Thl % /à the easiest GaF to9eta SD?a//' SJNWt8//mounted atexact latheCentreheight.

4,250 i nches

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7',' )? r )., té kti..j DreIneIMotoTooIvviIIhoIdandyoucan i ? : k ' . j l qy k ', Ysj .7 , t , t ' uu l l tj , ' ,l , $ yf 't :y l r k..Y y l t l k t 4-tk.y p t . ' y g @ , @ r $ ' A t l 1 > t ' ! ' ) Y t E i ' . i /. 4' t ( F . , ? j) ; . -r ; : t ,s : .,, : st p y , : s y: l i t yyy j sq j y t i@ g q j1 t y E t kt l# yj/ z jj oE t' . rj i use iton the toolpostofyourIathe vvith- 1 ' . C ; I j t : q ! s ) : ! y E y : t E L r $ ) $ ë ) E i t i t i z t t k y . ,ë y > 1 1 ' .# ' l ' ï r F i ? . ' b è : ' ' b ' ' p ' : 7 ! : è ' y . j ' , E t s ï s : . ) y ) j c t , t j : y a a . . t t j t p y t j y t t . z a y r t y j j t y t g j q y g k j ? ' j r . r z . j L r j : j . j y t g j ) t E : y ' . ) . o h l r ! L y;j l t ' j . j . j ) t ..( .: ; y . ) k . ' j ) j E , y y y . . : y . ) y j ; j ; j y y y : y j y y g j y q, . out fficulty.It can also be mounted to ) ty E jt; r1 t: ' E ) ( ;r j yj yy j yyy jj yyyy.j.yy y E t ! . 7 y . à . ? , . the di jj l p : ) s ) . y Dickson type toolholders with their ' 1 l î ' t 1 ( ' 7 1 ) C 1 : ' : ù l î pr yyi( tt ë i) : lsy.Eh:è E $ . L ? bI 3-t'- y.'.!! T $ #ti 1 $ # !) r . : ë: )# yt tE : i , ë ' t .' y t t r y t j . r è y)' ;!@Ej é j.) quick change capabiIity. tj' R Ir j L /J7 î 'y) y,t?lt îy Eijtk' y.).! r k y j y # r j ' . ; .) . y j y f t yy j j E j . , . r y , . . j L y j q ) s p p t . t y k q j j g . This is a small spindle, only O.750 ' .k l -' tE )y s l u . j : i ( . f: î ' t : t. ))j ,,. . . .-. 0 b -.j) /$ ' yy , st : , yè r jt inches in diameter with a main body 4 y * j # ( ! ) : ) t ' t f $ ' l : k ' . ) k ! Y ) ' h ) @ : 1 ! ) ; a j g ? ' 1 : t / ) ' . y k f j t y i r t ,r j r E l i y j y j E j j u y t j ë y oi t . E y j . ë y j t . j y x t j y t y ys y y j : j V! ly(l i hrîyj t u l t lï it jtl k,l , y jtjtj y j y j -g ,g . ->y$ z l j tC1 j)!à)h t)!. .j q i t / # tj n ry h! y1 f E Iength of 4.250 inches.It uses the DMT 1 jt1 ' 7 . ï ') . k . ; @ ,r ? t . 1. y-!.) -.kxa.. -. t! y E .î ryx.y y t .... .y ; ) j t . E ) E ; . t t , . . y yj yjyys, ' z /c t y jj y s. . ,yy colletsand colletclosersandso canbe t k yy y t y j y : , . .. j yy r t yr r j tyr y yy g jyys yy g y r j y y n j y y l . j t . y jy j y ij lj /r ' tl.y . tjlj yttyy used w i th alIthe accessories availabIefor l jj t ë y y q t j . ; : . r h y T t$ y j @ t . j C j , l : . g ë : ) t ! ) y # , y # : . t : . p ) ' , r E , q ty t y y y k . k d j ty $q ty ù .$:k,yy ., ,j rty jjj yjy x . ry t yygj j yt yl ny jt j. sh y, i yl jl yyy jj jy yk yjyt yt j r t. yt ,yl y y j t g r t y l y y y t j g y y j y y a j y g y r y t j y t , y j g t l r g j y y t , j j r k y j j y j y g j j r y j o j l j E j y .r j q j i s j y a y j y y z . y these tools.Itis designed to be used at ï t . /i .7 :l ' .j yy . j -. ttyz! ; ?; i t:è t ! $r : ::=:,k-r hr$r 1èt) i ë t ' )) Ii1l #$ ,t# .. ) u: tt. ytr s y j

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high speeds justIike one would use the

DM' ralthough itw ould be hard to spin itat ao#ooo rpm . The spindle issim ilarto the otherspindles w ith the caveatthatthe sm allerdesign requi res the use of m ore z 'w atch m aking#'like lechniques and isthus m ore unforgiving of even sm allm istakes.The smaller com ponents used allow the use ofthe M yford Iathe collets forholding the parts.How ever,the mostdem anding aspect ofconstruction is the cutting ofthe recesses to hold the outer races of the bearings. Free m achining materials are recomm ended and brass m ay be considered for the housing. It could also be used for other com ponents except for the S1 7indIe itself. .

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jtharderto,,weld.Thename , fo jrthisphe- work.

-jjcj .jm eans Turn the w ork around in the 4-J 'aw nomena ead tness yeis meIj tkngshor point and w strength per- chuck and turn the housing down to size. tj aatt

j aceofthematerialisshortenedor Thefinisheddimensionis4.250inches,

feduc ormaed.This interferes with w eldability r Re-centre your work and m achine the jsyj sg wjtjyyjyoyjoy -yijjtjtjjjsg ojyj -ja y aosssjn tjae otuerside justIike you did yyjn t e r oo tjys jjrst sjde.on this side the recess weI(j. yjya jjousjog js not identicalat both should be O.030 inches deeperthan the ends - the back end has a 0.030 inch bearing thickness to allow some adjustdeeperrecess in it. jjold the m aterialinthe 4-jaw and centre it accurately. The centring should ae outerend ofthe bar. concentrate on tj Face the bar and centre drill it. Drill a 0.437 inch hole a little over halfw ay through the bar. Bore a bearing recess

1. Housing The housing is m ade from a piece of . .. . o.75o inch free m ach,In,Ing stoc.K. * .o z: )

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inches Th long (finished to 4.250 inches).

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ere are tw o types offree m achining As usualwe start with the bearings. The materials that you should know about if . bearings Iused w ere as follow s. you w antto enloy m aking a Iot of sm all

steelparts.one is tlne Leadloy type of

Inside diam eter

0.250 in(6.35m m ) Outside diam eter 0.625 in (15.88m m ) Thickness O. 187 in(4.75m m ) SeaIs Shields

Both sides None

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dle on the bearing and it allows you to guide the bearing straight into the bored hole,The recess should be a easy fi t on : ,.; h . ,;, j, : ?j/, $, . (. ,,,,.,,:,2 .b.....v: ) ' . : i '?'' ' .'' )' : ' #E ' h)(jri yp . p t '' '' '' ' ' ' ' .) .: .t .y j y j y y y yy syj yjyyj .y ' )j j îj , t r t f E t rr,j y ' r) Ey :s tf,1 .tjy k :ysy $ f tt: yrj L E ( ) : t , ? )gy/gyh : t j (:j .y E.y t',,;ry y j j g j r y g r j y g jy sy yy : zyt t'y :':yy ,? ?: , .$y..(r .t y ( t ) C y : j E : j E y , E , ' y y t t , . g , y s ) j . g E ; E î E E î E j 1 E y y : C E # 0 è j t 1 J 1 t # E E ' : 7 . : : . ) j ; : ! . ! , j ( y y E ( ! y j 'ï',.tl '' , 7 f ' ? è E ' ! 7 E : . ,. j j . . , . ,y , . i:' : '/ . ' i? ) 1y ' 1j f: jh g.C ) : . : E Ah yf( g, t , y ) Jy E y r T: ,k,J j gti ! ykt j : qhyt ' k yT::: :qj EE

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putting the spindle blank in the 0.500

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inch collet and centring both ends,then .. ' . . W ith 1.000 inches sticking out,face and . f . . turn 0.750 inches ofthe shaftdow n to ' ',

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hold It in a sm all er collet against the

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l o jryoj. joojjsj antja yajncj. lsj aaft . , ,. CIOser,a j I in hand before you proceed w ith the next phase ofthe w ork. . .. set up to work in collets. Start by '

The% inchspi ndlemountedl ' n Thomas

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' noses on them , Ibuilt m y m icro spindle ' with a threaded Jacobs 1B chuck on it. How ever,Ithink the Drem elM oto nose is ' ' '' more appropriate if you have sm allcut- . ; . ters and high speeds in m ind, if notyou '. ' .. , .

dividlhg head with chuck removed to show V indlehousing flush with dividing headface. .

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piece offreem achining 0.500 inch steel rod 5.75 inches Iong. (Since I w as obliged to build a numberofspindles and did notw anttoo m any w ith Drem elM oto

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pieceofoneoftheseyouwillindeed bein

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' 2. The spindle '' ) ' ' The spindle is the m ostcriticalpartofthe

, Jt ë t c st ut kyty : y6 y :y r j: ,y rp f # j t )' C @ïE è 1 k : 1 (: E 1' : y . :: . ?(î:! ) , . . ,; . , , ,,, yy,.yy ; : ) èk, 1'''. : ' 7 ' :.? :' :.....k,' .: 'i :t.r : > .. ! ! ... ) : ' . ' : ' . 7 . . .' .E. E :' @. .' . :' '. ' . . ' ' : E ) t : . 6 ) t : . , , : : : ' V V : è ' : ' 1 ! ï ' . ' J ' ! : î ) . E E . L )5 y : ö )E y ' b ... '' :'' E. '' ''61' .li 3'.( ' 6 /: 1 ' 'a'j Yj':. 6 J ';:''' :

clover.LNote' .tellurium is toxic and w ill These are very com mon, easy to find give you a bad case of im m ediate garlic ! 5 ;1 E,

Chamfer aII edges, Polish up your

w ork. This com pletes the housing.

i ngs)and 0.625 inchesin diam eterinthe bar.Checkthisw i ththebearingheldon a W inch screw held in the tailstock.Using this technique allow s you to have a han-

m aterialthathasIeadaddedtotheironto m ake it more machinable. The other is thetopofthelinefree m achining iron bar

that has tellurium added to it to further ' ' ' enhance m achinability. lf you can get a

Numberneeded 2

mentallowance forthe bearing spacers.

O.190 inches deep (to match yourbear- project.W ewillmakethespindleoutofa

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1. Housing. ' r 2. The spindle. ! . .., 3. Spacers. ' f$ ' . 4. Pulley. . . 5. M aking the spindl e nose. 6. Finalassem bly.

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dojyo ot v eId wjyel l. lner lay rnra satie r1' nrs hes at ingC's oru te rra cIe.edges. Polish up your , yy yg yakss a asj to yn ja' cj ne natk ha nf er al jjj joj

bearings and they are quite inexpensive. The sequence form aking the parts of this spindle is as follows' .

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V*'* ly,free machiningmaterials Loctiteanaerobicgjuetohol dthebear1ncidental

X//the Components ofthe % inch spl hdle. Thisand the othersmallersplbdleuse 8dhesive'to hold the t7&fOrraO Softhe bearingsin place??thehousings.

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''eath ifyou ingestit. Do notw eld orsil- the bearing w ith 0.001 or0.002 inches ur uo.solder-) or so clear aIl the w ay around. Use

m akes their use problem atic.The m icro spindle w ill m ount everything that the

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turned dow n Iater to form the spindle ' , . nose. W e cannot do this right now : , ''.

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oendix 2 for UK equivalent)tpiforthe spacersas aneasy fit.

pulley nut. r Rem em ber that one of the bearing Finish the flange thatform s the protec- recesses in the housing is 0.030 inches tionforthe bearing seals.The flange i st o deeperthanitneedstobe.Assemblethe

have a finished dimension of 0.250 sqindle,bearings,pulleyandspacersoutinches(width). s lde the housinj and adjustthe unfinished spacer untllthe housing ends and

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i jaa as the bearing is m oved farther and em ery paper. W e willm achine one end ' etherto tj,e Ieft. down when we make the finaladjustr fa* nie cutthe threads at % -28 (see Ap- m ents. The spindl e should fit in these

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0.460,'dia

Figure 6.2 spl hdle nose detail s (seechapter /6'fordetalledDremelcol lettdimensions).

3.spacers ' ' 11 ' w e drilled a 0.437 inch hole in the housi ng. The spacers w e make have to fit wi thin this so w e w illm ake them 0.375 inches in diam eter w ith a 0.250 inch ream ed hole through them .The spacers are bestm ade as tw o spacers - that will

the bearing ends are the same distance apart.The 0.030 inch allow ance willgive the extra space needed to ensure that it aIIw orks w ithoutbinding. 4. Pulley The pulley dim ension m ay have to be ad-

reducethedepthofthe holestobedrilled justed to matchthedrivebeltyouhavein

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because w e need to hold this end in the collet. Cham fer aII edges for now to m ake iteasierto putthis turned partinto a collet. AIIthe rest ofw ork on the spindle w ill be done betw een collets and the tailstock centre to ensure that aII surfaces are com pIetel y co-linear w ith the axis ofrotation. M ount in a 0.375 inch colletand Ieave 0.250 inchesforfinishing the flange.The restofthe spindle can be tuned dow n to 0.250 inches in diameter.First turn the rem ainder dow n to 0.450 inches w ith a sharp toolin one pass. M ake a note of

exact,itshould cutso thatthe headstock si de ofthe w ork is bigger. Keep turning dow n until you have reduced the spindle to 0.270 inches in diam eter. A slender shaft m eans you have to take sm allcuts and use a sharp tool. M easure again to see how your Iathe is doing.These m easurem ents tell you w here the thick parts are so thatyou can respond accordingly. Next reduce the 0.270 dim ension to 0.250 inches in tw o equalpasses.Note how far you m oved the toolin the first pass and note how m uch w as cut from the shaft.Usethisknow ledgeto m ake an

and ream ed. The overall Iength of the m ind. spacerhas to be 4.250 inches m inus the thickness oftw o bearings.Ifthe bearings 0.093.,-.n o.375''ortosuityourbelt are o.190 inches thick,the spacers have to total a theoretical length of 3.870 inches.That is the theoreticaldistance fOra perfectfitbutw e w antthem to be a 7 bitIongerthan that to start with.Check ,zsc',dia this w ith your setup.After the spacers 0.250'dia.shaft '' are in place the spindleshould m ove back ' 3 '' end forth in the housing about 0.030 inches and both bearings should be flush Wi th the housing face when the spindle is c.a7s',(ua ' ptlshed back from the front. Startw ith tw o pieces of2.0 inch Iong Figure 6.4 Pullevdim ensions. , ;nd 0.375 inch diameter pieces. Hold '' '

t hecrossslidesettingthatgaveyouthis adjustmentonthesecondpasstoendup ' ts h /e nethtehr0. 375eac inch olleta ndfdfrriom lla oml ai ol ough hc one, hal diam eter- this is form aking an accurate at 0.2505 inches.Rem ove the Iast half assessmentofhow parallelthe Iathe is thousandth byusing afileand polishing cutting Poli sh this and then measure with 4O0 and 600 gritemery paper.The bothends.Itisimportantthatbothends bearingsshouldbeafirm slidingfitonthe .

be the samediameterto ensurethatthe shaftfrom one endtotheother.Itisper-

lathe is cutting parallel. If it is not w e

eoch side. Ream this out to 0.250 diameterand0.625incheslong.Hold in inches.Accurately face aIIfourends to the 3-jaw and face.Turn a 0.375 inch be square and clean and very Iightly diameterboss0.093 inchesIong onthe Cbamfereach end using 4O0 or6OO grlt pulley.Drilland ream a 0.250 inch hole

missible to thin the centre dow n by a bit

-

through the pulley. chamfer aIIedges.

haveto adjustthetailstocktomakei tcut to maketheslide easier. parallel. There is a discussion on lathe

once you get the bearing started on

Thmeachi pullni eyngisalt urninum edfr1o.m250aip ieceoinf free um nches

Turn around in the chuckand faceother œws-oo

adjustments in chapter 16 - read that the spindle on the right-hand side-you and adjustthe tailstock ifneeded.Getit can use a file and the emery papers to

usc-lo side fora finished Iength of0.468 inches

seetextorl extsnotes

as good as you can.If you cannot get it workdow nthe spindleahead ofthe bear-

Figure 6.3 Spacerdimensions.

Orto suityour belt.chamferalIedges. Thegrooveto matchyourbeltwillbecut Iater.

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5 M aklng the spindle nose Get out your Drem elM oto collet closer and go overIt w lth a palr ofcallpers I.e. know Its d' Im ensions.You w illbe get. to . . . bulldl ng to yourcl oser.sdl m ensl ons w .lth .de my notes as a gul only. W e stillhave the frontend ofthe spin-

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d letofinish.Puta0. i250inchcolletinthe lathe to holdthe sp ndle in the colletwith ' : ji 1 ;1 j

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Loctitethebearingintheshallowerof

the tw o recesses in housing.M ake sure you do not get adhesive anyw here it does notbelong.W ipe and clean up any

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un-threadedpartofthecolle tcloser..Turn spikls.Leti tset. .'

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spindle w as a bit too sm all - this .Is a Iargerversion of that spindle.The inner spindle diam eterhas been increased from 0.250 inches to 0.375 inches m aking this spindle considerably stiffer.

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. . Yj ie jnternal.COmpOn8r1tSOfthe 1 lnch . . dlam elersplndle.The sm allersplndles use spacersbelween 1hebearings.

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Outerhouslng 1 Inch 4.375 Inch (zs mm) (11smm) spindle 0.750 inch 7.ooo inch (2Omm) (180mm) spacers 0.5 inch 5.000 inch (14mm) (125mm) pull ey 1.25 inch 0.500 inch t32mm1 t15mm) Pulley nut* 3 /8-24tpi,1Ox1,purchased *SeeAppendl ' x2forUK equivalent

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k+ ) r t; '..i 'èt . ' . 'i ?j . jy/ (v : l l )' j .t py : .. s ùl y , ï ? y j t ? j y j k . j r j , . . : j . y . ;2 . . y y y y y j z ' (. . l : f : l . . g 2 , j . y u y . y y s y y r y t l . , j y g s j; 'j '.y , () , r ,. ) j . ? 'j j h t r y y y. :. . i) . L.y r.. .si )) . k:. 9q . .. ., .,: L j; .( : i.' q . j ,,: , :. . j . . . , . . ; g.r y k , ïy. $y. 6j $. q F t t i t l ' j è ' 6 ? ' ' . : ' $ q ' , ' ' î ' . ' . ; i , 6 ' . ': , ' , '? u ' ' . i;/;. . S jq lj j ? . ; : ; j . l q t l . t i è J : S . ' ) . j L ri ) : J J . :: . 2 .j .. .S ' j j ) j k # t 3 t r ' ' ( . ' ' . . . ' J ' , ' . . > . @ ' . î : î . . ' j . .j j ' t . . y r p j . . . . . E , . . . . ,u (. , . $)plkJ i' tq;), .. t.. :J.:

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y. r yj r qq yt j l ' t s . t y r f i t j j t ez :rs h ::lz , t ??; #' 4:, :k ?.@. 8nt$ 1 ( # ' . y k t : è : ( j t ; j p j t ! 1 : ! ' J j : r i 1 . 1 ) t r p o ' t 1 f i ' E y l t : ë t ! j ' j y , l r y i h p ï l / t l . h t y y j , . î j : ; y t , r t j ) , . $ r ' : , t : , ! ) ' , . y L , . y j . t , j y . y C E ; ! . ù h ï h t j , ; t ( 1 t @ q j d y , j : . j ? z : . : k uj ., rz tt h : ; p . k i . j ) g ) 1 L ; ' t ' : ' J . t . ; j @ E : ' ) ) : p k ) . t j ) : s . o . Ijz .7Ek.t/tt::'9 1 ?jjt. ;.é .jkj: ktklojï .tl$ l' k z . r)C , $: $' 2: s; .. 't S I :vo pi'! )'t ptq ! )f . ,: 'j@ tj12 33 ?.-vië jtp x?fl7 s2 .i kt xh t,I tE 'E vL rn1 e2r z?'r -t . wz r1 tt! -i

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Al l,/?e components o:the externalgri nding

' dle.,.Theexteriorhousing forthissp/ wl/e S#.pl.n . l sldentlcalto thehousmg , . ofthem.ternal grm 'd' mg spm'dledescribedi n the next chapter.

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Tosui tbearing

0.750 inch dia clearance Bot: sidesof

thehousingare ;aj I i dentjc .

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(and you havethe shortspacerto m eas, (,, . ure,to jg s ; now how m uch was too shortpj). r ' . l ) t Thisis nothow w e manufacture spindles

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jaw and centreasaccurately asyou can.

bearing

butin 1he am ateur's w orkshop whatever

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v 1. Om erhous. lng AS alw ays m ake the parts that have the internalthreads in them first and then m ake the parts with the m ale threadsto fit them .This m eans the housi ng has to be m ade before the bear.lng caps, The . . @ p .' houslng ls Identlcalat eltherend, each end holding a bearing that is clam ped by ng cap. a beari .ng . The housl Is made from a piece of . j jam eterand 4.125 s tee!1.500 Inc jes. ln d. . .ng . lnches Iong. Hold the housl In the 4-

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1n tw o parts and then one ofthe parts i s l . rnade srnal lerand s rnal Ier untllthe exact t g. I1r. 11 E ;1 E 1( : 211. I( 5!k l ' 1 E)1 : jI.1-1 ) 1. 11 E ;. I1E 11 14 : ) 41 L1 51 E 11 ,11E l1 *(: j1 El1 E ;.I1 l: ,. ,','...7.,r ' qoom q nnrl .1.6 unn rxwor-onf +h. .rxooa. ,x b.. . F ' 1(. new spacercan bem ade In a few m inutes : ' , j ( '1 ., .. . .

79 .

3. Innerspindle. 4. Bearing spacers. 5. Pulley. x 6. Nu1forpulley. 7. Key and keyway forthe pulley. 8. Finishing operations. 9. Plates forthe grinding w heels.

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u,à' T ly t ytj r llj racesofthe bear* ' yyjt k ytj. yyiti t/ jE . l) lE lj t :y , 1ngs.The spacer* 1sm ade . jj .l Ls .. i' .tï' s l .61l lt fjrl R. u/ y gl x .?:.gi it . 't .. z i o . ' r , ; j ) :1 7 ! 1' . 0 . ,l c .g

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yjje key .to getting the bearings to fit jyu.j. ! a ; @ t 1 y jo y j y u , .oper1y Is the use ofan adjustable (by jt jsj j;y : 4,4. t 24e jjy .jj i gjj j yy y. , yy jsp y. ? pr p r j y t y j s j j o . -i -k-t x . s ; t .. t : j. tt y. yj .jaojjjyjjogjsqaooyjjayw usj. jjj. joyw ojj -yyjsy y$1èt t' >g ' '. -i J)tyvz

t: ' : d f ! t,k' ,.' a . f: ' ) 3 .;.? rë p : p # $lqj #.V6 l ' . kr'e.

1. Outerhousing.

V ake Sure thatthe partis parallelto the spindle shaft - if you do not get this righl, 1he bearings w iblbear a: one side The parts should be m ade .In the follow- only and prem ature failure w ill result. ing orderforease offabrication: Place a centre in the end and drillthis out

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Diameter Length

ex o. 1 Outerhous.lng (1aa .50k Jinch 4. inc.u mm) (11 :zu omm) 2 Bearing caps 1.500 inch 0.375 ' Inch (a8mm) (lomm) 1 lnnnrsnindl e 1.000 inc h 6. nc * ''''''''''' - T-''- - '-- '500 --- i -h l26mm) (165mm) . ' 2 Bearingspacers 0.625Inch 2.000lnch 116mm) ' (50mm) 1 PulleY 1.B00 inch 0,900 inch t38mm) (25mm) o,x.-. . .a - . . 1 NUtfOrpull ey. ,g zz-zw tpl ,1/.x I.u, jlas ed p ur c g Key forbearing l/ax% 3mm x 3mm brass i srecommended

Bearing selections The bearings selected are as follow s:

2 1 ..:E k' 3 ;, -! E 1 ;1n 4 ::E 5 rt 1 ; .mm l p . o.37 5oo I n ( 1 4m r n ) !tlr . nrnl 0. 5 in (' Inouble seals '

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Figure 9.3 Detallat:ear/bprecesses ateitherend ofhouslhg.

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1.500 inch dia 24 tpi

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to 0.500 inches in diam eter and 2.250 inches deep.Bore this out to a diameter of0.750 inchesfora clearance diameter. W e can do halfthe w ork from each side.

2. Bearing caps The bearing caps are m ade from the

accom modates the bearing cap. The inside diameterof this recess should be 0.005 inches Iargerthan the OD of the bearing or 1.380 inches.M ake the bore for this 0.187 inches deep and cut a threading toolclearance recess in the I ast 0.060 inches. cut 24 tpi inside this recess asshow n on the draw ing.The exact diameterofthe threads is not cri tical but they need to clearthe bearings and should be wellformed so that they will hold securely.cham ferthe first and last thread w i th the thread cutting tool. W e can make the recess of the bearings next.The bearings need to be a firm push-fit in the housing. The recess for them should have a totaldepth of0.125 inchesplus thethickness ofthe bearings. The bearings are nom inally 0.375 inches thick so the total depth of the recess should be 0.500 inches.Afterthe recess is formed,turn theclearance forthe seals (itsdim ensionsarenotcritical).cham fer aIIedges and polish yourw ork.

larger threads first - that w ay if you I m ake a m istake, you can make i tinto the ' sm allercap. Start by m aking a split collet for the caps. A detailed description of how to m ake a splitcollet is given in Chapter3. (Blank needed = 2.000,.dia by 0.437', thick.)Filetheburrsoffthecap blankand hold itin the splitcap. M achine a reaister O. 156 i nches Iong and 0.080 iJches Iarger in diam eter than the inside diam eterofthe threads in the housina. This is 0.005 inches largerthan you need (theoretically)for24 tpithreads butitis better m ade Iargerthan sm aller. t24 tpion this register as described Cu in Chapter 3. This has to match the threads on the housing. Once the threads are right, cham ferand polish yourwork. Repeat this for the cap for the other end ofthe housing. W e w illcutthe slots forthe spannerwrench, in the caps,Iater w hen wehavetheverticalslidesetup on the Iathe. '

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Figure9.4 Beanhg cap dimensions -two are needed. ' ;. , , .

' ' the w heel is held rigidly when is use. Although we can get away w ith smaller Spindles for the tiny Drem el M oto Wheels,a three to fourinch wheelrunning atfourto five thousand rpm needs

.

.

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'' 5 '''''' :' finishthis w ork w ith no problem s. W heelnotes:alIgrinding w heels have a m axim um rpm that you can run them at printed on the wheel.This rpm should not be exceeded at any tim e under any cir-

to be supported substantially.The m ini- cum stances. A w heel that is cracked mum diam eteratany pointonthisspindle should notbe used.An uncracked wheel,

is0.500inches.

The spindle is m ade from a piece of Steel1.000 inch in diam eterand 6.000 inches Iong.The work is alIto be done betw een centres. Hold the spindle in the

.

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suspendedfrom apieceofstring,willring

when struck w ith a piece of hardw ood. Grinding wheels should alw ays be held in blotting paperIike pads.These pads distribute the clamping forces on the w heel.

3-Or4-jaw chuckand face and centre Thearborplatesshoul d be desijned to each end. Startby making the end thatholds the grinding w heel. If the design provided does not suit yourparticularneeds,now is the tim e to decide w hatyou w antyour Spindle to do and design an arbor and Wheelholding arrangem entto suit.Ifyou do not know w hatyou w ant, you can leave this section un-m achined at this

A jrindingspindl eneedstohaveasub-

suitthe w heelsthatyou have in m lnd and should m atch the diameter ofthese soft paper pads. Do not over-tighten the plates onto the w heelorthere w illbe a dangerofdam aging the w heel. Turn the spindle around betw een centres and m achine the m ain shaft to suit the bearings.The bearings need to be a firm fit on the shaft. If you intend to do

time.Since we have centres on both high-speed work with this spindle,the

stantlalinner spindle to m ake sure that

Sides of the shaft w e can com e back to

72

section that m ounts the pulley w illneed

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1 y )) )k I ' . t. o'o7o inches Or . 1 ; ; . Ifw e take 0.070 inches offone ofthe t i tspacers, we should be able to tighten

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P fiOrntotool Ctl' t' t Cut jftyeo hinder ave bYOt uil t e uuor and ru gr lt Whi ll .

indeed be in Iuck here. Ifnot.justbefore j;e mad e itmight your cri lcut s ar be wor tthica your whi le et to o take half.adozen

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.,r , ttiji,torabitIooseatthis tlaem sharpened. !m i ghtbe abi time and some flnaladjustments willbe once you have the fityou want,the needed.Sincewedonotwanttohaveto sqindlewillruncompletelyfreel yandyou m ake a new spacer w e should rem ove w lllnot be able to detect any end play

descriptionfortheIDgrindingspindle. c inapthe speinsur dleehto usbear ingiw th asbe artin gj , atteri alaIittlebitatatimeuntilwegeti t withyourhands.Runthespindlefortwo M ak he ngi seat to he 1 . )m ' righ Thatishow togetthebearingsjust timed minutes at 3500 rpm. It should

4. Bearing spacers

bottom of the recess. Pass the spindle

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Th e theoreticaldistance between the i nne

throughthisbearingandplacethetwo i

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inches.This has to be spaced with either bearing on the spacerand push itinto the one ortwo spacers however,it is easier recess and tightto the spacers. Put ' the

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toTh make tw o spacers. e spacers are m ade of 0.625 inch f r ee di machining stock. M ake the inside am eter of the spacers 0.500 inches. Ream to bean easy push-fitoverthespindlexTheworkhaslo bedoneinthe*-jaw chuck after carefully centring each

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richtin the housing.

otherbearing cap in place fingertight. Pu' t the pulley and nut on &he spindle and tighten itdown. The bearing nuts are threaded at 24 tpi. This m eans that one revolution on

s pindle in the l-jaw and the tailof1he atelyanddeterminethecause.Fixit. spindle in the tailstock . Pl ace a dialindicatoragainstthe spindle shaftorthe pulIey and move the spindle gently in and out w ith the tailstock. M easure how m uch the spindle m oves - you w ant to end up w ith an end play of betw een o.ool inches and 0.002 inches.Atthat stage you w illnotbe able to feelthe play but you w illbe able to measure it w i th the dialindicator.Some play is needed to allow an oilfilm to btlild up under the bearings w hen the bearing are run.This film w ill elim inate the last bi1 of play w hen the spindle runs. ltis very im portantthatyou w ork with sharp tools w hen m aking very fine cuts. steps of 0.0005 inches taken w ith a

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the nutmoves ilin 0.0417 inches.W e

know that the second bearing that we m ounted i s not seated in its recess but w e do no1 know how far il is from 1he bottom of' the recess. Tighten dow n the second bearing nut fingertight and mark the position ofthe nut relative to the housing.Now Ioosen the firstnutaI11he w ay and ' tighten dow n the second nutaIIthe w ay keeping track

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pl etely flat and chamferand qoli sh aII ofhow farthesecondnuthadtobetightedges so that you get perfectflts w hen ened.Ifyou had to tighten it 1 75turns you assem ble' them to 1he spindle. to m ake the bearing seat i t means it

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Clean up and check forproperfit.You m oved. need the spindle, the bearings, the . . . p,,,! ,, , . , .

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Once the spacers are right,each ofthe end caps for the bearings can be tightened down on the outer races - doing this should not affectthe fitof the bearings.Ifitdoes,itm eans thatthe bearings w ere not fully seated and that therefore the spacers are stilltoo long. ' ' 5. Pulley 1 The pulley show n is m ade of 1.500 inch stock.The material needs l: o be 1.000 inch Iong. M achine the pulley as described in Chapter 3.M ake the groove forthe belt to m atch the beltthatyou intend to use. 6. Nutforpulley

p iece ofemery paper(400 grit)can be Use a X-20 (see Appendix 2 for UK enough in the flnalstages

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W arm up enough ' thal you can ee

' knothertechniqueisto remove both warm upslightlybuti tshouldnotgethot.

r races of the bearings is 3.250 spacersonthespindle.Placethesecond 1 bearingcapsandholdthehousingofthe Ifitstartstogetatallhot,stopimmedi-

spacer.The Myford collets w illnothold 0. I 625 inch stock. Start by m aking 1he onger spacer 1.750 inches long. M ake t Ihe shorter spacer 1.625 inches Iong or ongerifyou havea concern abouttheexact i m easurem ents.Itw illbe OK provided tistoo iong. M ake the ends of the spacers com -

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ltoolw ill equivalent)purchased,unplated nut for . A dul tend to grab suddenly and take a bigger the back of the spindle. Turn 1he ntlt cut than you w anted.Tools can be kept down to be 0.312 inchesthick.This can

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ofthespindle (oraIargeroneatthe

10,000 rpm so a sm aller pull ey needs be provided atthe driving end

motor). @ The spindle quills are designed for

ferencesbetweenthespindles.

Chamfer each edge. The clearance betw een the flange and &he housing should be 0.032 inches.Cutthe spanner notchesasdescribed in Chapter3.

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* This spindle has to run at above

struction.This chapterconcentrates on the machining ofthe quills and otherdif-

O.125inchesthickatthespannernotch.

Next make a collet chuck to hold the I at p esand machinethe cross sectionsto

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to the design of the O D grinding spindle described in the Iastchapter.Please refer

Holdthespindlehousinj inthe4-jaw

aclosefitonthespindleslaaft,

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W e stillhave the caps to face and to cut the six notches forthe spannerwrench.

9 Platesforthe grinding w heels '' Figure 9.8 Pullevnutdimensions. M ake the platesto match the w heelsthat you intend to use.The tw o plates thatgo on eitherside ofthe grinding w heels can 7. Key and keyw ay forthe pulley be made from eitherW inch plate orfrom File the key forthe pulley from a piece of slices cut from bar. In either case first scrap brass.lnstructions forcutting the machine each blank to a flatplate W inch keyw ay in the pulley and in the spindle are thick and 2.000 inches in diameterw ith gi ven in Chapter3 on the basic spindle. halfan inch hole in it.The hole should be .

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The design ofthis spindle @. s verysimilar

usewi thstandardDremelMotoTool

The differences are:

collets,closers and accessories.

* The wheel m ounting arrangem ent The arbors forthis spindle are designed has been modified to allow the to use the m any grinding wheels and ar-

heelstobemountedattheendsof borsprovided bytheDremelMoto ComW removable quills that can reach into pany as a part of their hobby Drem el

standardo. sooby20tpinut

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chuck and centreit.M achlnethe face of the bearing cap to give you a flange

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match the draw ings.M achine the recess

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Figure9.9 Kevdimensions.F/ 7, to f/ ' t Aeyeapbvhand. . . .

f st an enat etyap utlt heenoout e dir ia me td ert .h Th thwa ye or uowi lo hatv dsii fdfi culty holding the plates.These plates can be m ade from thinnermaterialbutthatis harderto do forbeginners. .

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'' Rgure 10.1 Crosssection of/D gnhding spl hdle. Theparts ofthe splbdle shown aboveare identicalto the OD gr/ htz/ hgspl hdle. ï;. , .t o.,

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w heels and arbors provlde an Inexpen- Sequence form aklng quI .ty grl. .ng Wheels for The qul .lls are m ade 1 .n a Sequence tj. jatl .s ve source ofquall nd1 si . 1de Variety of not.Intu.1t1 Ve becaUse tWO Sets Of prec1the 1 ' nodeIeng1neer.A w *

wheels,smallcuttersandarborsI .saval .l- sl .onoperatl .onsjlavetobeundertakenon

jn the United Statesthesewheelsare between centres. Speclalholdlng f1x-

.red. r: lrll!/Ided w ith 0.125 inch diam eter tures are requl -sanoutI1ne ofthe sequence: arbors.A 3mm arborwould beveryclose Here I to this size and there m ay be otherm anu,de how many qul . facturers in Europe who provide 3m m * Dec. l lls you w ould ' E arbor s f or t hel r ur opean cust om er s i f I i ke t o have. 's ' thl Is the case wher e you 'buy w heels, * M ne the recess in the spindle for 'fy your thachi you need to modl qul l l s t o ac cept e qui lls. 'ng to use. 1he arbors thatyou are gol * M ake the 1w'odIholding fixlures to m atch the spln e recess exactly. -s Raw m atenal * Leavesecond fixture in chuck and do The following raw m aterials are needed not remove. - ' @ Machlnethe spindle end ofeach quill

j.; lk :, !k ,.; hr kk .. ,p kj .j'j (:2jj.j1L(jjj-)-)(:)I.j15;j,jl((j .I . ; l (11 413I -I Irq l l) , 2 Bearing caps w j.y j yy g ; jy g ; j, jj . j (a8mm )

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j. :, :.r j,. .r kj /. -z ?k, /. -k !r kI .1 ; ; -1 (111( :l p I -I I1 -1 1)

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y g ; j.y jj g; jg; j. jj . y (15m m )

. 1 Bear.lngspacers 0.625 .ln

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M ak1ng the gr* 1ndersp1 -ndIe 3-ue main d' Ifference betw een thisspindle . - j . . tj a nderSpIndelSIn oje w ay .ndtheOD grl .a ... . xooa j :je x=j o-u- ted to (u ' jj t. kn ua on un u. 11 jl 1. o, n www . wa wj .y . . a j j o w y j j a y y j y o j y a y a y y j o v g q j a y j < rajy(ace W* 1th repeatabIe accurac9. Th* 1s requ1reS thateach quillregisterto the spindle in 1he Same'WaY that a threaded Iathe 'ndl chuck reglsters onto a Iathe spl e on the M yford SB7. . ,, , First m ake 1he partof 1he splntBe lha t .n . i i s hel d i n t he bear i ngs a nd t he housi ng l Bearlngs . See Chapter9 On the OD grinding Spindle the Sam e way thatyou m ade the splndle r n m,.w . -, vu x. .u. = =. - the same bear ings are 10 be tlsed for TOr1ne Q JLJgrlnuer.Ine Ilnlslleu ulstance this spindle. . frOm the frontof.the frontbear.lng to the f ront of the splndle shoul d' be 0.469 ' tt .g,,. , .,. '. ,. ., ., ,r.? . ' t.1. j , , . i . ' . l l nc hes. Ai l ow enough m a & er ,' ,. . , . .. . . lalt.o alloW #. :. .. thls tO be flnlshed to thls dlm enslon. .

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-ndle to gl -ve Face the spl Itan exactly

1nch d1aI. netef , . $jer. jgtk.jtj yo,74o 0 .463 . !nc1 face. cha m f er each si de I i ght l y. Next 'llmake the recess that the quills wwie ll wl ' ' dentim ount. 1n.The opera t l ons a r e t o b e I caIt. o those wew' llluse for m ak' lng the .. 'lls. j aoldlng j Ig and test . J' I g for the ' qul In fact,w ew ant1 he f ac e of 1 he s pî ndl e and '' ' ' thefaceoftheJlgsto be absolutely ldentlcalso thatthe quills w illm ountto each of

yj)t. ;jy j(j )yy, y s; l lyyy . jjtgày. ty.:tt. ? :y . y . . y j . ' , . . y , ; s . t ( , . y k t :( y j y , j . ; t y t , y y yjj ,j yj yy : . g j .j , y jj g jj g yjg ; jj . ; jj g jjj g jj .yy jj g; j.gjj.yyjjj.yjyjjj.yyjgj.;j,j,;jjg;jj.gjjyjj.;jjgjjgjy. : rjt jj y.yj j , g,j yi yg j jy jj y( j ty j.j ;E g, jyjy , yj j rj@ tj j y) y .,y j j j j y y j y j y j t , j y yy y y j . g j y , . j y jjy y yy jj y ,, , gyj ,y ..g yyj .yyyy y jyyysyy y y j , yggy.yjyyj gj j gyj g jjyj.jt yj j yj gyj . yj y j yj j g yj g jj, j yy g ; jyj y j , yjgjy; y .jj g ; jy u y jj .; j jyyjyy.,, .. ty j r y (yy , j,, y yj,jj y y j y y g . y y yy t ,jy ,, vj ), )y yy yyjy yy y j j , y , y . j . y y y y y y j j , . s j j y , . . y j ys jy . yjjyy jj g yyy jy j y s jj yy ,y.y..yyyyg yj y. y y. j.yyyjyjy yyy t , j) q ))yyyyyyy yy ,j j . y y y y y y . y y y , ve'' %' ' # t , . y ) t $ , 1 . t k t y k t p y j , y j ; y y j y y y j y j . j y . y j ; y j j y y . y y y y y j y . y j ; y j j j y . ., ?( t,: (, ) ,) tyyjjy,):y.yjyyy ,y , yjy y ,

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.. ;î p ,k t' l . s k)( ip7 'k i bj, s9y,.(;:: k ' t r. : ;:E tl ytty j l i t. y : ):t yj; gt . y: j a y r. y. jake therrl. T13ese JIgs are tO have the yo o o yj y . j j j)y j.yj y j yyyjj y yy .)..) yyjjjyjy jy jj j j y . y s y s j . y y s y g y y y y j y y j y r . y j y y t j y j y j j y y j y y g a x actsan1egeo1' netryaSthequl jy s j y . y yj y j y j jt j y y jt j j jjq j y,; j y sy. .yjyy ys yayy yyyyj ayyy,yyyymyyy.y .l l û , t g ! t l j t / p , :: yy y syyyyyyj y jyy.yj yjyyyyyyjy . '' 'i kq'k 'V': -ï -j 'ka ''j ln jyyo ,y ajsjyjs a a ,ojs, jo j .yso yyyo ' o'sy.o 'j X# thel . nternalcf7/??pD?1f?1fsOj.tjtejngema/ same m ountlng prlnclp e as. w e use for glinding S#N. 5d/O. The/0D#W qUl. . . ll/ &holdt ng & threaded lathe chucks:a reglsterforcenzmal lcupped grlnd . ing wheel. tring and a threaded section,..to. pullthe quills into the spindle head.Tnls Is agood oun t par tsedtha need to be w ay to(jm . and rem ount mtany tim es. puta centre on each end ofthe splndle remove jj .jj M ake two fixtures but do not rem ove Qnd t .hen Work . be . tween centres.T e quI tjje second one from the chtlck.Use the end IS to be flnl shed Iast. . dj Once the body Ofthe spln e i J 'aw to hold a piece of 3 /* inch free m a. .s com j)e- 4l''Sted' SOt ' chi ni ng s t eel 1 . 500 i nche s Iong.Leave I t tho lathe up f Or us l n g t . j collets. Hold the Splnd e . In a ().6oo inch sticking ou1ofthe chuck O.5 inches.Use .

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.. z; yyy,s. . jy j .. y'j . : y yj ytyy, . r k:''tF......?.1,' t,ftt,,,t4.. :.tt!,7, !., t''t. ,.t41:ïyyksjyyq .L , t : i 7y a l: tj h 'y , k t l y j r ) . , : y j j ( $ ) , . g y . : ( , y , j ) . L t . v . E . y j x y j y y y j q y t , . j y j j r l j l y j ' l j l j . t t . k ! j , .w. t' i j k t : t : ! ' . ) è : ? , E t j t y t j k j y i n p / î ' ' t y : j u ' . : j j t t l t l t l v t t r / i lt ' . '' ë z $E k ' j ' ) .( ! , r 't :) -. , . , . . v, : L w , j , . x , y à c y t E j j ks j u s o , y so o ay kys j j . ) T k j ) ( t ) ) : . g k ? p . @ ' ) , r t ) k : k z ë j . r t k t , k F t l 1 a . : ' ' j ' x t ' ï a ' e , : à t . : y ) x . t . 4 : t . w 4 k i l ; ? : g . k x ' u ' , t : u t c 4 . k b ï . k v â k b v ' v > t 1 a r ' e ' 'q ' l . .' h ! / t $ t . : i r . ..1 23 î2 1 ' 1 .. ' m einternalgrinding spindle.The extraspace atthedriving pullevisforasecondbelt fOf . hi gher#r? WJ/ KJ speeds'TheSecond V&? //haS thetor nn;Fbartlsed to installandT' efnovethe . . quillsl nlt.Both COllet() /O. 9tMSand the &O//&!S areM/ a#fbYDremel'

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(16mm h (105m m ) 1 Pulley 2.000 l .n 1.200 in (50m m) (30m m) 1 NutforpuIIey* 12 x 20 tp114 x 1.5mm , j;,j yyj . s'j y,(;j yjyyy j 1 CU1lh(1Ider 1.000In 2.000 ' In (25mm) (50mm) 1 Key forpulley 0.125 insq keMs' tock 3mm sq key stock *seeAppendi x2forUKequi valent

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partin the4-jaw ifiteverbecomes nec- again withthe tap,making sure thatyou essary.(Re-cenlring isto be avoided but do notgetthe tap cross threaded in the Wemighthavetodo itin spiteofourbest threads.

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efforts so w e m ight as w ellgetprepared Face the partvery Iightly to clean itup for the w orst now .) Face and Iightly and cham fer the edges and polish cham ferthe partand centre drillitw ith a sm ooth.W henyou makethe quills,check

C entredrill.WheneverYOu make ajig, lhateachquillcanbescreweddowninto 9ou should turn a true surface on itthat this setup aIIthe w ay.AIIfits should be

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can be used forfuture re-centring (ifthe w i thout any shake w hatsoever.A very

1

needeverarises). smalltaperistolerableonthequillregister Drillwith a No 3 drillexactly 1.000 toeaseassemblybutshouldbeavoided.

r

inch deep and tap the hole W -28 (see Appendix 2 for UK equivalent) with a tapered tap follow ed by a bottoming tap. Use a thread cutting Iubricantas i t helps to cutcl ean threads.Blow outthe chips. Take a look at the threads cut w ith a m agnifying glass andtry thethreadsw ith

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Drilland ream a 3/:6inch crosshole in thefirstholderyoum adeforatom my bar for tightening i t dow n on the quills as they are m ade and checked. The hole should be across the unm achined end of the holder.Here we are talking aboutthe holderthat is loose and notthe one that

a brand new high-qualily m achine screw . is to rem ain in the chuck.

The fitshould beperfect- ifitisnot,get

Do notremove the second holderfrom

a new tap and startover.I tis important the 4-jaw untila//quillmachining opera-

to getthis step ri ght. tions, on aIIthe quills, have been comW ith a sharp boring tool, bore the pleted. Even then do not rem ove this

threaded hole out to 0.300 inches in holderfrom the4-jaw'chuckunlessyou diameter exactly 0.312 inches deep. need the chuck foranotheroperation. Ream this out to 0.3125 inches. The lfyou need to rem ove the chuck to use threads at the end of the reamed hole the Iathe, rem ove the chuck w ith the

80

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hotderin it,then you can putkt back and do m ore W ork.lfforno otberreason,i tis worth itto have a spare chuck ortw o for occasions Iike this. Inci dentally,there are

diam etqrfree machining steel.Cutallthe quillblanksto the desired overajjjengths. The two basic quills need to be 1.500 and 2.500 inches Iong overall- overly

tjmes when you should seriously con- Iong quillsare hardto use. siderdoingworklikethisinthe3-jaw and Startbycuttinga centre,themounting notinthe 4-jaw because youcan usethe threads and registers on aIIthe quills at 4-jaw todothe workofthe 3-jaw butnot the same time.Nextdrillthe cross hole the olherw ay around. So if you w ant to for1he 0.125 inch tom m y bar in allthe

tieupachuckwithasetupforarelatively quills.Thetommybarisneededtomount

l ongtime ,1ieup1he3-jaw chuck,(ora t hequillstightlylntheholdingjigfor1he facepl ate)ifataIIpossible nextoperation. .

Startbytakingablankandholding itin

Making thequills ' Mountthe 3-jaw chuck.

Thequillslhalholdthegrindingw heeîs need to bem ade so thatthey w illrun as true as possible. M ost users will need only tw o quills (a short one and a long one)but ifyou think you w illneed m ore than two quills,theyshould aIlbe m ade at the sam etim e so they willaIIhave identicalfitting and runningcharacteristics. EachofthequillshastohavetheDremel

the3-jaw with 1.000 inch ofblanksticking out.Face itand place a smallcentre in

1he end of1he blank. Turn dow n 0.375 inches of the quillto 0.250 inch diam eter.Cuta threading toolclearance atthe end of the turned part. Using the lathe startcutting 28 tpion the quill- this w ill m ake the threads straight. Using a tailstock die holderclean up and size the

74-28 lsee Appendix 2 for UK equivalent)threads.M akesure thatthethreads

Moto colletsystem nose formed on iton go aIIthe wayto the shoulderrecess by

oneend, andthem ounting threadsforthe reversing the die and recutting the grinderspindle cutatthe otherend. The threads.(Use a die with the jackscrew

Apaceinbetweenisasqacerandcouldbe thatIetsyou adjustthediameterofthe

madeto any shape deslred by the user.I threads.Adjust itto cutlarge threads, ahow a strai ghtdesign. then adiustthediameterdownwardsunThe quills are aII m ade from ! 4 inch tiIyou getthe fityou w ant.)

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ustthisdimension forafirm fit. TermAdj inate w i th a clean shoulderatthe unmachined end. Cham fer aIledges Iightly. Rem em ber that all threads should always be chamfered at

60degreeswithathread cutting tool.

Repea' t these operations on a11 1he quillsthatyou are going to m ake. Isuggest that you m ake a halfa dozen quills while you are atit. A quartef inch from the shoulder, drill and ream an ! 4 inch hole across each arbor for getting a purchase on the quill w ith a tom m y bar. The hole m ust be reamed to give it a good close fiton the tommybar. lfyou do no1 ream i1#it will be Ioose on the barand soon the hole will getdeformed and look terrible. The cross drilling can be done by holding each quill in a 3-jaw chuck held in the Thomas di viding head anddrilling the hole withthe Iathe spindle.The tom my barhole should

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bechamferedverylijhtlyateachend

.

It is worth repeatlng that if you have

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t j . 1 1/ . b' ,., fixture and use tk!e tom my bar to I >htendown.Bringthe quilllengthdow n t0jg t0 size as per your reotlifem ents. Face tj ae end ofthe quilland centre drillitwith asmaî'Cefore dfill.Bring up the tailstock wi th a ballbearing centre in i t and w ork

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firm enough fitin the spindle and need

the threads to pullthem in aIIthe way This means that a thread ortw o should. be fully engaged before the register start gage. Thi ster isa goaod ru ledftoor alIfits st to hae tn use a regi s and thr ea m ount an a'ttachment accurately. The factthatthis rule is notfollow ed is w hat m akes it hard, som etimes, to ge1 a Myford chuck back onto the Iathe nose. The register and threads should not engage atthe same tim e. Thatis allthatis needed on one end of each ofthe quills.M ake as m any quillsas you think youwi llneed hevent enma kelyane coed uple morebecaus eyou w, it ll ual them and itiseasierto make them now . M achining the qgillshanks and collet r ecesses Re move the 3-jew and put the 4-jaW, with the holding fixture stillin it, back 00 the lathe spindle. Screw the shortestquillinto the hold-

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from here on.Turn the outboard Pi inch be w ellworth yourtroubl e to try m aking of 1he quil610 BXBCSV C1.250 inches in a Drem elnose on a piece offree m achin-

Turndownfrom herebacksothatvou jeave l/ainch unm achined to tj ae rkgja of the tom m Y bar hole. The shape of the quillbetw een the holder and the collet oseris not criticaland you can m ake it cj /otlIike. assimilo OrZS e'Zborate isi '

Lathecut0.277''-40 threadson the

nose to fitthe colietcloserforthe Drem el M oto Tool.This should be a close fitw ith as Iittle playas possible - there isnota Iot ofroom ' to play w ktj,at4o tpiso go very Carefully.Backthe centre offand replace w th a drillchuck.Drilla ! 4 4inch hole in thi Note equill,allthe w ay through the shortest jtispossibje thatDrem elM oto (and espe- quills and 1.000 inch deep on aIIother ciall yio' tjperEuropean m anufacturers)are quills. Ream thi s out to O.125 inches. aeir custom ers with 3m m Use a Drem elM oto grinding wheelarbor prov tjkng tj

shanksontjaeirgr nding qi 25 i wheelsandtools to cbeck this hole forsize and conforminstead ofthe 0. ncj nshanksused in the usx .I fo i s i s t he c ase you have to j ream to fit tje shanks you willbe workkj w with and m ake the collet recess and

ity.(To repeatm y earlierstatement,iti s possible that European m anufacturers are providing 3m m shanks on the grinding wheels.Ifthi s is the case you have to

yj jjae tureads for the US Drem elM oto co etcloseraref0. i 277''-40 threads and shoul d b e cut t o ta colletclosernutpurh c M ased from the m anufacturer. Dremel oto m akes a numberofcollets fortheir many tools.lthinkthe bestcolletsforour use klare the num ber 203, 204 and 205 c oo ets.vou need to purchase only the :z: koc! a collet - these collets aIIuse t dclosingnut.Measuretheactjestandar ualnutthatyou purchase and w ork to it. q I originally designed the high-speed spindle to allow m e to grind the tir nindingndl e ends (at the end of the zhayftspi s) that are needed w hen m aking clocks. It can also be used for grinding threads and fora num berofspeciattoolm aking operations.It i s not sui table for

you Willbe w orking with and m ake the colletrecessetc.tom atch.) You w ill most probably be using w heelsw ith Vsinch arbors.M easure your IA inch collet and form the nose of the quillto acceptlhis collet.Drill5/3:inches : % inch deep and cut a taper of 60 included degrees. Refer to drawings but check with w hat is being provided by

tgej aolebehindittomatch.

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between the centre and 1he holding jig pleted quill s,and m aybe ruin one,itwill

82

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exteosive internaîgrindîng because the tiny Drem elMotogrindingw heelscando Only so m uch.However,they can touch up internalsurfaces to provi de that final touch thatis needed so often. Before you start on your half-com -

dni i amesteover r.We msatkii g this 0pose. .005 i crap. Thereisnothinginthisworld che size a ar te thi mn e on pur In ikg es exper ience.

hol e hol efortommybar Figure 10.* Cross section ofqullls. . , . ,y.,,,r , ,r 'u .. $ (... , ' ' ' ' M achine the next 0.250 inches of the not built the George Thomas dividing blank to a diam eter of exactly 0.312 head you are working with one hand tied inches. This diameter m ay have to be behind yourback. A book thatdescribes slightly m ore or less tban 0.312 inches the construction of this toolis a ,,m ust depending on the size of the hole that read''forany serious am ateur. was made by yourream erin the holding The registerson the arbors shoujtjkje a

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yourDremeldealerbeforeyoujroceed.

Place a grinding wheelarborIn a collet and tighten dow n the colletcloser.Start the spindle and check for proper operation.The w heelshoul d be held tightand run com plelely true - ifitdoes not,YOu have som e detective w ork to do,BO tha t rx

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Clean upthetqhe uillcol and ucl rn own th neck. Remove l ett osd er , col lee t and w heeland deburr,chamferpolish up the quill.Unscrew itfrom the fixture and Store it. The firstquilli s ready foruse. Repeat these operations on all the quills thatyou w illbe needing.The only

G HA PTER 1 1

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d q i u fi f l es rea nn cd et w he i l i rb I o eni g ner ths e ha l e nn kg st . hA sIoo fth th ee r dim ensions are to rem ain the same.

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6, Design sketch fora small Drem el M oto also m ake a very nice Fi ugur .=e 10.,

i '' ' atthe end ofthe quillto allow the chuck diam eter pull ey can be found for the

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small,accuratechuckthatfitsonthese UC' V' H9*5/W/* threads This chuck needs a flatsection .

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jaws to ride on.Cut this flat.You will motorwithoutdifficulty.This meanswe want to have one of these chucks on need a pulley with an effective diam eter hand to hold odd-sized shanks. of0.697,say 0.700 inches orIesson the . ' spindle.

Pulley

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The pulley can be m ade the same as the OD grinding spindle pulley if you do not have extrem e high-speed operations in mind. The sm aller grinding w heels have to run ata m inim um ofabout 15,000 rpm to cuteffectively.The Drem elM oto runs at a maxim um speed ofabout30,000 rpm . Let us assum e that w e have a 175O (145O in GB)rpm m otorforourspindle. This m eans we need an 8.6:1 driving ratio between the m otorand the spindle. Let us furtherassume that a 6.000 inch

The sketch in Figure 10.5 shows how

you can m ake a sm allpulley forthe end ofthe spindle shaft.You can reduce the shaft dow n to 0.250 inches forthe pul l ey ' to m ounl on and leave aboul 0.032 inches ofm aterialon the bel t itselfunder the belton the pulley. It is unlikely that we w illdo this with run-of-the-m ill''V' 'belting.lsuggestthat we use the now readily available 5 or 7mm round polyurethane belting stock and m ake up a belt to suit our needs, Instructions for using the polyurethane belting com e w ith the belting.

Ifyou have nevermade a spindle before M T shank can be used w ith this spindle. and you need a sm allspiodle, you w ill The taperis draw n into the spindle with a want to take a close Iook at this design. draw bar. There are no provisions for

Thisisa good projectforabeginnerasa threads on the spindle nose and so no fifstspindle. It is a Ii ght,fast spindle and itcan be used on the sm allerIathes. I t is sim ple and is designed especially forthe beginner. The com promises accepted in the design are intended to make thespindIe easierto m ake. Morse tapers hold tools accurately and there are times when a sm allerspindle is needed. ThisNo 1 MT spindle i s desi gned to have an outside diam eter of only 1.500 inches.Only tooling with a No 1 ''

chucks or nose type collet closers are eitherneeded orsupported.The bearings are glued into the housing for ease of conslruclion. Thetooling forthisspindlew ould either be cutting tools thatalready have a No 1 MT on them or are mounted on arbors thathave a No 1 M T. Tooling forcutting clock gears and pinions is available for this taper. Arbors for m ounting drill chucks are also available for this taper. '

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4.250 inch overall

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certain smalllathes (Sherline)use this Bearingseleclions ( ..' ; t'' .,;jv.,' . tajerintheirspindles.Thespindleisbest .

sulted to light tasks and is not heavy enoughforalIbutthesm allestm illingcutters and drills nevertheless many,many usefuland interesting thingscan bedone with these. The bearing arrangem entforthisspindIe is a sim plified version of the other arrangementsinthisbook.Onebearingis usedinfrontandonebearingisusedinthe back of the spindle. This is a sim ple arrangementthatservesthe purposesw e

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Frontbean' hg Outsidediam eter Insidediam eter Thickness

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oneofthese.)Unlessyouhaveaccessto

.

Diameter

Length

1 .500 i n (aamm) 1 ooo i n

4. in (1500 1smm) 6.000 in

(ismm)

(1ssmm)

a ream er(eitherborrowed orbought)to

Bearingspacers 0.750 in

do thejobright,Ido notrecommend that

(2Omm1

(90mm)

youmakethisspindle.Ifyoumusthavea Pulley

2jD t 0O0 in fzf' t Rl

0 j750in S-ORRmI

spindle this size, you should consider using a steeperhom e-m ade taperthat is Nut* draw n in w ith adraw boltorconsiderone

3:5O0in

0 18tpi, li625 x1x5mm .

ofthe othersqindles. Considera 20- *SeeAppendix2forUKequivalent

degree (orIess)lncludedangle asastarting pointforyourexperiments. W e w illm ake the parts in the follow ing In orderto keep the design as sim ple as order: possible,the spindle uses double sealed ' '' , . bearings that are exposed on one side 1. The housing. (the otherside faces the innards ofthe 2. Thespindle. spindle).Ifthe seals orbearings getcom - 3. Spacers. . : .

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true it up. lt should be true at both ends 0.062 inches deeper than the bearing. to ensure thatthe two bearing recesses Polish the restofthe housing and cham are perfectly in Iine. Face the housing feras before. face, centre drillthe face and then drilla This com pletes the housing. 0.250 inch hole in the housing as faras

yourequipmenlwillallow .Theworkwil! 2.Tbespindle

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' Fjgure 11.2 Housing dimensions. '

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starttogethodtla syouproceed.UseaIot Nextwe willmakethespindle.Theraw of coolantan ubricant as the hole gets m aterialforthe spindle is a piece of free aining steel 1 000 i deeg. Drillthis hole out to 0.500 inches m acj nch in diameter indiam eteras farasyou can go. Borethis and 6.000 inches Iong.A1lthe work on outto 1.000 inch l.n diam eter halfw ay thespindle jstobedonebetweencentres.

ority item foran infrequently used item. Therearetwowaystomakethehousing: .

1 ) 1

the housing accurately in the 4jaw and that on this end the bearing recess Is

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applications, so in a w ay these are that clam ps the bearing outer race in throw aw ay spindles. place.Idecided notto m ake the threaded . . . .

1 1

c.c6g. inches deeperthan the bearing to Repeat the above drilling and boring aIlow some adjustment. operations and fi t a bearing on this end m arl with the spindle housing. Hol d juslasyou didontheotherend exceqt

prom ised,itis the design intentthat the 4. Pulley. ''. ''' , '. bearings cannot be replaced,the spindle 5. Sizing the spacers. . ! m ust be discarded.This decision trades 6. Finalassem bly. ease ofconstruclion w ith durabilitv.Here durability is being considered the Iow pri- 1 . The housing

This is true formany modelengineering with and without the threaded section

!!.

''Loctited''intotherecessandsoshould

yj ae two endsofthishousingare iden- Turn the housing around in the 4-jaw . i ca l t to a lengtb of 4.250 inches. t exceptfordepth- oneendhastobe Turn i

w orlh the efforl. (The tapered pjug w ould be easierto m ake and even then it Housing is notrecom mended that you try making spindle

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Borearecesstoallow abearingtofitin

therecessand beflushw iththeouterIip of the recess. The bearing w ill be

There are only 8 partsto this spindle and

The taper could be bored but i t is not oescripli on

'

fdoing thisisthatthespindlecan then everbe taken apartforanyreason.W e 0 ngis wi)jnotapply the glueuntileverythi in place and we are sure every operation has been com pleted - it w illbe the Iast thkogthatw edo. Ifw e decideto do w i thoutthethreads,w e w illnothaveto m ake thetjjreaded csam ping capsthatfitin1he o

intodthout eho usmeet ing.Th e de willbe to thi s.othersi bore

have athand.Itisnotclaimed thatthisis two of them are purchased par' ts (the bestwaytodothejob,onlythatisasim- spacerisin two parts).

Rearbearing (sam easfront) Outside diam eter 1.250 in (32mm ) Insidediameter 0.625 in(16m m) Thickness 0.437 in (12m m)

nercan bore an accurate No 1 M T recess.

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ons so we have to gluethe outer secti racesinplacewithananaerobicadhesive sucja as Loctite. The majordisadvantage

have a clearance of about 0.001 inches allthe w ay around for the adhesive to flow . This is an easy fit - the bearing should fallout with a Iittle shaking. Polish the outside of the housing. threads. W ithout the caps is the quick Cham fer alledges at 45 degrees. This waY to build the spindle. com pletes one side.

Itisnotrealistictoexpectthata begin- Listofmaterialsneeded

.

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1.250 in (32m m ) 0.625 in (16m m ) 0.437 in (12m m )

pIe way to do i tand thatitworks.

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drawbarusedbyyourcolets .

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Figure 11.3 Splndle dlmensions. , .

Figure 1:.4 spacerdl. mensions.

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Makeyourpulleytosuit' thebeltingthat

cannot be m ade too tightorthe spacers

Hold a piece of free m achining steel will collapse under the pressure as the 2,ooo inches in diam eter and 0.750

hole is drilled and reamed.The reamed incheslong inthe 3jaw .Faceand centre hole itselfneeds to be slightly more than the part.Drillto ' Pi inch in diam eterand

a O.25Oincb,0.a12ora0.375inchdiam- afewtimesandeventuallv fJrcewillruin eterhope tothe centre ofthe spindle from the spindle and the bearin' g

0* 625 inches in diameterso thatthe boreandthenreamto0.625inchestofit Spdcers slide on easily onto the spindle on your spindle. It is often a good idea

each side for the draw bar. The hole

Section betw eenthebearings.

cutthe % -18 (see Annendix 2 forUk'

checkthethrezrln Iowingtheworktobeheldbyadogwhile fora qood fi%0on 1he nu rchasn a'Z5*I' ' -- -*'Q' m aking the part.Ifyou do nothave a dog chamfW erthe threads. 'arge enough,turn o.62s inches of the spindle dow n at one end to fit in your a. spacers

dog. Make1hespaceras1wopartsforeaseof First w e w ant to m ake sure that the fabrication and fitting.One partis 2.000 lails&ockisse1righttogiveanunlapered incheslong andthe otherpartis 1.125

ltiscriticalthatthespacersbefaced totrueitupbeforereamingi tparticularly

between tine bearinqs constant for any Turn a 1.12s inch diam eter boss qne Iength ofspacers. o.12s inches Iong on the part.Cham fer

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jeng' th ofthe partand m easure each end. should be about O.100 inches longer

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Both diameters have to be identicali.e. thanthefinisheddimensionbetweenthe

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within 0.001 inches or less of one bearings. M aking the spacers is a

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stock untilthey are.Ifthere is to be a dif- Use 0.750 inch diam eterstock.Hold the

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and notIooserasthey m ove uptheshaft). inch hole.Carefully face and cham feraII

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Chapter 16 contains a discussion of edges on each side of each spacer so

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tailstockand headstockali gnment.

that they w illbolt up true betw een the

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lg2'000di a

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88

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Wewillmachinethepulleyendfirst. b earing.Again,thyeIt wospacerstogether ' j' have to be slightl ongerthan the space 7.

Turn 5.375 inches of the shaft dow n to 0.625 inches.Cbeck the fitofthe bearings to this shaft,they should be a firm push-fit aIIthe w ay on this shaft,You

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another.Ifthey are not,adjustthe tail- straightforward drilland ream operation.

f erence,the tailend should be the end work accurately in the 4-jaw. Drilland thatissm aller(sothatbearingsgettighter ream each spacerfora finished 0,625

totake aIightboring passthrough ahole

truesothattheywillfittoeachotherand ifyourdrills tend to wanderorifthe t he bearings as truly asyou can make drilledholehasbecomeoffcentreforany them fit. This w ill make the spacing reason.

CUt.Makeafinishingtestcutalongthe incheslong.Together,tostartwith,they

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blank and place a centre on each end.Drill have to take the back bearina on and'off .

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a 0.625 inch diam eler m ounting hole. yhis w ould serve most purposes on a spinulethis size.zhere is only onegroove On this pulley forsim plicity's sake.This w ill accept a ''V' ' belt that is 0.375

Usethe4-jaw ,and face each end ofthe shouldnothavetouseforcebecauseuon

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W henmakingthesespacers,the4-jaw you wlllbeusing.

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edgesand polishto completethisside.

thefitjustright.Boltthespindletogether

Reverse the part in the chuck and hold now using the spindle,the tw o bearings

adhesive manufacturer to cl ean the and then finish itup With the tapercutparts. Only the sm allest amount of the ting ream er.

bY the O.126 inch long boss.Carefully and the two sqacers.Putitnexttothe facetue pulleyinanticipation ofturnin, it in situ on t'w spindle. vue part t' aat is going to form the body of the pulley should be o.soo inches thick, turn the rest of the m aterialaw ay. chamfer aII corners and polish. oo not cu& the belt grooveyet,we willdo thatIaterin situto

housing.. rl ae dl stance from tlae frontof one uearing to the uackoftheotuerbearing should be the same as the spindle housing Iength.w e willshorten one of the spacers by this amount to net the rightfQlt. Now assem ble the parts inside the

adhesive needs to be applied, just

geta perfecsy runningpulîey.

housing.The bearings should be flush

bearing.Place the two spacers on the orYainchrod.Maketherod 0.750inches

Mountthe bearing spacersand the pulIey on the spindle and ' tighten down w ith the nut.M ountthe spindle between centres,true the outer periphery of the pulIey and cut the groove forthe belt.The top ofthe groove should be 0.375 inches

with the housing faces.

soindle and follow up by gluing the back bear - ing into its recess. w ipe off any excessadhesive carefull y butIeave enough forthe pulley.lmm ediately place the pulIey and the nuton thespindle and tighten down.Turn the spindle by hand to allow t:e back bearing to settle in.setaside in a verticalposi tion to allow the adhesive to setovernight. The spindle can neverbe taken apart.

6. Finalassem bly Finalm eans finaland w e do notintend to do it again. Before w e start on the assem bly, w e have to be sure that everv-

wideandtheincluded anglebetweenthe thing isjustexactly as we wantitto b' e.

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sides ofthe pulley should be 40 degrees. Take Iightcuts.AIIthe work isdone w ith a grooving or parti ng tool. First cut a groove 0 .4Oo inches deep,then set the Com potlnd Slideto a zo-degree angle and

Clean and poli sh aIIthe parts.Check the seals on the bearings to m ake sure that they w ere not dam aged in any way during the handling done in the fabrication and testing procedures.

finishcuttingonesideofthepulley.Then

Firstplace oneofthebearingsonthe

Set the compound to -20 degrees and CUtthe Otherside ofthe pulley.Finish the bottom Ofthe groove flat.Use a double Ws-degree tOOI to cham fer alI edges. Polish aIIsurfaces. A keyway is not needed,we willql - ue the pulley to the spindle.

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5* sizing the spacers The spindle bearings wil!have theirouter races held in the housing w ith Loctite. The innerraces are held w ith the spacers and the pulley nut in the back.Both the

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spindle and slip the tw o spacers onto the spindle. Place the other bearing in the backofthehousing (the deeperrecess). From the otherside place the spindle in the housing and thread the spindle throuqh inq. '''' the second bear x' e Slip the pulley onto the spindle.Place 1he nu1 onto the spindle and tighten dow n. Thespindleshould run trueand free and there shoul d be no backlash in the bearings.satisfyyourselfthatthis isw hatyou are Iooking for,ifnot,now is the tim e to

inner and ouler races have to be the makethenecessaryadjustments. same distance apart forthe best operation of the bearings and therefore the spindle. As presently constructed, the spac ers are Iongerthan they need to be a nd one bearing w ill stick out of the

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anough to w etthe outerrace and recess. girst glue tl ne front bearinq into tbe shal loW errecess. M ake sure it seats aII 'be way in. w ipe excess adhesive off w * i th a papertissue. Position the housing on one end to Ietthe frontbearing set. push the spindle through the front

Ctltting the No 1 M T

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0.375inchesofthedrawbarjoesinto

Spindle running in the spindle bearingsso thatitw illbe com pletely trueto the bearings.W e w illrough bore the taperfirst , ,,. . '' . ë. ' ' p ' L ! '' . , '.? . , , 'k , . , .. ... I ..... . . , ' '. , . ' '' , ,,h : .. , rL , ', . ' '.

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Iongerthan thedistance from the back of an afborto &he back of the spindle.This should be m easured from your spindle. Cut0.750 inches ofthreads on each end to m atch the threads in the arbors.The threadsneed to be straighland itis worth thetim e to cutthem on the Iathe to m ake sure that they afe. yue pktco of the threads is to m atch the pi tch on the arbors thatyou plan to use.Itm ay be necessary to m ake a num berofdraw bars to suityourtooling needs.

TheNo1MTiscutinthespindlewiththe

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housing. The adhesive should be applied to a W eneedtodetermineexactlyjusthow cleaned and degreased recess and race. much we havetotakeoffaspacertoget Use the cleaning agentsupplied by the

Thereisadetaileddescriptionon cut-

ting tl ae xo 2 u . r fortue basic spindle in chapter 3, Read that and follow the instructions given to ctltthe No 1 M T in this spindle. , M aking a draw bar '' ' M akethedraw baroutOfapieceofW ,7:6

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ti ghten (ratherthan Ioosen)the works. theoperator)ofthe wheeltobecut.That

Clock m aking. ings w ore outratherfasterthan w asconM aking this fram e orspindle is a good sidered tolerable for accurate w ork and

This is a prim e consideration because re- w ill reverse the direction of rotation of ti ghtening things in the m iddle of a Iarge the wheeland the pulley can then be on

assem blies thatfitinto otherassem blies. Each part has to be m ade accurately because each contributes to the accuracy ofthe overallassem bly. A verticalspindle as used in a sm all

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ness.The fram e can be held in the same the operator,face the lathe.See Figure way as Iathe cutting tools are held on the 12.2. Tbis is as seen from above the compound slide.Since the cutting forces involved in cutting sm allclock gears are sm all, i t can also be held in a quick j change system .Itcan,ofcourse,also be Gear mounted on the carriage and the vertical slide ifa few accessories are m ade up.

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Tai f stock

The bearings The selection ofthe bearings isthe key to the design of this fram e. Rather sm all bearings are to be used.W e need a bearcutter

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Mo vjr nen duri q? aCuuxgOpefauon

Figure 12.2 Dl kection/W which cutting should takepl ace,Iookl hg down

Figure 12.1 Section acrossfram e.

on theIathe from above.

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M aking the fram e parts The fram e is m ade from barstock that is 1.250 inches w ide and 0.500 inches thick.You w illneed about10.000 inches

that the cutting take place when the ofthe material.As always 1recommend frame moves from right to Ieftas you, free machining steelforaIImy projects-

t o sqare forthe threaded adjusters,so thatIs w hatw e w illuse.

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Since we do not want to get into the business of using Ieft-hand threads and aIIthe problem s that go with that w e need to do som e planning.It is desirable

0.250 inches.These bearingsw illfitwith a 0.500 inch by 1.000 inch barw ith room

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wheelcutting projectcannotbetolerated top.

I ifprecisionworkistoresult.

ing wi th an internal diameter (ID) of

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the clock w heel. Ihave addr essed thi s specificconcern in this design.The frame described here has the specialattribute of being supported on sealed ball bearings top and bottom . The bearing posi-

lathe is essentially a gearcutting frame. tionsare adjustableso thatthegearcutThere have been complaintsaboutthese ters do not have to be ofa fixed thick-

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m eans that the pulley that drives the spindle has to be on the bottom !Notthe end ofthe w orld,buthighly inconvenient to say the Ieast,Our belt dri ve arrangem ent w illbe difficult i f we do not pay close attention up front. M ostl y w hat this m eans is thatw e have to take some measurements on the Iathe we are planning on using before w e start. The other al ternati ve is to devise a m ounting forthe fram e so that the cut-

projectifyou have a serious interest in designedtouse.Itseemed thatthe bear-

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counterclockwise (ccw). This in turn

You willbe interested in this particular as regards the bearings that they were

V erticalspindle or gear cutting fram e

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0.625 in (16m m ) 0.250 in (7mm ) 0.187 in (5mm ) Yes,both sides

These are Com mon, inexpensive bearjngs.Specify a high-quality close fitting bearing,yourdistributor w illknow w hat you m ean. The most serious problem w e w ill encounter is w i th the direction of rotation of the cutting wheel. W e w ant to dri ve the w heelin such a way that the driving force on the pulley w ill alw ays ting wheelcan be on the farside (from

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exercise in making parts that fit as one ended up with an odd Iast1:00th on

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Iathe. This m eans thatas seen from the ' top, the cutting w heel should be rotating

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sary.You could usesom edrillrod (silver

steed)tomakethespindl eitselfsothatit is good and stiff but you do not really need to. It's nota11thatIong and slender in any case, and the Ioads imptoessm edal by cutting sm allbrass gears are qui l. prepare 4 pieces ofthe baras follow s:

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* 2 pieces 2.000 inches Iong for the top and bottom .

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Fuure!2.a Top:basicgearcutr/ngframe

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. 1 piece 2.500 inches long forthe yartsidentical.Themostimportantthinq toolholdertang. M ake the tang Iast Is thatthe threaded hole thataccepts the

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so thatyou can fi tthe mounting that bearings be centred on one end of the you decide on foryourparticularap- parts and be exactly atrightanglesto the plication. face ofthe part.This can be guaranteed by m ounting the plates on a face plate The first two pieces,the top and bot- and cutting ' the lhreads in the lathe. tom are identical. Start by m aking the The bearings that we are planning to parts exactly 2.000 inches Iong.M ake use have an inside diam eter of 0.250 sure ' that 1he ends are at righl angles to inches, an outside diam eter of 0.625 the face and sides of the part. File aII inches and a thickness of 0.190 inches. im perfections so that alI6 sides of each These w illbe held in threaded pieces that part are flat and at right angles to one need to be 0.375 inches greaterin diam-

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eter than the bearing OD wi th 24 tpi

Put m arking blue on each part on one threads on the outside diam eter. See f .

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0p i l9hlY estim ate the centre Iocation .Th sgives us a barwidth of1.250 ofBOL t em the face plate and drilltw o holes in the j aes. inc fkxture to allow you ' to m ounti tto the Ma r k a n d dr i l l t h e t wo b o l t d o wn h o l e s ba r These a r e 10-32 f ac e Pl a t e. Cent r e t he cent r e but ton at one end ofthe bar. on ::A)clearholesthatareto bedrilled ' Uk Iathe Centreand bojttjae barfixture tight ( to the faceplate. ioch in from the ends of the bar.Deburr d file the surface down afterdrilling. Rem ove the centring button and drilla ' anu ark the centre ofthe face ofthe bar Centre drillin the part. Drillthrough Fk

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pjate m akes it easy to m ount the part tbO bottom plate as close to Identicalas paral lel to the cutting face in a Iathe. POSSible.

Make a boltdown jig from a piece of %

Vachinetheotherplateto be asidenti-

inch sq barstock. Drilland tap two holes to match the holesin the barand boltthe frame bardow n to this fixture,good and tight.check ' to m ake sure thatthe parts fittogetherand that they sit flat on the

CaltO this plate as you possibly can. . sack offrame '' The back of the fram e is m ade of the sam e m aterials as the top and bottom .jt js 1*soo inches Iong. specialattention jg yo j;agjsauyo makjyw yj qaayyyjguj CCCt j jyj gsgjsy jo yjja jaoyoyy

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assem bly is square and parallel.lfnecessary, adjustthe faces wi th a fiIe orby re-m achining.The top and bottom plates

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àg top and Fiqure 12.s setup srthreadt :olro?ylpfatesin yar/?e (on faceplate). . q.(''

bearinos W I1I run properly in them . Lay the assem bly on its Side to m ake Sure ' tbatitIies flat. Clam p one end plate accurately to the

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A1this point check thatthe hole is actuaIIY Centred on the three sides ofthe bar. lfnot,nOW isthe time tom ake acorrection bv repositioning on the face plate. W hen everything isaIIright,open the hole OUtto 0.800 inchesdiam eter.Thread the bole SO that #ou have threads that are 0.876 by 24 tpi.These willhave a theoreticalinternaldiam eterof0.832 inches. Tbe exact diam eter is not critical, it is

pjate on a face plate because the face more importanttogetthetoqpla' teand

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' J mark the same distance (0.500 i nch.Openoutto/2inchwithadrilland bore 1he hole outtoabout0.750 inches.

jpches)in from one side.This w illbethe entreofthebearings. ln the drillpress c drilla No 34 hole atthis point and tap i t 6- 32 (4BA).M ountacentring button to thishole and fix itthatthis bulton is equidjstantfrom aIlthree sides. This can also be done by m achining a disk 1.000 inch j n diam eter and 0.375 inches thick and usinc this to centre the nar t in the Iathe ' (ont Whefaceplate). lti s easierto cutthe threadsinside this

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wings. w e need another0.125 inches face pla'te and are parallelto the face

df ramaterialbeyondthese piecestohold glate.

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1.500i nch orillandtap 10.:,2 fourplaces.

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back pl ate and spot the holes through bI y that willnotslip on the bolts. into the back.Drilland tap these holes 10-32 (2BA) at least Fi inch deep. Bearingsupportrings Bepeaton the othersi de. The bearing supportrinns thread into the

Now using Loctite between the parts threads thatwere cutC In the upper and bu1 not on the threads (and this takes lowerplate justdescribed.lf1he lhread

s ome careso use very Iittle adhesive) diametersarenoti denticalintheabove assem ble the two ends onto the back parts you w illhave to m ake two differ,

and Iay the assem bly of a flatsurface on its side.M ake sure itIies flat.M ake sure aIIcom ponents are vertical and tighten 1he screw s dow n good and tight.Once the Locti te sets you w illhave an assem -

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entsets of bearing supports, one setfor each ofthe plates. Start w ith a piece of free m achining steel 3 .000 înches long and 1.062

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part off a section O.218 inches thick. M ake one more partidenticalto this one. qepeat the process for the other end

Next we need to cutw rench slots into CbUCk'Face the end and centre drillthe piece. Drill into the part 1.500 inches these tw o sets oftw o parts.Atthe least deep w ith a 0 .250 ioch drill. Open this we need an , yaincj. jslotacross theback of out w ith a 0.600 inch dril!and bore this the partsto allow usto tighten them into

cutto 0.562 inches. the threaded bearing hole - four orsix The bearing seat has to be the diam - w ould be better.The slots should be eterofthe bearings and 0.080 inch deep. 0.125 inches wide and 0.109 inches

The bearing should be a push-fi tintothe deep.At this depth the slots willjust recessbored andalittlelesslhan halfthe barety missthe bearing recesses.Debufr

bearing(0.016inchIess)shouldgointo h ole,slots,threadsandtherecessaIIthe w ay around.

the recess.This w illIeave 0.032 inches between the caps when tight on the bearing. Thread 1.500 inches of the outside of the bar to 1.00Q inch by 24 tpi. The threads are cut to be a snug fit on the

Place a bearing between the tw o parts and thread the assem bly into the threaded hole in the bar that fi ts these threads.Ti ghten dow n w ith a piece of1 /B inch plate m ade into a special wrench

Iarger of the two end plates that we just forthis purpose.See drawing.The made.W hen cutting fine thread and trying for snug fits, the follow ing points nee(jto be keptin m ind: @ Keep the w ork clean and free of burrs.

. Keepthethfead bottoms clean.

. yake very sm allcuts orYObIW illhave over-cutbefore you knOW it. * w ork atslow speeds. . use very sharp threading tools. , Use a thread gauge to position the '? threading toolaccurately. . oo notf orgettoround offthethread CrOWnS before YotItestYotlrfi ts. ; î .7 .

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bearing should be a snug fitinthe recess.

plateandmaketwomorethreadedcups

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ir aches in diameter. Hold in the 3-jaw fori t.

Figure 12.7 Cl amping rings - fourringsarerequired. 96

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Figure 12.8 Ihreaded cupshold the Ofll6'fraces 0/7Dlace / ??theframe.

Figure 12.6 Backplate.

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threads,take a very fine finishing cuton tjya jace of tjje part, cjnam fer the last threads on eacla end. M ake a recess o.oao inci nes deep and tlae diam eterof

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bearing should feelright at hom e in i ts housing.It can be moved up and down by threading the assem bly up and down and then re-tightening it.At 24 tpi,each turn of the assem bly moves the bearing 0.0417 inches orabout0.0 10 inches for

everyquarterturn.Fairly accurateadjustm ents can be achieved.

The spindle shaft Iwilldiscuss tw o w aysofbuilding up the shaft (and describe one). one scheme has the pulley between the bearings and

the otherhasthe pulley abovethe bearings. 1think the iatter is preferable for most users because the bel t i s then 97

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easierto remove.Alsothe beltandpulley but the sm allest pulleys w ill interfere do not get in the way of the cutting w i th theirabili ty to reach the w heelto be operation as m uch as they do otherwise. cut. Placing thepulley outside the frame

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The basic desi gn is of a shaft that is built in tw o sections w ith the cutter clam ped between the tw o sections.Each section i s then supported atits otherend by one ofthe two ballbearings.The pulIey can be placed on either half of the shaft or outboard of the bearinqs. The m ain problem is that the cutters used in ock m aking are rathersm alland thus aII cI

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sstiffaspossible.Thisrequirementalso hal fthethicknessofthebearingsothat

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raducestheSpaCeaVailabIeforthepulIey, wecancIampittotheinnerrace.Next soeven though ejac very design Ihaveseen drillacentreintheendandthendrillaNo intheIiteraturep esthepulley betw een 11 hole 5/ainchdeep into the part. Caretbe boarinfs,Iam going to suggestthat fully tap this 10-32 (2BA).About0.375

inches in diam eter (aS in one of M r. be w ilding's elegant skel eton clocks and . y 1.000 jnch - (halfthe bearingthickQbotlt the lim it of w hat can j;s tjorje oj s . . a . n . t t j j e cut t er ROSSI- (halfthecutterthicknessl the Myford buper /)anq Ina

allows us to use a Iarger pulley and to have m ore space to m ounting and driving the spindle. Letus take a bitm ore tim e to consider a pulley betw een the bearings. If we m ountiton the upperhalfofthe shaft, it w illinterfere w i th ourabiliw f' n nmn w hat is going on. If we m ount it on the Iow er halfofthe shaft, thesw arfwillfalldow n

the m ountings to clearthe above dim ensions. There is also a problem W i th cutting extrem ely sm allw heels and pinions but I

cutter m inus 0.010 inches. M ake sure thatthe step nearthe yz inch diam eteris absolutely clean so that the cutter w ill not hang up at this point.It m ust seat havefoundthatthose arebestcutw itha perfectly.Check the diam eterw ith the horizontalspindle Iike the basic spindlein cutterthat you intend to use.The stub chaptera.

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needs to fit inside the cutter and there

Ajjjjle work of making the spindle should benoplay - thisisa criticalfit.

Portsw illbedoneincollets.lrecom m end that aII spindle parts be m ade of silver Steel (drill rod). This w ill give a Iittle Qdded stiffness and w e need every bit thatwe can geton a sm allspindle.However,silversteelis hard to thread and itis Dotessentialthatitbe used. First take a 12.000 inch section of 0.500 inch silver steeland polish it so thataIIblem ishes,rustand dents on itare rem oved.This w illallow the parts to be h6ldinthecolletswithgreateraccuracy.

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we use w illbe a standard Thornton cut- Confirm the Iength foryourfram e. Once ter 1.000 inch in diameter w i th a 7m m the Iength is right,turn a stub dow n to

pull eytqsui tyourcuuer

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the Partand form a boss 0.090 inches

djstance Iong and 0 0i It is desirablesgt tjae di ther shoaftthe framebeas end.Thissh25 ouldnbc ehaes snin ug fai tme int tehreoIn owe between the beari

the better location is outboard of the inches ofgood threads are needed. ksarings,on top ofthe fram e and that is Turn the part around in the collet and on. face the W aY IW illdescribethe çonstructk i t.place a very sm allcentre on this Letusassum e thatthe largestw heelto end. Rem ove and m easure the Iength be cut w i th the Spindle W ill be 9.000 the theoreticalfini shed Iength needs to

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hol e through the centre.W e willdesign 7mm indiameterand thethicknessofthe

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nrlto itand the belt.Also considerthat it Take a good Iook at the draw ings. e that j sharderto drjve a pulley thatism ounted Start with the section ofthe spindl near t he I a t he b ed. I n ei t her cas e, we goe s under t he cut t er . Cut of f a 0 .500 I oW ould have to uSe Sm allbeltsto drive the inch piece ofsilversteel1.000 inch Iong. tv' m ckltter because the space available is so Holding the partin a halfinch collet, face

smallaspossibletogiveusashaftthatis bearing and just a wee bitshorterthan

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Centredrillanddrlllandtap 6-32 (4BA). Carefully chamferaIIedges and polish aIIsurfaces.W ipew ith oily c10th and set aside.This section is now done. The upper section of the spindle is identical. Take a 6-32 cap screw w ith a Iong threaded section and salvage the threaded section from i t.A Iong set screw can also be used.Screw this into one ofthe spindle halves and placethe cutteron the

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ontothescrew.Thecuttershouldbeheld Finalassembly perfectly. Firstdoadryruntrialassemblytomaku RuntheIathe 80thhalvesofthespin- sure thateverything willwork the wa>

Everythingisnow inplace. Notesonusingtheframe Tijhtenthetwo clamps ontheIower Theframecanbemountedeitherinatool bearlngandtightenthecapscrew onthe holder for a quick change system or

not,we need to find outwhatis wrong chanceto make adjustments.

thing ontopneedstobeIooseatthistime done ifonedid nothave a quick change

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and fi x it before we go any further. Clean and prepare the parts for finaj Unscrew the tw o hal vesofthe spindle assem bly. and put the bottom half of the spindle M ount the mounting tang to the back

butthe spindl e willbe constrained by the system .Itw ould also be possible to use a upper bearing. The bearing should be Iargerm ounting tang with a hole in it so joose up and down.M ake sure it is and thatthe assem bly could be bolted down

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and thecutterawayfornow.

Using sim ilarscrew and registertech- and atthe mating parts.Using Loctite on niques m ake the top bearing clam p. the m ating parts gives you strength

oftheframe.Use Loctite on the threads

thentightentheuppercapscrew sothat onthetool -poststuditself.

againsttwistingofthejoint.Thisjointcan

radialplay in thesystem buttheremight ease.Use a discarded washing machine besom eaxialplay. orsim ilarutility motor(forfurtherinforTheaxialplayis' takenupbvmovingthe malion see Electric Motors.W orkshop

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dle and the cuttershould now run true.lf you think itis going to.This is yourlast

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M ake the pulley on a piece of free

maclainingsteelstock1zsoi nclaesindi.

be welded butthereis adangerofw arping.

Nextmountthetoqandbottomplates

ameterand 1.000 inch Iong.Hold the totheback.Hereagaln useLoctiteonthe n the a-jaw and take a cutto true threads and atthe mating parts. Before parti the diameter.Face the part and centre you tighten the parts down, Iay the

drillit. orilla 1o-a2 clear hole through assem bly on its side on a flatsurface to thepart.Turn the bearing registerand a make surethatitIiesflat. 0. 500 inch diametersection to clearthe Allow the adhesive in this frame frame The pulley section w illbe ? /2 inch assem bly to set.W ipe away aII excess thick and w ill have a pulley groove to adhesive and m ake absolutely sure that .

ma tchntthhe ebpa elt i ng t hatyand ouinhol tenddittoinutshe e. t h erebear isnio neinCl thean ethr eaded reclyess eIstfhe or Tur r t ar ound t he ngs. and l i ght oi x inch collet beltsectionexaFcat cly ex tl ai enc ph arI t on to gma Mac kehitne he oi relcyepar s' st th s, rebe adsc. ar Lef ocul ti.tewillsetupinfairly

bottom ofthe spindle in the pulley.Every- bolted dow n w lth packings as would be

the spindle,upperbearing and pulley are The spindle can be run at betw een one.Oncethisis done,there should be no 2000 and 3000 rpm , for brass, w ith

I owerclamoftheupperbearingupgu ntil p racticeseriesNo16andElectricMotors l the play just disappears.Then ti hten l h the Home Workshop'W orkshop Praceverything dow n w ith the upperclam .

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regardsthe properand preci se rotation of centre heightforw heelcutting.The spinthe cutter. . dIe should be qerfectly vertical. The

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the groove to the dim epsions of your Assem ble the two halvesofthe spindle choice.Bore outthe m outh ofthe hole in and the cutter.Place the tw o clam ps that the pulley to acceptthe head ofa 10-32 hold the Iowerbearing on the Iow erbear-

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to make sure thateverything assembles the upperbearingfrom above and threa

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nentsandtheupperand Iowerbearings isnotquiteflushwiththebottom.Placj e

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up correctly. Nothing loose, nothing the upperclam onto it. tight,Everything Iinesup and runs true,i f Place the bearing clam p on top ofthe not,fix i1. assembly and put the cap screw dow n into the spindle. Do not tighten yet.

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shaft fora tommy bar.Chamferboth ter.Placethelowerbossofthesqindlein

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run freely w ithout eitherplay or binding. The spindle needs no m ore than about ! 4

pleteIy.Cham feraIIedgesand polish with plate on the frame.Do not tighten anyemery papers. thing, Drilland ream a ?/:e inch cross hole at Placethe Iowerhalfofthe upperclamp the centre in each hal f of the spindle on the spindle and Iet it rest on the cut-

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Inthefinalanalysis, the spindleshould published by Nexus SpecialInterests).

(2BA) socket head cap screw com- ing and thread aIIthree into the Iower

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j q fl j iL i lii l t q î j i j qv l x k k yljyjt y. y y) l q v q y j . j y yy y j y yyy. yj . s yy

t ance betweengtih e bearings and thus increases the ri dity of the spindle as

vj aese are b0th valid observations and Njjjs spjyytjs js kj -yojyjqjojj yo yjojjyjo yjya

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jj .jj r l r jjj :jj r . r , ! j. j I : j, . g jj l ! ,ij j y ,j r . jj l yj j 4 j E 2 ,j :j: t ! ;,E y jjsyssyjsojyg jjjs syyysyyj o oss jys jyjyjjy W it11OUt t11C Zbi1itY 10 m OUl ' 1tChUCQ nd face plates as show n above. NoteSta ha t this m oves the M orse taper in and deCreases the amount of m etal between .

w ould not be acceplable in an induslrial

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thinkyou need to make asuch aheavy in the book.Iwas nottotally satisfied

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duty spindle foryourday-to-day am ateur with the factthatthe front bearing is so engineering needs. far back into the housing.This was the Tlais spindle could be m ade Pi inch (or best com promise Icould com e up w ith

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mo re)longerandwinchmoreindiameter ands' tills' ta vwithin1he2.000inchdiamto m ake it even m ore heavy duty eterspindl e housing,and use automotive

f ortheMyfordSuper7B.Therewillbe Quantity others w ho think Ishould have selected Inside diam eter

0 .750 in (20m m )

this as the basic design in the book. Outside diameter

1.750 in (45mm )

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the insideraceofthe frontbearing and the Morse taper.Thisis notcriticalbut

clam shell m ounting plates that w ere i s notdescribed in detailbutcan be built made in Chapter 4 for mounting this by follow ing the instructions and changspindle. ing the dim ensions as needed. using taper roller bearings m akes this a substantialspindle and som e am ateur Bearings selected . engineers w ill consider it to be overkill

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i nchesindiameterinsteadofthe2000 spindle.Figure 13.2 isincluded only to

bearings and separate seals.I tis also the Iittle harderand m ore tim e consum ing to most rugged of aIIthe designs.Ido not make than any ofthe restofthe spindles

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Figure 13.2 Sectlon across spindle wlth taperbeanbgs.Bulldl hg ?rwlthoutthe chuck reglàtershortens splhdle.

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Insidediarneter

1.000 in (2srnn' 1l, shafts. 1ze

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Description

Length 6.750 in

Housing

2.w0O in (50m m )

4...ww i n (115mm )

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pull ey

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1.126in

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. Face and drilla large centre.

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thepolbhedSealS&?-/' afOSneededOnMtake he Remove the centre and m ount your sp'yayesjtattand thetv/w'/?spg//ey. (jr. jjj. jng tackle- w e can drilIthe centre thesetf8fr/0terstoSulttheS6b 8/&th8tPO& &S&-

lnternalsmhdleassemblvo/taperedbearing

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spindleshowi ng relativebearing andseal placementson theshaft. A wide:ear/kw placementl ' sdemkableforstiffness.

a' true surface. Bore a slight 6o-degree recess in the end ofthe hole to allow the spindle to continue to accept the centre accurately.Replace the centre. . Note If using M yford chucks on these highspeed spindles itisw ellto remem berthat castiron chuck bodies have a finite rotationalspeed before they burst. osoo. o.soo'' '

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operations when wefinish 1hespindle in sitT uh in he rings. etin itibea alwo rkwillbedonebetween

1.750inchdi ameter 1 z s c i o c hd i a me t e r 1.125*by12tpi

the 4-jaw and the tailstock centre.W e

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finished spindle.Ifnot,now is the lim eto start overbefore you have done a Iot of finishing w. ork. . . lnstructlons form achl nlng the spindle -ven l 'n Chapter 3 on nose threads are gl the 2.250 inch diam eterspindle. Once you have the registers and threads right,m ountthe two face plates on the Iathe spindle. M ount and centre spindle on the second face plate as

OverallI ength=6. 688inches .'

Thesequenceformachining' thespindle eterand6.750inchesIong.Wewillnot

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. .ngsand the seals. * Open thl .s out to 1/2 I .nch I .n dl .ameter Fl rstpurchase the bearl The seals selected should have the sam e as faras it w illgo. ora slightly Iargeroutside diameterthan @ Support end with a ballbearing centhe bearings.Theirinsi de orsealing diam tre. eter should be 0.250 inches Iargerthan * M achine M yford 57 spindle nose on the ID ofthe bearings.W e willmake the end. .ng tw o parts to f. I t the bear. lngs and the seals. * Reverse and re-centre usl Foltow ing a logicalsequence? ,the parts face plates. WiIIbe fabricated 1n the folIow ing order: * Face and drilla Iarge centre. l * Dr1IIhoIe 3 /81nch 1n d1am eterto m eet I g. syjjjytjjas j ... j. .. , ..s , .., . , . jjojs jyom otjjers' jde. .. , 2. Mal .n u . .C'. . C '. @ W OFk betWeen Centre and reversed IIOUS. Ing. '' ' . . . 3. Drlvlng pulley. ' face plate. 4 Nutfordriving pulley. ' '' * M achine restofspindle. 5@ Flnalassem bly. . '. . '. . . . '' ' ' The splndle w .lllbe m achl ned out of a 1.Sni ndl e ni ece of m a t er i al 1 . 7 50 i nc hes in diam œ *

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Diam eler 1.750 in

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fi i sh, thteheonsepiin ch amtet r pangrto h e over-cutoneseat. rn ont of ndl ed ti ha ise goi tf ot be

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s urfacescanbebroughttoahigbfinish frontbearing.Thespacebetweenthe by applying successive grades of em ery two seats does not need to be a tight fit

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paper to tbem w i th a drop of oib. start but should not be too Ioose because w e w ith 220 grit, then 400 grit and finally do notwantto rem ove any m ore m aterial

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6oo grit and even 12oo grit.spin the than we haveto.The pull ey hasto be a workat1ooo rpm and clean up between tightfitbecausei tformsanoiIsealin this grades ofpaperso that no Iarge grains design.Thismeansthatthefrontbearing

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in the finished spindle e nd oftih nd'tle .Dhol rilleafrb n chothher ole ingOnce sactu a11yarfiethappy thr ough te tos mpi ee 1he om i the you wi th the seating of

si de. Makesurethatthecentreisperfect thebearings,iti stimeto cutthethreads afterthe drilling (fix it if it is not)and forthenutthatholdsthepulleyandinner

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re a nrtaons iletr hf einwo asis veearta.lmo stt hee ernt ehs in et omfi ni e dpfoin ishr eksa .sitprogresses h toasgt eotp to tsos Reme mb -irt eps ed al t Now workbetweenafaceplateand inghastobetightateachbearingbut t h e b jlbndl ear n.gFace ntand reascwe dthe wîtot ht he c anbeyou loos eintboet eenwher bear ntg s.bea Thi basi ca spi ei ce entd rei her means have kw now ei he rs .

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Nowwehavetopoli sh,toahighmirror other,thedangerbeingthatyouwill o.2soby28

11 u ndertheoi Iseal .I fwedonotgetthi s Fi rstpreparetheseati ngfortheback bright,w e willshorten thelife ofthe seaà. bearing,then prepare 1he sealing forthe

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4.250inchesoveral

bring the tailstock centre up to the part. races in place.These threads should be Again rough machine the outline ofthe cut to m atch the purchased nut. The spindle first. threadsare to extend o.125 inches undef

we will start the finish work by thepulley(this0.125inchesincludesthe

machining the seats forthe frontseal, recesstocl earingthethreadingtool).

then forthe bearing innerraces. w e are

once you have a nice setofthreads

aimingforafirm totightpush-fitforthe cut,chamferonaIIedges,andcleanup bearing innerraces.This isthe hardest thework. part ofmaking this spindle.The portion

ThiscompletesaIItheworkontheout-

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forthe seals first and then bore forthe bearings because there is a possibility that we will disturb the bearing bore w hile we are m aking the sealseating.By

done forone side and then the same getting the sealwork done and out of

effortistoberepeatedontheotherside the way wecan then boreforthebearafter' the parthas been turned around in ings and be assured thatwewillnotdis-

the 4-jaw and sized to a 4.250 inch turbourwork.Theruleistoalwaysdo length.

the mostcriticalpartIast,eventhoujh

Hold the housing blank in the 4-jaw that is the worst time to make a mls-

ofthe shaftbetw een the bearings can be side ofthe spindle except forcutting the

and centre it to run true at both ends. take.

turned downjusta bitto allow the front keyway.The No 2 MT stillhasto becut.

Facetheend anddrillacentre init.

bearing to slide overto its seating afterit

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Iam notgivingspecificdimensions for

Pass a file over the housing to clean these recesses because the chances are

hasbeenslidoverthebackseating.

2.Mainhousing

uq aIIthe bumps and blemishes.Polish thatthebearingandsealswillnotbethe

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withtherestofthespindle.

Iow barwitha1.000inchholeinitcanbe

tooltocleanupthebartosuit,butavoid sealwillconform to therecess.Use a

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c tt ,a wt eri wi havt e thl e ah reh)ollow 8a 0u thtio bn earingshavethesameinsidediam- n (noo viall lma tetrooma naksema lIb at

W eneedtoholdthisintheclamssowe notoverborethesealand/orbearing Cannottaketoo m uch off.)Thenpolish it recesses.

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First we have to m achine the back of the register flange and the back of the seat forthe front seal.Once the flange and sealsea' t are right w e can proceed

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The blank forthe m ain housing is a piece of free m achining steel2.000 inches in diam eter and 4.375 inches Iong.This is ' to befinishedto 4.250 inchesdong.Ifhol-

obtainedthiswillsaveaIotofwork.If .

Thetw o ends ofthe housing are identi-

W1th em ery clo' th - this should give you a nice finish. Ifthe finish is not to your Satisfaction, consider taking a very Slight cut with a round nosed turning

doingthisifyoucan.(Keepinmindthat carriagestoptomakesurethatyoudo up.W e w ant an accurate,polished sur-

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exact size that lhave specified,so m ake the recesses to suit. If the sealand the bearing have the same OD, the recess has to be sized for 1he bearing and the

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thehousing,turnthehousingover,turn finishthepulley. theIengthtoexactly4.2soinchesand Likethetaper,thedrivepulleyisbest maketherecessontheotherside. machinedinthespindlebearings-pl ease

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referto the instructions in chaptera.

o iving pulley 3. rank forthe driving pulley is a piece 4. Nutfordriving pulley The bl

diam eterand 1.000inchIong.Asalw ays basicspindle in Chapter3. it is the sam e m aterialas used to m ake See the detailed instructions form odithe housing. fying the nutin Chapter3.This nuthasto

Hold theblankin the 4jaw and centre have a setscrew placed along one face

accurately. Face the blank and drill a foralocking device. Thereasonforthisis

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o soo inch hole through the blank.Bore thatwe need a very fine adjustmenton thisoutto 0

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750 inches to be a tight fit on the spindle.Remem ber:the pulley has to be a tightfit because itforms an oil sealin this design.

the nut to allow us to set the bearing clearances to the right setting and this is the easierwayto do this. The setscrew should be a very short 8-32 socket head Turn theshoulderon thepulleyforthe setscrew .M akeashortbrasspad(0.060 seal.This is the sam e size as was turned inches Iong)to go underthe setscrew so .

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bly).This is OK bedause itis not worth gets stifftap the spindle back and forth the trouble to take them back out. Clean aIIpafts and grease them Iightly w ith a semi-liquid Iithium grease - a grease works betterthan an oil. A sticky grease Iike that used in front axle bearings of a caris a good choice.

w ith a plastic mall et aIIthe w ay round from both sides to m ake sure thateverything is seated as faras it willgo.Tighten the nutsome m ore and repeatthe tapping.Once everything has seated firm ly

Ioosenthenutjustenoughto removethe

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pullev groove See the detailed instructions given in Chapter 3 on the basic spindle. Follow lhose instructions. The pkllley groove should be m ade to m atch the belting you W illbe using to drive the spindle. '.''.' ' '

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tailstock w ith a centre in i tto supportthe otherend ofspindle. Lock the Iathe spindle.You can now place a w rench on the pulley ngt and take up the nut som e more.Not m uch force is required on the ItisIikely thatthe bearing outerraces wrench. Keep tightening the nutas long are already in place (before finalassem - asthe spindle doesnotgetstiff.o nce it

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ttlrne - nce this taper is machined in the bearings to be absolutel y true to the bearings, it is best if this assem bly is neverdisturbed afterthis operation. Clean and grease everything.

ing.Placethespindleinthehousingfrom Machlnl' hgtheMorsetaperandthe

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sd reSi amed and the pull ey groove is the a-jaw in the lathe and bring the Peri

this side and the other greased bearing innerrace on the spindle from the other Side and press i'hom e.Place the second Sealin place.Place 1he pulley on the spindjeand pressithom e.Place the nuton the spindle and takethe nutup by hand. l '.7 . , . k :' ' ' '. z .

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spindle apartagain,before the M orse ta- the colletdow n.placethe halfinch rod in

pulley inachuckorinanyotherdevice, determinethateverythingwillactuallyfit

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ApointwillcomewhenitwillnoIonger

5.Finalassembly bepossibletherotatethenutbyhand. ginalassemblytakesplaceonceweare Atthispointplacea' Piinchrodinacollet su ' '-rethatwe willnotwanttotakethe andplaceitinthespindlenose.Tighten

areidentical,itdoesnotm atterwhichside bearings is desirable.Keep in mind that the spindle is introduced from . Place one the seals create drag on the spindle.Set greased bearing innerrace in the spindle, the Iock nutsetscrew . . place a sealoveritand seati tin the hous-

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aIIedges on this side and polish.The seal setscrew istightened hom e. seat has to be protected ataIItim es,any . ,' , blips on this surface w illruin the sealin a reslassemblv hurrv.Do notuse thissurface to hold the The purpose of the test assem blv is to

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Now slow ly tighten the nut onto the pulley as you rotate the spindle by hand.

Since both endsofthe spindlehousing tightness.The slighlesl pre-load on 1he

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sare that the seals seal and clear the rotating surfaces properly.

onthefrontside on&hespindle.Chamfer lhati ldoesno1m ar1hethreadsw henthe

under any circum stances without pro- togetheras planned. tecting it. Assem ble up the spindle and m ake

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of free m achining steel2.000 inches in

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Instructions forturning the pulley and cutting the keyway are given in Chapter

Onceyouarehappywithonesideof 3.Pleaserefertothoseinstructionsto

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speed spindles do rem em ber that cast iron chuck bodies have a finite rotational speed before they burst. ' The drives needed by these sm allspindles m ay be divided into tw o basic cat-

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1800 rpm . To do this w e w illbe using motorsthatrun at1750 rpm (1450 rpm in UK).Thecutstaken w illbeIighland in most cases w e w ill be using nothing more than ? /8inch and % inch end m ill s

for milling. A drive that w ill serve w ell for thi s

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should rememberthatthe majorenemy of aIlcutting tools is heat.W e do not w antthe cutting toolto gethot.W e can coolantataIItimes.Slow erspeeds m ean slowerfeeds.Take yourtime. AIIthis m eans that there is no good

moved up and dow n w ithout adversely drl ve from the m otorformostofourm illaffecting the belttension. i n g applications.Tiny mills willneed a higherspeed. spi ndl e ' '. . Im ade the motordrive formy cartridge Mot or spindle using the follow ing raw m ateri.

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* % by% by/8inchangleiron(or5 /aby % wlllalsowork) * X inchrod

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nrrangem ent.

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First w e need to attacn a cotlp'e w', pieces of angle iron to the base Of the

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the size ofthe m otorpulley and,ifnecessary,the belt. W hen using milling cutters,beginners

thatitmoveswiththeentireassembly.ln reason forustorunthemilling spindle at thisarrangementtheverticalslidecanbe hi?h speed and thatwe can use a 1:1

dryer.Thesemotorsarerelativelyeasyto mountifyoufindonethatalreadyhasa base mounting base on it. M otors w ithoutabasearebestusedforsomeothef application because we do not w ant to

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dle aw ay from 1he chuck lo inspectyour work, then everything moves aw ay as one unit and you do not have to worry aboutthe m otorbeltcom ing loose. The w eightofthe m otorm aintains the tension in the belt.The belttension can

Spindlesmaybedrivenfrom overhead on awashing machineoron aclothes

gearorfrom motorsmountedrightonthe carriage ofthe Iathe.lpreferthatthey m ount to the carriage so that they can movewiththespindlebeingpowered.

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ting butratherwhenyou move thespin- speed,itiseasierto makeitbychanging

Normalm illing drive

Rochdale,Lancs.,OL114DD.Donottry applicationisbestmadefrom arecycled 10usePVC beltingasthiswillstretchfar % hp appliance motorofthe type one toomuch. mayfind on asmallresidentialfurnace,

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be adjusted by adjusting the moment keep itcoolerifwe useslow speeds and

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w edesi gnbeeasytopu.i ntouse.I fthe efforttotm ountadoubl epole-doubl e spindle is m ounted to the verticalslide, throw sw i ch in the starting w indings so

that the weight ofthe m otor applies to tension the belt. The pivot point forthe motoris attached at/to the cross slide so

high-speed grinding drive.

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egories:(1)normalmilling drive and (2)

m itted w ith a 5m m or7mm round polyurethane belt.(You need to understand that to transm i t the sam e am ount of pow er a sm aller belt can be used at a higherspeed.)A polyurethane beltcall ed Bondaband is availabl e from N.S. & A. Hemingw ay, 30 Links View , Half Acre,

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Not T r epeatthestatementi nChapter13if a sva&h eageass em bl yti s s d.T heinqmcut ajo-r mspent i ndl e (formto t pumrpade osesil I fheansapidj ust ad nt of doi ng hisu i se . not dur needs os be n. t ndl e-

butathigherspeeds up to o.125 horse Formostofourpurposes,wecanrunthe poweroraboutloo wattscanbetrans- milling spindles at between 1400 and

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and for m ost m illing applications it w ill thatyou can reverse the m otorw henever :e,then it w ould be best if the m otor you w antto withease. was motlnted Onthe carriage also so that The pulley on the motor can, in genthemotorandspindlecanmovetogether eral, be thesame size asthe pulley on the

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Thetwo majorconcernsindrivingaspin- using Myford chucks on these highdI e are m aking sure thatadequate pow er can be delivered to the spindle at the right speed. On these sm all spindles it w illseldom be necessary to deliverm uch m ore than 0.25 horse pow er or about 200 watts to the spindle. This can be done with a standard, appliance type, fractionalhp beltthat is b inch wide for the Iarger spindles.On the smaller spindles,Iess pow erneeds to be transm itted

ment by Ietting the w eight ofthe m otor is effected by reversing t

to mountthe m otoron a swivelling base. w illgive you inform ation on how ' to go I t is important that the motormount about doing this. lt is wellworth the

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to have a m otor that can be reversed

wewkllavoidtheneedforbeltadjust- withease.Onmostmotorst j a hees reta vr etri s nagl

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have spindle housings that are the same

(zaoc rpm in uKjAc motorwillmost sizesoonearranqementcanserveboth jikely be used.W e willw antthe surface spindles althoughthe ID spindle has to be speed of1he grinding operalion to be be- driven al a higherspeed. tWeen 4000 and 6000 feet per minute. The grinding wheel centre should be

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fastasthey need to be foroptim um cut- spindle and then add the motorand drive. Fi0Llre 14.5 ShOWS the periphery Ofa 4 tj ngs y'jjjs does nOtm ean that We Carlrlot

USethem - wejusthaveto bemorecau- inch wheelmounted on the OD grinder.

Figure14.3 Motormountl hgarrangementasseenfrom above.Thespl hdlecan a/sobemountedyacing theotherway. The motorcan beflipped end éorend.

tiousabouthow wedoit.

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A high-speed grinding drive is bestac- mounting lo allow long shafts to be

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this m eans about5000 rpm . W ehaveto Spindlecentre.(There w illbetim esw hen check the m aximum speed ofthe w heel youwillw anttom ountthesetothevertiWe use/buy to make sure that w e can calslide.That is not being addressed

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jriv esyslem. Tool-postgrinderdrives ' whendesjgnjngajaijj a-speeddriveunit We havetwotool-postgrinderspindles

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otoreasily. Iathe. mNextw e need to have a way tosupport The overhead drive system can be sup-

very YUCIIM Vhis IMCaNS We Con Of1ly are going to be Cutting a I0t Of clock

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the pivot shafton the cross slide.This ported eitherfrom the roofjoists ifthey GanbedonebymountingtWOangleirons are nottoo farup (basement joists are ustaboutright)orfrom theIatheitself.A totjjecrossslideasshown in the figure. jnUm berof designs have been discussed

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vj aepjatethatmountstothetopoftlle

compound slide hasto be Iarge enoughttj ajjow the side plates to clear the com pound slide on yourparticularIathe. Tl Platedoes nothaveto be ableto rotateoae the com pound because the entire comrlpound Car)be rotatcd ORlr hc CFOSS Slide. The m otor for the tool-post grinde r arrangem enthasto be m ounted in such a e following basic requirem ents: * M ove w ith thespi ndIe. * Notbe in the way ofthe w ork . . Notbe in the w ay ofthe operat or. * Beltd ive m ustclearthe work. . Allow rf oreasv 'beltadi *ustm ent. As w e did with the cross slide m ounted drive, w e can use a half inch rod that passes through the plates forthe compound m ounting to be the suppor' tforthe m otor. A new belt of a sui t abl e si ze w ill haveto be obtained forthenew cent re-to-

WaYasto meetth

ground.This requirem entdOeS nOt appIy to the quill mounted wheels on the ID grinding spindle.Since w e know thata 4

inch chuck willclearthe top ofthecross Slide, we know that a 4 inch grinding w heelm ounted atcentre heightw illclear the cross slide also. It also m eans that this is about the Iargest w heelthat w e can m ounton the OD grinderspindl e unIess we can fix it that the wheeli s past the cross slide, then a Iargerwheelcould be used. However, Iarge wheels m ean

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caution Safety i s alw ays priority numberone. W e have not given any consideration to safely as regards the exposed belt drives in the above discussions.Depending on how you intend to use yoursetup, y-- -,--,d -I- -y- m -ke tl-e --------y arrangements to ensure that you have a safe operation.

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w idth ofgear Holethrough gear Module Typeoft00th form

0.250 in O.125 in as needed asneeded

Cutting the teeth ltis betterto startby m aking a gearw ith afew teeth (16to 24)becauseyou have

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dimensions - you cannotmachine itafter about getting the divisions right. Pick a the teeth are cut.The teeth willbe too num berthat turns the dividing handle a

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you can makeaspindle,youknow how squaregraphqaper.

ness on the shaftatthis time.lnstead course,depend on the actualgearthat

to use it,however,this is notnecessarily The followlng aspects of spindle use true and certainly was notso in my case. are discussed: . . .. , There is a considerable Iearning curve ' that can be m inim ised w i th a Iittle guid- * Cutting gearsforclock m aking. ance. @ M aking a dividing plate fora dividing The firsttim e spindle usercan use the head. follow ing notes as guidance forusing the * Drilling cross holes. various spindl es described herein.Ittook @ Cutting a keyway. m e a while to l earn how to use spindl es * Cutting a slotin a screw head.

when I first starting using them and

* Drilling verysmallholes.

these notes reflectthe experience 1have gained.

* OD grinding. * ID grinding.

turn a true point on the end ofthe shaft to indicate the exactcentre ofthe gear. Coat the gear bl ank com pletely with marking blue. This w ill m ake it m uch easierforyou to see w hat you are doing asyou cullhe gears.

you are cutting. M ount the cutter in the arborand the arborin the spindle.Low erthe cutteraxis to the height of the Iathe spindle,now m ove the carriage tow ards the part that you had machined as 1he gear bîank and centre the gearcutterexactly on the cenM ounting the spindle tre ofthe pointyou' form ed.Use a m agniRem ove the com pound from the cross fying glass to m ake sure thatyou are at

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on the verticalslide.The spindle has to the gibs. The cross slide is not to be

beexactlyatrightanglestothelatheaxis moved ajainuntilwearedonewith the

m ind is thatthe sm allerthe partthatyou Let us discuss these one at a tim e to are m aking,the m ore cri ticalthe setup is. clarify the needs and procedures: By critical l m ean that each and every aspectofthe setup becom esvery im por- Gearcutting

end exactly parallelto the Iathe bed and gearcuttlng. thus the cross sli de bed. Understand in Nextraise the spindle up w ith the vertiYourm ind thatm oving the spindle up and caIslide so thatthe cutterclears the outdown and in and out on the cross slide si de diameter of the gear. Tighten the

tant.The system isnow muchlessfor- Readthe entire sectionbefore proceed-

Willno1chanjeany ofthese aspectsof gibs on 1he verlicalslide so tha' tthe

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its relationshlp to the gear teeth to be m ovementis a bitstiff.W e w antto fix it

IthelpstokeepashopIog.Startashop setup a dividing arrangement,justhow

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Iog and useit- i tisavery usefulresource. to cutthe teeth.W e are discussing tinY Never w rite anything dow n anyw here brass cl ock gears as com pared to Iarger

The spindle ism ade parallelto the turning face by bringing the verticalslide on

exceplinyourshopIog.Sketches,ideas, work.

Whichitismounteduptoafaceplateand

notes,dimensions,phonenum bers,birthdays,promises,lists ofthings to be done and w hat you did and how you did it. Everything goes in the log. I t takes m e aboutayearto fillaIog bookand Iuseone ruled at 5 divisions to the inch in tw o

Securing it while it is up againstthe face --------- - - - ----,- - - plate.Then m ountthe spindle on the verI ticalslide. ' . The spindleis m ade parallelto the Iathe shears by using a square betw een the Figure 16.1 Aligning the cutterwith the Bhears and the face ofthe spindle hous- gearblank (top view).

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Suppose that we are cutting a clock gear that has an outside diam eter of 0.3O0 inches and 20 teeth.The specifications forthis gearm ight be as follow s:

Outside diam eter

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as close to the bottom ofthe teeth as afford it,getyourselfan extra chuck or possible. tw o,and getin the habitof Ieaving w ork

shallow teeth afteraIIthe otherteeth

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lfyou need lo cuta rack,itis bes' tdone in a chuck ifMou need to rem ove itfrom with the cutter in the Iathe spindle and the lathe. In this connection beginners

the rack mounted on an angle plate on are advised thata 4-jaw is more useful the verticalslide.The teeth have to be than a 3-jaw chuckby being more versa-

spacedverycarefull yandeveryprecau- ti l e a myaj oone rben fi t). If( onl re ow of holes has to be

Iook at how m uch uncut m aterialis Ieft

tion has to be taken to avoid backlash

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ontopofthet00thjustformed.Consider thing that is done before parting off. this the land. W e want i t so that the W hen youform thegearoutline,Ieaveas marking bluejustbarelydisappearswhen much materialas possible to make the

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One hole from each row Iines up on a ing concern w ill be t get the spindle radialIine.ln order to do this right the exactly parallelto the moot on of' the cross Spindle and the Iathe nose have to be at slide. This is im portantto i ensure thatthe the e height. drilling takes place along the axis ofthe lts iam s easierlo drillallthe holes w i th the spindle. . The centr e drill and eventually break. Wi l l l oc a t e t h e ho l e s mor e a c c ur ately hendrilling ahole tha' tisno1atright The depth of the hole drilled should be. anW gles to the shaft being drill ed it is , Stlch that it is about 0 .010 inches in som etim es necessary to m illa sm al lflat diam eter greater th an t he hol es t o b e on t he sha f t w i t h a n end cut t i ng m llto drilled fortheIocatingpin. So,if we are createa flatthatw e can drillstraightiint t o. tlse a 3 /az(0.093)pin,the centre drill Thiscanbedonew iththedrilling spindle So houl . d go i n dee p enough t o m a ke a l n ci dent al l y 0 t is also wellw orth your ,i .103 i nch r ec es s , W hen t hi s i s dr i l l e d whi l e t o ha ve a I engt h of r od t h at is Outto 0 093 inches,a slightcham ferwill exactly the length of th rem ain..Thi e di st ance rom s willhelp to guide the Iocat- the bottom of the spigot on the lf athe ing pin. (Thi s al s o m eans t ha t 1 he hol es spi ndl e l o t he t op of t h h e lathe bed.This ave to be a m inim um of about 0. 125 rod is used to setthe height ofthe spininchesapart.) dle quickly to Iathe spindle heightw hen Once aII th e centre holes have been the spindle ism ounted on a venicalslide. drilled the w or k can be m oved to a drill Both spi gots are the sam e size and m eas, pr ess and f i ni s hed t her e i f t hat i s pr e ur i ng t o the spigot lets us ignore w hatferred. DeburraIIyourwork . eve r m ay be in the spindle. Note ifthe dividing can be done on the ,. .. George:Tho as dividing head,the drillis Height spacers '' bestheld in m thebIathe spindle.In thatcase On m y lathe, the lathe spindle centre is We W ould not Strongly rec e discussinglhis here!(1 2.125 inches above the top of the cross omm end that you consider slide table. This has to be measured on m aking the George Thom as dividing every lathe because every Iathe can be head. You wi l l en j oy maki ng i t and you sl i ght l y di f f er entinthisdimension. W rite W illuse it alm ost every time you are in the exact dim ension dow n in yourshop Yo tlrShop.) Iog on page 1. The spindle itselfis held in two 2.500 Drilling cross holes inch w ide plates that have been cut W hen dr in illing a cross hole in a shaft Shaft, is held in the Iathe spindle , the half.W hen held in this clam , the spindle , and the is 1.250 inches above the surface thatit drills are held on the verticalslide i n t he is m ounted on. This m eans that we need Spindle. The importantthing is to getthe spacer s or risers that are 0.875 inches spindle atthe exact Iathe nose heightso thick to place under the 2.500 inch by thatthe hole willgo rightthrough the 4.ooo inch plates. The easiest w ay to centre ofthe shaft.Since this isan often- m ake these spa neededsetup, the best thing to do is to of % inch roundcst ers i s t o ethem out ock. M mak ake 4 cylinders ma keup as pacerthatwillallow youto 0.875 inches Iong with a 1764 hole mount the spi ndle on the cross s/fde so through each one. Cham fer the edges.

Ctltting a keyway on a shaft Cutting the keyw ay in the pulley i s Ctltin: a keyw ay in a shaft is done in described in delailin Chapter 3 on the tW O basic ways depending on thetype of cartridge spindl e. keY to be accomm odated.Usually either

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thes quare Aftermakingaperfectscrew,weoften keY is 1he preferred key. Of cour se the resor:to cutting the slotin itwith a hackkeY doesnothaveto besquare - it'sjust saw and spoiling the Whole ef fece, t.we No indl that Square keys are easier to use. For m ore ,

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plate. Hal f 1he key goes in' to the shaft and

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halfthekeygoesintothepulleyorwhat- thenpullingtheIathesqindleovertoone

side w ith a weight applled to the chuck. An alternative m ethod is t0 hold the Iathe chuck steady w ith an expanding m andrel with an arm that YOu can tie dow n to the tablethe Iathe ison.A draw ing thatshow show to make such as m andreland arm isprovided in Chapter16. M ountthe cutterto be used On a halfinch mandreland m ount in the spindle. The spindle is bestm ounted On theverticalslide.Lower or raise the spindle to Iathe centre height. Lock the carriage to the lead screw w ith the half nutand disconnect the system from the gearbox. Cut into the screw by m oving the carriage - you can contro!the depth Of the tocuta key slotover$4 inch w ide. cutbyw atching the divisionsOnthe Iead Oncethe spindle is setup, moveitover screw handl e. Slots should be about to touch the nearside of the shaft to be 1.25 tim es as deep as theY are w ide. Slotted.Then raise the VSS up and m ove i' tinto 1he shaft,half1he shaft diam eter Drilling very sm allholes plus half the cutter diam eter, Tighten Here are few tricksto keep in m ind When

downthejibsand makeyourcuts.The drillingsmallholes:

tlse ofcuttlng oils willbe helpful.Check Yourw ork with the key thatisgoing to be tl sed in the slol.

Cleananddeburrbeforeslidingthepul -

Then the only rem ain- forthe T nuts. M ake them to suit.

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everis m ounted to the shaft. W e m easure from the theoreticalOD ofthe shaft. The key depth can beover-cutin eitheror b0th directions butitis betternotto. The key w idth should be a snug fit. Ifthere is asetscrew,itshould be positioned atthe key slot.W hen cutting a setscrew hole and a keyw ay, cutand tap the set screw hole afteryou cutthe keyway, that way YOu do not have to line up the keyw ay With anything w hen you cutit. It is easierto get the slot width ri ght With a W oodruffkey cutterthan itis w ith an end m ill- an end m illcan tend to cut Oversize.Here Iam m aking the assum ption thatthe m odelengineerneverneeds

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engineeris interesled in the key can be Thetrlckisin holdingtheScrew sothat m ade from brass or soft iron, Brass is the spindle can be used to cul the Slot. easi erto work with and more than strong The easiest way to hold the screw is the enotlgh forthe work w e are interested in Iathe chuck. A w ay has to be found for - aIIyOu need for a key is a scrap of holding the chuck steady W hile the cut i s

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Spindles: Comprehensive Guide to Making Light Milling or Grinding

Making Light

Spindles End

Spindles End

Spindles End

Spindles (Workshop Practice Series)

Robin McKinley - Spindles End

Mechanical Alloying and Milling

Models: A Comprehensive Guide to Attracting Women

A Comprehensive Guide to Chinese Medicine

High-Energy Ball Milling

Comprehensive Guide to Wilderness & Travel Medicine

Medicines: the comprehensive guide

Hypnosis - A Comprehensive Guide

Principles of Modern Grinding Technology

Robin McKinley - Spindles End

McKinley, Robin - Spindles End

Mind Amongst the Spindles

The Britannica Guide to Sound and Light

Secret Guide To Making Ninja Weapons

Inventory Accounting: A Comprehensive Guide

Chilled Foods: A Comprehensive Guide

Pediatric Oncology A Comprehensive Guide

Python Power!: The Comprehensive Guide

Inventory accounting: a comprehensive guide

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