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Nexus House
BoundaryW ay
Hem elHem pstead
Hertfordshire HP2 7ST
England

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Firstpublished 1997

@ Textand i
llustrationsHarpri
tSandhu 1997
ISBN 1-85486-149-2

Typesetby Kate W illiam s,London.

Printed and bound inGreatBritain by Biddles Ltd., Guil
dford and King's Lynn.

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lntroduction
Designing a spindle
The basic spindle
M ounting the spindl
e
A sm allerNo 2 M orse taperspindle
The m icro spindle

7 1.000 inch diameterspindl

e (25mm)
8 1.250 inch diam eterspindl
e (32mm )
9 Light,tool-post OD grinding spindle
10 Light,tool-postm ounted ID grinding spindl
e

1.500 inch diam eter(38m m )

AIIrights reserved.No partofthis publication may be

reproduced in anyform ,by print,photography,m icrofilm
orany otherm eans w ithoutw ritten perm issionfrom
the publisher.

1
2
3
4
5
6

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77

Sim ple No 1 M orse taperspindle

Verticalspindle orgearcutting fram e
A spindle with tapered rollerbearings
Driving the spindles
Notes on using the spindles
Notes and ancillary inform ation

p86 j
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92
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APPENDIX 1 SIdrawings
APPENDIX 2 UK equivalenttables
Index

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CHA PTER 1

Introduction
This isa bookaboutm aking auxiliary m illing and grinding spindles for use w i
th a
sm all Iathe. Although the experienced
engineerm ightpick up atrick ortw o,the
book is aim ed primarily at beginners.AII
the spindles can be made in the am ateur
engineer's w orkshop by anyone with
average machining skills. The spindles
are described form aking on and use with

willgive years of service in the dirtiest

environm ents imaginable butratherthey
are designed to be spindles that are easy
to m ake and use in the am ateur's w orkshop.Ihave m ade every attem ptto keep
the number of com ponents needed to
make any spindle to an absolute m inim um .lhave tried to m inim ise the need
for sophisticated equipm ent as w ell as

theMyfordSuper7BIathe,howeverthey the need for highly skilled work. Of

canbeadaptedforusewithotherIathes necessi
ty,alIthesplndles are ofone of
w ith relative ease.
The spindles range in size from 0.750
inches (19.O5m m )in diam eterto 2.250
inches (57.15m m ) in diameter and are
suitable for a variety of purposes. A
noveldesign fora gearcutting fram e that
uses sealed ballbearings ateach end is
also included.
The book provides the novice am ateur
engineerw i
th a ready source ofinform a'
tion and discussion about the construction ofsom e ofthe various typesofspindles thatare needed by the amateurfrom
tim e to tim e. W herever appropriate I
have given reasons behind the decisions

two baslc designs, each being easy to

follow .
Keeping thedesignssim ple m eantthat
the spindleshadko be ofone ortwo basic
designs.In one design,two bearings are
used atthe frontend and the back bearing i
s free to move in the housing.Both
inside and outside races are clam ped on
the frontbearings and only the innerrace
is clamped on the back bearing.ln the
second design,only one bearing is used
ateach end but both the innerand outer
races of each bearing are clam ped or
glued. The second design w as slightly
harderto build in that itwas a Iittle m ore

madeto helpgive the buildermore confi- difficul

t to get the spacers just right.
*'

dence in his orherdecision to make any

m odifications forexperim entation.
These spindles are notintended to be
industrialgrade, heavy duty spindles that

How ever, you get a spindle w ith Iess

axial play in the bearings. Since aII
spindl
es can be m ade to either desi
gn,
you have achoice as to which design you
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decide to use on yourspindle.You can

The m icro spindle w as m y effort at
also com bine features from both designs designing the sm allest possible spindle
into the spindle you m ake.(Spindles w i
th w ith ball bearings. This has an outside

are available, for a sm allcharge, from detail.Alhoughthis spindle m ightbe a IitNexus Special Interests Books, Nexus tIe Iargerthan w hatyou had in m ind,itis
House, Boundary W ay, Hem el Hemp- very versatile.M odify the spindle nose to

glued in bearings are a form ofclamped diameter of 0.750 inches (20m m) and
bearing spindles.)
the body is 4.000 inches (1O0m m )Iong.

stead,Herts HP2 7ST.These draw ings suit yourlathe and the accessories that
are on A4 paperand areavailabl
e ineither you have athand ifyou are notthe lucky

Since the usefulness ofa spindle is Here again Idesijned with the Dremel

imperialorSIdimensions.

ownerofaMyfordSuper78 Iathe.

spindleinChapter3.Thiswillallow you resourcefulamateurs.

havebeendoneontheMyfordSuper7.

spindle,especiallyifyouareabeginner.

availableforusewiththisstandardspin- are included.The constructionofthese

setofdrawings forthe projectbutalso bearings.ThedesignthatIcameuqwith

completely dependenton the accessories

that can be used w ith it, I have used
standard lathe nose threads and tapers
when possible so that aII the standard
Iathe accessories and other standard
com ponentscan beusedw iththesespindles. In particular I used the M yford
Super 7 spindle nose standard with the
No 2 M T (M orse taper)on the cartridge

M oto accessories ln m ind as a resource.

Thisis a spindle m ore sui
ted to the m any
lathes that are sm aller than the Myford
Super 7.Since Ido not have access to
one ofthese Iathes,and have neverused
one,Iw asunableto offera design fora
spindle m ounting that lhad actually built
and used.ln otherareas Ihave presented
som eideasthatw illbeusefultothem ore

Thespindles are designed to be builton

asmalllathe w ith a m inim alneed form illing operations.M ostofthe w ork lcarried
out w as done on a M yford Super7 with
the average com plem entofaccessori
es.I
did usea 5.000 inch (10.000 inch in the
USA) South Bend Iathe to do the heavy
work when a Iot of m aterial had to be
removed.How ever,alIthis w ork could

to use aIIthe tapers,collets,colletclosIhave also included a couple ofdesigns

ers, m ill holders and chucks that are for which essentially only the draw ings
dIe nose.The use ofthe No 2 M T,w hich
allows a % inch shaft to be held very
accurately,m akes itm uch easierto m ake
arbors for clock cutters etc. because

M uch of the succqss ln making anyIcould notresistIooking into w hatw as

thing is not sim piy a matterof having a needed to m ake a spindle w ith tapered

spindles is very sim ilar to the construction of the otherspindles in the book so
the repeti
tion of the instructions i
s
avoided by doing this.

has to do w ith knowing how to m ake the

setups and in which sequence to do the
work so that it turns out right. I have
m ade an attem ptto show the w ay in aII

Ihaveavoided using anyexoticmateri-

straight shanks and held accurately w ith

aIs altogetherand every com ponent and

quences w ith the reasons forusing them

relativeease.

allthe raw material

s should be readily

areprovided.Theseareespeciallycriti
cal anothersetofmountingjlates.Myspin-

ered itbestifthe many arbormounted have recommended the use of free

tendedtobehigh-speedqrecisiontools.I how smallataperbearing spindle could

wellasthe collets and colletclosersthat materials are easy to use,their m achinare available for the ubiqui
tous Drem el ability is equivalentto thatofbrass.They

herent properties of the Iathe and the use of slightly Iarger bearings and a 1
standard com ponents provided by the inch diameter forthe internalspindle at

inthe construction ofspindles thatare in- dI

e is 2.000 inches in dlam eter to test

tnavetriedtoshow thebullderhow thein- be.Going to 2.250 incheswillallow the

m anufacturercan be used to theirbest the bearings.

of difficulty contact Microflame Ltd, ajplicationsthatwehavein mind.Their

advantageinbuildingtheseprojects.

sllghtly highercostwillbe m ore than paid

forby theadded pl
easure ofusing these
materials. I have avoided the use of
exotic tooling except forthe use of the
ream ers for the M orse tapers. These

W ith reference tothecartridgespindle isincludedintheprojects.

inChajter3:ifyouhaveaMyfordSuper

tersthatareoftenneededbytheamateur amateurengineers.

wanttoconsidermaking.I
tgivesyouthe thatthere isa slightly hijherpossibility

clock arbors, pinions and other sm all counter productive. Since these are not
parts with precision.Thisspindle w illalso toolsthatyou need every day,itm ightbe
allow the m aking of sm allprecision cut- possible to arrange to share w ith other

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greatest versatility of aIlthe spindles in of errors in the dim enslons given for
the book and is described in the greatest these designs.I did not build any spin-

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Ibuiltonlythoseitemsforwhichthere

7 or slm ilar Iathe and you are going to are photographs. If you do not have a
make only one general-purpose spindle photograph for reference you need to
foryourshop,this isthe one thatyou w ill exercise m ore caution w hen building in

engineer.W ith a little care and patience,

Forthose who preferto work from fullitcoul
d also be used to grind fine threads. sized,form alengineering draw ings,these

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ed to allow construction of the spindles

areincluded inthe book.M aterials needed to m ake the spindles are readily available and every attem pthas been made to
m ake sure thatnothing thatishard to get

smallparts and tools for projects Iike the pointthatnotusingthem would be

'

AIItheinformationanddrawingsneed-

The bearings used can be a m ixed bag

ofmetric and im perialsized bearings.ln
general the sizes are not critical and
whateveris available in yourarea can be
used by changing a few dim ensions.

interest was to have the ability to grind reamers simplify making these tapers to

also so that you do not have to m ake

M oto Tool(w idely available,butin case are m ore than strong enough for the
Vinces Road, Diss, Norfolk, 1P22 3HQ;
Tel.01379 644813) w ere able to be
used w ith this spindle,These w heels are
very inexpensive and serve the needs of
the am ateurengineerw ell.Here m y m ain

.
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these projects. Both setups and se- whiletomakeit2.250 inchesindiameter

grinding wheels,cutters and arbors as machining material

s throughout.These

is provided for your consideratlon in

Chapter 13.Ifyou first build the 2.250
inch diam eterspindle and then decide to
build this spindle it w ill be w orth your

these arbors can now be made with

In the sm allgrinding spindle Iconsid- available on eitherside of the Atlantic.l

Otherspindlesofferspecialadvantages
that are needed under special circum stances or are better suited to sm aller
Iathes orto specialsetups.
Ifyou decide to m ake any ofthe other
spindles,firstread Chapter3 a couple of
tim es to get the principles and techniques described w ellin m ind.Itw illbe a
trem endous help to you in building your

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make the necessary correctlons as soon
as possl
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teur engl
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build these spindles.
Good Iuck and happy turning.

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Decem ber1996 Avenue,Champai
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D esigning a spindle
This chaptercontains a very short tutorial/discussion on the design ofthe spindl
es in the book. (This is very rnuch a
sim plified approach and no consideration

w illput the machine to.These are

1he purposes forw hich the m achine
is being designed.
* The ideas on which we are going to

is jiven to the making ofcalculations

focus have to do with designinj

whlch area m ustin anyseriouseffort.)

The basic idea is thatthere is nothing

difficult about designing a sim ple m achine ifone goesaboutitin a m ethodical
way.The ideas presented are applicabl
e

toanybasicdesignproject.
The facts before us in this particular
case are as follow s:

spindles foruse bythe am ateurenglneering com m uni

ty. These spindles
w ill be used for a variety of purposes,the m ain ones being lightm illing and grinding applications.
* The bestand m ostpopularam ateur's
lathe on the m arket is the M yford
Super7B.Atthe risk ofsounding Iike
Ihave Iostm y m ind early in the gam e,
Iwillsay thatno othermanufacturer
even com esclose to providing such a
good Iathe. For this reason we will
design forthisIathe.
* M ost am ateurengineers,in general,
and in spite ofsom e evidence to the
contrary,do nothave a Iot ofm oney
to spend on theirhobbies.

* Before there is a spindle,there are

draw ings.It is m uch easierto w ork
from a drawing that has been carefully thoughtout.
* Before there are any draw ings,there
w illhave been som e sketches.W e
have to m ake sketches and w ork out
the dim ensions and positionalrelationships before w e can m ake the
form aldrawings.
Itisalwaysa good idea to keep trackof
* Before there are any sketches,there w hatyou are thinking aboutby wri
ting it
m ust have been som e i
deas.Neither down,so tetus Iistourconclusions.
do sketches have a Iife oftheirown.
W ith the above facts in m ind w e com e
They are expressions of ideas that to the follow ing conclusions:
we have aboutthe m achine that we
thinking aboutm aking which in turn
@ W e willdesign relatively sm allspinare determ ined by the uses that we
dles.
5

'.
'
r.

'

. They willbe m ounted on sealed ball w hich is a.125 inches (79.35m m ) on

bearings.

centre.

. Theywillbebel
tdriven.

2.1.W e w illstartby placing criticalcom ponents on the grid.Atthis stage we are

. we willaccommodate the use of working with sketches although I am

M yford accessori
es w hen possible.

. w ewilldesignto allow versatility of

use.

aswe can m issthespindle bearings).

The larger spindles w ill have to have

SothemountinggridlooksIikeFigure

. w e w illdesign for m ounting to the

Myford s7 tables and sli
des etc.

1
l

the equipmentatourdisposalthatdoes

thestudsstraddl
ethespindleasshown suggestthatwe clamp only th'e iJ
'ner
in Figure 2.3.This takes up m ore room
but also gi
ves us m ore space to w ork

IfyouanalysetheIoading onthespinZle

showing these as draw ings in the book.

Now that we know where the spindle you willsee that the axialload on the

If we are going to use the Myford

nose is wi
th respect to the mounting back bearing is minimal. Its major pur-

accessories with this spindle,we need to

with.

race ofthe back bearing and Ietthe outer

race slide back and forth in the housina.

studs, we can think about placing our pose is to provide radialsupport forthe

. w ew illkeep costsdow n.
. w e w ill keep down the skill Ievel
needed to build.
. w e will Iim it the tim e needed to
build.
. w e w illnot use exotic m aterials be-

usethesame spindlenose astheM yford

uses.Let us assum e a 2.000 inch diameterspindle w ith a M yford spindle nose
at one end and a pulley atthe otherend.
W e w illrepresentaIIthis w i
th sim ple rectangles in oursketches.

bearingstom issthestuds.W e need tw o

bearings,one in the front and one in the
back.The front bearing is m ore critical
because it is the one that bears m ost of
the Ioad and forthis reason it should be
as close to the cutter as possible.W i
th

cause they are expensive and hardto

find.

Now I
et us position ourspindle sketch
on the grid.Ourspindle can be positioned

this in m ind w e w illtry to place the front show n in Figure 2.5.Keep in m ind that
bearing as far forw ard as we can and this is where we clam p the races.The

to use eithera single grid spacinj ora

posi
tion the smallerrearbearing as is racesareheldattheirOD bythehousing

inches(39.67mm )on centre andaresuit- The next tw o figures show w here the
able forhold dow n studs thatare 0.250 spindle w ould be in regard to the grid for
inches (6.a5m m )in diameter.This tells each ofthese m ountings.

Letusplacesom ebearingsinthe spin- rectionsw illbeproperlyconstrainedifwe

turnthespindlepartsto closedim ensions.
Eachsetofarrows representsaclam p-

'
.

'

.,

The M yford mounting slots are 1.562

double spacing as the conditions dlctate.

usthatthespindle hasto fiton a grid

convenient.

U O

(3>
>

inches(39.67mm)oncentreortwicethat withinthehousingofthespindle(aslong

z O

OZ

1.x2i
nczes

,
.

r
, .

',

j,,w jnojxs

,
(,
,

()

(3

dIe to see how they Iook forposition.

.
In a m illing spindle,mostofthe load is
.
taken up by the frontbearings. Industrial Figure2.5 Thepointswhere thebeanngs

C)

:)

$
:3

c)

g
1.562inches=39.675mm

.
.

Figure 2.1 M ountlw gn'

d forM vfords7
tables.Studsare 1.562inches (39.67mm)
on centre,
??b0th dlkections.

.
'

Fgure 2.3 M ountl'

hg thespht//e forIong
spaow .

:ruo

milling machinesoften usethreeand four wt

w.gecyaswes.
vjte(ssxevearygsar
ejust
.
.
.

. .

Figure2.
4 Bearings.smhdle.pullev andhole
added.

'

nuts.Theotherside from each nutw illbe

either the body of the housing or the

C)

spaong.
.

ing device.We need three clamps or

Figure 2.2 Mountl'

hg thesgvwt
we on short

backend ofthespindle.(Thereare other

w ays to control the distance betw een
theouterand innerrecessofthe bearings
and som e of these are show n in other
designs in the book.)
The concepts presented above are

and attheirID by the spindle so these di-

The smallerspindles willbe able to

1.562 inches (39.67m m )on centre.Our m akeuseofthetypeofm ounting show n

m ounting bolts will be either 1.562 in Figure 2.2 even ifthe studs have to be

'

not seem to be Iikely,so Iam aoinc to

bearings toqethervery close to the nose. *n WO&*t'/v t'me 00 OX#/Or/ theposslbllitles.

W e w illuseJustone in ourdesign. Atthis
stage the basic concepts are in place
and we are ready to w ork outthe details.
How w e hold the bearings w illbe critical.The front bearings m ust be integral
with the spindle. This m eans that both
the outer and inner races have to be
Clam ped tightto the housing and spindle
resgectivel
y. It w illbe best if the back Figure 2.6 Thepcvhrs where thenuts -/'//be
bearing is positioned exactly but, with used.

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the chucks etc.A quick Iook atthe bearing catalogues confirm ed thatthe spindle
design could be accomm odated within a
2.
250 inch (65m m ) diam e.ter spindl
e
.
housi
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mi
lling spindle.
Th
e spindle Im ade uses inch m aterials
and m etric bearings bOCaUSe that '
Is the
hOW it W orked OlX at'
th'
ls time!To sim17Iify matters, the designs presented in
the book use either aII'
Imperialdimens'
Ions OfallSldim ensions lseeAppendix
1forSIdraw ings).lintendto explainthe
reason for using the dim ensions that I
used w henever applicable. lncidentally
the new digita!calipers are a realconvenience in that they allow you to change
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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
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Bearings chosen
'
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'
Nose end bearings
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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
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Type
Deep grove bearings
w ith axialand radial
load capability
A jternate
AnguIarcontactbear.
ra/
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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
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evelofthe races
butwe m ustm ake sure. e also w.antt
o
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t sw arf does not flnd .
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ts
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hen you
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ens
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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'
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ted in the selection
consl
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bearings specified above. M any
of thebear
ings could have been used. Do
other
lability ofbearing putyou
not jetthebavai
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(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

ofbear1ngs 1n the front.

(y
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.ng
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1 purchased

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ed
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wantto keep the costIow and we have theroutofthe bearings(undesirable).
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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

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

-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

..

l.
1

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 / 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 Setion 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

18

E
E
.
i
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i
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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.
!
'

'

19

'

'

11
l

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

ii
!!
q

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

I
' .

1
7
'

II:I

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-

iI

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

,,

- - - -

- - -

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 '

-

(I'
!

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

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

way.Ifwe getthis right,we willhave a terin your4-jaw,do notdo it.l

twillmar fefistersturnouttobethesamediameter cutby the factory willnotalIbe exactly

lI
I

l!
hi
'
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k
i
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h

I
Ik
h
.

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

lI

situ. '.:', ,.., - -,.

.
.,
?
,;r,
)r.k .,

tl

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

' l'''.

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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..

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21

11
.

w'''

'

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
.
.,
. 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
<. .
'
,
face the outside face.W e are not trying m inus o.oos inches so that the nut can
to getthe blank to the rightIength atthis be brought up to the threads without
oast
en
pi
rdl
emount
ed #j e c t drjjj itjja o soo jnujjcer
a. interference. w e want this diameter as

an ID of O.750 inches. The shoulder

form ed will hold the inner race of the
bearing after the pulley and pulley nut
have been installed on the shaft.
Assum e that the housing i
s 4 .250
inchesIong asspecified . W e w antthedistancefrom the frontofthefrontbeabog to
the back ofthe back bearing to be 0.

I
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onaspi
ndl
ethati
sbei
ngmotordri
venatfrontofthespi
ndl
e.Herewewantati
ght ingwe
arenowreadytomachi
netheseat- !
forthe backbearing.This bearing has

,'- h
ed
t
ot
f
ag
cte
pl
a
eother

'

. '

turned too far.M ake sure thatthe cent

Wre
is supporting the w ork properly.
Place the bearings on the shaft and
tighten the nut down on them to check
the fits. Rem ove the nut and bearings
and setthem aside.

/00y.5'or7'Faceplate

:j

about this, mount a face plate on the plate. M ake sure your spindle is fully The flange on the spindle w illhave a
cleaned spindle nose and plate threads seated and tightin the second face plate. finished thickness of 0.375 inches.The
Beginnersshould notethata lathespindle nose side ofthis flange has already been
tends to ride up on a thin oiIfilm w hen finished.
rotated.This affects the centring ofthe Firstm achine the threads and then the
7'Ip
F.
n
'd
F.
acepl
ate
mounted part. The test should be m ade seating for tlae double bearings at the
'

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xnsap
nt
st
n'f
acepl
at
e ;
j
kri
e
j
1i8
ru
bo
si
y
um
teu
l
y
t
rue '
u;
.m
wau;.;
,.j
'e
.nr
-,
,
,j
,--ay
--wjo.y-jjyoke.yo.meettl
aalaood
rgeshoul
aspoder
ssibfle
stohethba
atckwe
wi
ll
ha
v
ebea i
nch
eslessthantheIengthofthehous
n7
g
or
bea
r
i
ng
t
o
or
4
hole from the otherside.Clean up the @.
063 inches.Therefore the Iocation
a

Figure 3.10 Spl.ndlem ounted to faceplates. Centre afterdrilling to create a true sur- tlghtened up against. Use the nut you ofthe shoulderw illdepend on the thick.
earlieras yourgauge.
Note thatb0th endsofthespl
ndlearedead
face forthe tailstock centre.Atthis point made
s ofthe back bearing selected.
Next machine the threads forthe nut. nes
on centre. .
k
.
,
you
have
t
be
spi
ndl
e
nos
e
r
unni
ng
t
r
ue
Turn the spindl
e down to the internal
.
,
,
22

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0500in .

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twobrgs.

.,.

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us
o'jw Inches
,.

,.

2'2soi
nch

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Recessfor

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:, :

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Recessfor

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42soinches

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in thechuckjaws.Ifyou have a
bousing
fixed steady itcan be a trem endous
Iarge
nsupportingtheoutboardendofthe
jaeI
pi
us
ing.
hoThe
frontbearings are Iargerthan the

untilthe partis running true.Tighten the

chuck jaws a Ii
ttl
e at a time as you go
(but nOt too m uch oryou willruin the
chuck).It m ight be necessary to run a

bearingsowemakethebackbear- s
moothfilelightlyoverthebodyand
polish it to getthe bum ps and scratches

back
ing recess first.In this w ay if we m ake a
m istake, w e can open the recess out to
be the recess forthe frontbearings.
The back bearing is designed to m ove
back and forth in the housing as the spin-

out of the w ay of your dial indicator

before you can get really serious about
centring the body.
During these operations there is a large

d1e heats and cools (not much heating overhang outside the chuckjaws.Under

Recessfornut '

;S '.J''' '
,
k' ' f'' '
.
, '. j
.
' '

cs .
Figure 3.11 opl
ndle 'IIINS/WJ.

andforth betweenthesetwoprocedures

and cooling i
s anticipated).As such the
bearing iS Clamped Onto the spindle and is
freeto move in the housing.How everthe
m ovem entjntjje jjousing should be afirm

these condi
tions it is very im portant to
take small cuts and work w ith sharp
tools. Using free machining m aterials
also heIpstrem endously. ltis a good idea

push-fitwith no jlay.This is the easy tore-checkforconcentricrotationbefore

doiat
t
me
hete
sr
hof
us
tdheerbHe
ack
e
arinngwe
aI1twheant
waay geSi
stnce
ed,tithiessnot
pinpos
dlewi
llemo
turIik
ybhous
eOK-.swa
yabto
keanas
plndtlerial
ansdpiwndl
oueldbut
notwe
be yoFac
uma
khe
ethous
hefin
alc
utsput
. in a Iarge cenreb
agai
sibl
tos
t
ne
tl
he
uit
lema
for
indus
et
ing
and
.

firm push-fit.
ing between centres,a Iittlem oreskilland can get aw ay w ith this for the kind of tre in preparation fordrilling and boring.
Turn the rest of the shaft down to care w illneed to beexercised.The im por. uses we aregoing to putourspindleto. First drilla hole 0.250 inches as far as
'

0.750inchesforthepulley.Thepull
eyis tantthingistoholdthehousingasaccu- Thesequenceofoperationsformaking youcango.Openthisholeoutto0.500

to beaslidingfi
tontheshaftso you can rately as possible (within 0.001 inches the back bearingrecessisasfollow s:
lnches.Borethisholeoutto 1.500inches
get it off easily. Cut 0.750 x 16 tpi total indicated runout (TlR) along i
ts
in diameter and 2.250 inches deep or
threads(orm atchthenutyoupurchased) Iengthand atany pointon thediameterl * Hold the spindle body accurately in halfw ay (itcan be plus orm inus 0.050

on the lasthalfinch ofthe shaft.Check andkeepitthatwayduringtheentireprothatyournutfitsthisto yoursatisfaction. cedure forany one side ofthe housing.It

the4-jaw chuckfortheentirelength inches).Thisisa clearancedimension.

ofthe housing.

W e w illm achine the sm allbearing end

first.If we m ake a m istake and overbore
of the outside of the spindle except for this.Ifyou use sharp tools and take Iight * Centre drill.
this end, w e can open this out for the
the keyw ay forthe pulley key.
cuts, you should not m ove the spindle @ Drill72 inch hole 2% inches deep or Iargerfrontbearing end.
deeper.
W e have to bore a recess forthe back
'
5.The spindle housing
'
.'
* Bore outto 17zinch hole,2W inches bearing thatis afirm push-fi
tforthe back
Now that the spindle can be used as a
deep.
bearing. The recess has to be 0.250

W e are now done with the machining takes a chuck with straightjaws to do * Face outerend.

'

'

handleforthebearings,wecanstarton

1
:

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the housing forthe spindle.

.;' .

Co
t
Sg
Se
Ct
Rherasperfectlyaswecan.Ifyou

bearing.The bearing sits 0.063 inches

inside the recess and there is another

0.187 inciaesontheothersidefortravel.

u ounttl
ae bearing on tl
ae spindle before
w ithtl
ae above inm ind uold tiaespindle you putitintiae reeess sotuatyou have a

CIeYhO
anuNOUS
pand
finishing.
iRO Zfld tile S/irldle itsolf are
'

* Finish boreforrearbearing seating.

aemove bodyfrom cuuck.

inches in diameter and <.

'
s inches long.
vl
ais allow s pisofan inch on each side for
tho m OStCFiticzlParts Oftho YOViCO.11 is
jjaj that W 6 gOt thOSO W ofkino

* Boreroughoutlineforrearbearing. inchesdeeperthanthethicknessofthe
* cham fera1ledges.

The raw m aterialforthe spindle hous-

ing isa pieceoffreemachining steel2x

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

i.
7:I.
6!

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-

Cel
xre arld fOIIOWed the SeqklencesStI9- housing.

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Clearance 1/32

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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 Partllsectionshowing how thefrontbeanbgsareheld.

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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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(b) Cutthe threads forthe cap thatw ill is to m ake sure thattne

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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
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. Face outerend and size housing for properIength.Itneedsto be 4.250 inches about0.005 inches so w e willm ake the
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Iength.
Iong.Centre drillit.Drillthrough as faras recess 2.01o inches in diam eter and '
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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'-'
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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
ofthreadsatthe front
Rough bore out the entire recessthis.
and threads.
beanhg outerrace.
* Cutthreads.
. r';... ) ..; . before you do anything else.Rough bore
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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
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needssomethinkingaboutlofullycom' Nextw ew illaddressthethreadsinthe g

lassasyougo.About7xto1OxIsa
good magnificationfora shop glass Look

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ale threads
to fit
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these so the exact dlam eter OT tnese
threads iS nOt as criticalas getting good

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he bear
ings,cleanIIup=and pol
ish alIsur. 8f1d about 0.375 inches thick (orIong).
r
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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.
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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

andproceedaccordingly.

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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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0.187inch

0.125inch

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

iame
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eerkFi
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h.isNeap
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thininn
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Be
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to
ob
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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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eterin thls one chuck.

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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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2.300

-.. .... cutbetween

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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:
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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.
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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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taking place. The threading tool

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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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areadingtool

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rp1

clearance

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2 oojnc:di
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wemadetheinsidediameterof passesateachsettingandcutonly0

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

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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
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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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edutl
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on,wa
went
wo
dbnoelt
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ea
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sla
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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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on the nut.Ifyou startgetting a point at
ou
tsiuediameterofthe
the thread crow ns w hen cutting the
' beari
ngs
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threads, file them down imm ediately or
you are Iiable to get an erroneous fit.
Threadi
ngtool
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(This condition m akes the nut seem
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tighterthan it really is.)
BearingNut
colszinr.h
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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
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cr
ea
t
ed
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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
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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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Turntheqartoverand turndown the notinterferewiththebaseofthethread

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2.250inchdi
ameter
2.c90incztdiameter

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2()
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Figurea.1a Approximate dimensionsof

whatthenuthas to match.

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

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get the threads just right.W ithout the

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

sgurea

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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

. --1 l

'

Y be a need forsom e modifi

cation ofa
dIe.ysea.csoincupuIjeysbownisti,s ma
comm ercial pulley to prevent interfer-

bel
tsthatareW inchtoXzinchatthewid- partandchamfer.

'

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a vsedrivepulley

0 ,,

i.
ona.

33

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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
ceahlr
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.
.

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

'

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

'

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'/'

'

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'

'

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
, .

'.

Particularlybadnut).Thisbeingthecase, 12.preliminaq assembly

'

m er

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

)',
.

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

'

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
.

,.

p.

jaw chuck bythespindlepulley.

. putthe tailstock centre in the centre

in the nose.

. centreaccurately inthe4-jaw . '

.
,...,.

..
1

()12s,deep

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y.-.

. -.
,

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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. D
not allow this bearing to faIIout as yot
proceed With assem bjy.
..uttne
F
, tW O
.ronl
.Dear
. l
.ngs On I
.ne
,.. Spl
-!l
.mr
.

dIe and nutthem dow nastightaspossi

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

'

.
.

. '
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o.a7s inch shaftwith

accuratecenterheld
indri
llchuck
'

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.
,
.. . .

..
,

j,

l.

. . . '''

'

threads and alIbearinj surfaces.Then

..

Ce
teri
athe
spin
ndl
e nI

'
,

@ Holdthespindleaccuratelyinthe4-

Theinsideofthenutisrelievedto allow together. However, adhesives can bs

. ..

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

,.

. . .
.
''
.

'.
.
Di
ali
ndi
catormountedoncompound
and moved backand forth with
compoun(jsji
detosetangl
eof
compoundsl
ide

p.9klFe 3.22 How tosetup the taperangle on thecompound slide. M ountthe

d
i&JP
lindicator/
W compoundandabstuntlcompoundp
:
spara//e/tothetaper
DO
. X st
eepertaper/spreferred.

'
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H
oldacc
uretelyine4yja
won
theunfi
nishedpull
.

r(:

centerwi
th
.
t
ailstock center

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. ... .-. . -. . .. ... ... .

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t 't

atfrontbearing,Hold
mustbefi
rm.

,, .

ream erin the spindle and itis possible to

go alltbe way to the fini
shed taperfrom

this hole wi
th justthe reamer(ifyou are
using freem achining steel).Howeverthis

nOtt

m aking internal No 2 MTs so do not

Since no-one l know has drills over

'

project.

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
.

.,

.,

thel-jaw.

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

. ''

''

.. ...

.)
;
.

,.

tjaecompoundison9 .

voushouldnothavetoscrapeifyou makesaIotofworkforthereamerand

. --.---.------.--- -----------. -

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1.
1
4f
j

!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.

jj
j

.. . ,.. k, ..

- 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 spndle 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-

'1!
j
l
fl
'/
.

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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Thesenoteswillbeofassistanceifyou

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.

.,..

14. cutting the spannernotches in the

i
nchrodinhandwhilethemachiningis unhardenedtaperwilltakeustotheenk
d
tslowl
eycu
to
tsa
.v
Toa
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.oo

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

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36

37

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bearingnutand6inthefrontcap.wedo way setthe com pound to -20 degreea

.

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.

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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

38

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amebear
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ings
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no
thave
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thisholei
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b
e at Ieast Ya inch In diameter
because the draw in bolts forsom e

hold the front of the spindle In a 3-

andcap.Youshouldbeabletocut0.062

theshaftdoesnothaveto bethe

, .

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* lf you want to take the big hexago-

verticalsli
de and place stopson the angle

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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).
,
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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.

tfff

''
-

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
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neOneoft
hetheWplinac
holesinthe t
ebu
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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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'iwewilladdresstheclampingplates.
y
rst
vye
sequence ofoperations is as follow s:
'
. cut plates approxim ately to si
ze
with a saw .
. square and size platesin Iathe orin a
milling macbine.
. :jue and m ark up the plates.

. 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.

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ougcekth
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orn
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es
ssb
ae
rf
v
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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

'

o.soo inchesthick.

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.

.'

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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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

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
t
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horl
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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
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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
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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.

vjjendrillthroughateachofthe4holes aNo7drill5
/ainchdeepandtapeachend
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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
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come loose with ease.W e need the hole
Nut
,
y

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

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
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42

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43

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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,

oams

!l.

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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athe,youneedtomake ablock
0fvourI

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spacerneedstobeofaheightthatwil

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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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finishedTlae Iastthread should be lef'tun.

Asneeded

o.zso'
.

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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.
.

'

absolutely essential.Ifthe mounting isto

e Verticalside,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

'

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

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

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

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To m ount at exactly the centre heighl

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D
ril17/64
through
chamferedges

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ontal
totneaxi
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Of
at
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sr
ih
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bes
accom

pgure4.4 optionalspacersforplates.

plished by confirming that the slide is

actually parallelto the face ofthe chuck

Since the loads transm itted by the

' ''
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t' '

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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Figure 4.5 Studsformounting spthdle.

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Tbe end oftbe stud thatfits into the :'

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nuts shoul
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.M ounting on thhe cross sl
ide
w illnot go aIIthe w ay through the nut.
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M ounting att e cross sIide alm ostinvari- Thiskeepsthenutfrom breaking theslots
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ably m eansthatw e are going to mountat in the table if over-tightened. I
t is also
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These
ar
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avai
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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. , .).;.k.
,;. pastthebottom faceforthesam ereason,A.Marks(Modelog)aretwosuppli
ers.

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tbeMyfordcolletsandtoolholdingfea-

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
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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
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forslots that are 1?
/1e and 3% inches on
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jotscutinthem It is
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jsoeasiertoclamparectangularsection
a
io aIIkinds ofstrange setups thatama-

El
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ngalowsusto
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el
ev
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Th
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tydur-

smallerspindletobefabncatedthatcar About2.000inchesinfromthebigend

3.125inchesoncenters

1.562..

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('#2MorseTaper

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Figure 6.1 A smallerNo 2 Morse spindle housed?'

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1''1
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ta

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Figure s.2 Frontvjew ot.spindle

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sqsare
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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

.'
.

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-

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

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 Splhdlenosedlnensions- 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

49

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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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0.625inchdia

downtojuslunder0.750 inchesin diameter.Adjust the threads to match the

Flaure s.s snintil.zy,

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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

.
g'

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

'

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,

'

Rem em ber to use a cool shaft and a

w arm bearing when making the fi
t.You

cangetabetterfitityoutakethetimeto

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aawchuok
,
Housi
ng

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.

50
.
.

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smallsquare

uatnebed
.
Figufe 6.7 seton
g up the block forrnac/shin9'

nextin greatdetailis the preferred hous

'
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

.' '
.

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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u ttjjon you do also have to make aset take a very smallcut across the face of
OfClam shellholders fortheround hous- the part untilyou get to a diam eter of
iD9. The block style housing described

I
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offreemachiningsteel2.000 inchesby '

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

I
.

''

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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4.Block style outerhousing

can. Use a dialindicator to m ake sure
l Will not describe the m achining of a that opposing faces are equidistantfrom

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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rowns w illdeform slightly and become

24tpj

;j $.:I.

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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tfveadingtool,aboutoneandhalfthreads
gr(),060 incheswi
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on theface ofthe block,you have itright ing Iaterw ork.It is also a reference thal

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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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centre only, to avoid m aking an interm it- again.Some w orkers claim that a rotat-

P Turn the block around end forend and recess and does not have criticaldimen-

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the part an p

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(Face the mount the body accurately in a 4-jaw

''aper.

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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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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0.906 in

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1,032i
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5.062inchoverall

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

'

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

oa
fru.y-ea-a --

se

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e
'x
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tcWGo

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

'

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 Detals o/'hotzs/bv.

52

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

)
.

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 dam 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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th
.

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

'

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

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

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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Lightly chamferalledges and go over (b)Recess fornut

53

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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

it

;
'

'

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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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
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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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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.
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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
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bel
tsare notavailable to you,you
m ight

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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Once the groove is right, cham fer aII
edges and polish the entire pulley w ith
4OO gritemery paper.
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Set up the vertical slide w ith an angle
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notches should be /8 inch w i
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,

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
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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
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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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(If using a stepped pul
the

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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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Firstm achinethefini
shed outlineofthe

pulley and then machine the pulley

work willbe done between centres.Iti

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Chiningprocess.
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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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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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yeis
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and w
strength per- chuck and turn the housing down to size.
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feduc
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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. *
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inches
Th long (finished to 4.250 inches).

''

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
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putting the spindle blank in the 0.500

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inch collet and centring both ends,then .. ' .

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turn 0.750 inches ofthe shaftdow n to
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set up to work in collets. Start by '

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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 '.
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, .

dividlhg head with chuck removed to show

V indlehousing flush with dividing headface.
.

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

'

pieceofoneoftheseyouwillindeed bein

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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
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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

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

.
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dojyo
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eId wjyel
l.
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bearings and they are quite inexpensive.

The sequence form aking the parts of
this spindle is as follows'
.

'

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.

'

''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

$1:7
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turned dow n Iater to form the spindle ' , .

nose. W e cannot do this right now : ,
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- - - ream 0.125inch - -

.
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-x

a
: 0.295''di

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

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

'

.
,
.

'

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

ws-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.

60
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61

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w

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-

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

'

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

1i'h.I'''' ..

un-threadedpartofthecolle
tcloser..Turn spikls.Leti
tset.
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good f.I
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needed for your particular closer. After
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Note thatthis is a throw away spindle,
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9o togelherquickly.They are essentially
throw aw ay spindles that use anaerobic
I adhesi
ves to hold the outerraces of the

.
' ''
''

'

64

j)eanngs
. .vjjey w ijjnot be easy to take
apartto replace the bearings.
Do notscale the draw ings - use either
the given dim ensions orcalculate a value
from given d'
Im ensions. Non-critical dim ensionscan bem ade to suityourneeds.

6s
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; nescription

shownwithaspindlethatwillacceptthe

k cuterj
w using 1.250 inch
2
(32mm)
:
gjjjstjje
g.y5g jncjj

4.375 inch
(112mm)
7pggg jncjj

JZCObS 1B chuck - this chuck w illhold a

0.250 inch tool.A Iarger chuck and a
Iargerdriving PUlley could have been ac-

acers
j Sp
(16mm)
i
j
puj
ley
.
Puje9 RUt*

4.000 inch

longerand m odified to accept4.000 inch

grinding w heels on a half inch arbor. See
drawingsforthe 1.500 inch diam eter
spjndj
es to see how this m ay be done.
,, j:j.

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eterm icro spindle in chapter6 exceptfor

the diameterdim ensions. Please referto
the detailed building instructions in that
chapter.only those items needing special attention on this spindle are discussed in this chapter.

still best to use adhesive techniques.

Once we get to 1.500 inches in diameter, othertechniques can be used m ore
easily and the time investm ent required
starts to pay off.

who thought that even the 1.000 inch

Quantl
ty

diameterspindlew astoosm all.Thisisa

Iargerversion ofthat spindle.The m ain
spindlediam eterhasnow been increased
from 0.250 inchesto 0.500 inches.This
makesthisspindle stiffenough form ore

Outsidedia.bearing
Insidedia.bearing
Thickness
Seals
. ..

1.125 in (28m m )
0.500 in (14m m )
0.375 in (1Om m )
2 (both sidesneed
to besealed)

Xp-20 t17i,12X1.25, ' ;

making this spindle.

Anaerobic adhesives need about
0.001 to 0.002 inches forthe adhesive
betw een m ating parts.The outerracesof
the bearings are held w ith adhesive.This
aese
allow ance should be allowed on tj
fits.

Thisspindlewillbeofinteresttothose Bearinjselections

S
ta
l
nt
m
i
aY
l
'OS
gp
i
n
in
io
dn
l
et
.
hi
H
so
i
s
wt
e
hv
ees
r,
mi
a
tll
et
s
s
i
t
lu
ss
ues
adhesives to hold the bearings in place

r
'w750
u-- i'
-''
--.--m-'--ndl
.-'
- can be rebuiltoverthe years.
0.
nc
h-diam
eter
icr
o'-spi
ef-or

'

againverysimilartothe0.750 inchdiam- the bearings.Atthese sizes Ithoughtit

i
;1

1.250inch 1
.000inch
(2smm)

(azmm)

kajconsiderations
and Ifeltthata serious spindle should not
fallraw ,so i,
ao+rnolia,
a. ylar ls. be designed to use adhesives so that it

Even a spindle 1.250 inches in diameteris alm osttoo sm allto try to m ake arThe spindle described in this chapteris rangem ents to clam p the outerraces of

. ,
'

0.625 inch
(106mm)

we
aoaoa
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ve
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=

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Diame4er

This is a substantial spindle and is

Length

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oraw ings

DOnOtscalethedrawings- useeitherthe

Ziven dim ensions or calculate a value

from given dimensions. Non-critical
dim ensions can be made to suit your
needs.
't
.

4.250incheslong

'

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0500inc.hdia

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bearing
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. . Tbreadsand
registerto
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1.250inchdia

0.688clearhole

pujaytomat
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mohllfIolw n.oa

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Figure 8.1 1.25 inch dlame

' terspindle with Jacobs /8 chuck threads //1
can also bemade with theDrem elMoto Toolnoseonlt).
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Figure 8.2 Spindlehousing dimensions.

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66

serious work.
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1.250 in dia

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Figure8.B Spacerdim ensions.

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17

thatare needed specifically forthisspe- tionalseals at the bearings.Friction at

cialised w ork.
Two spindles designed by m e w illbe

the seals m ay create m ore heatthan can

be di
ssipated during operation to be gen-

described:oneforexternalgrinding (this
chapter) and one for internal grinding
(chapter 10). The spindles themselves
are of similardesign but the method of

erated which, in turn, creates special

problems for the am ateur engineer. In
industrialapplications this is handled by
using Iabyrinth seals and (even pressu-

hol
dingthegrindingwheelsandthesizes rised)mistcoolantsystems.We could
of the w heels are different enough to
..,

'. . .

use a simplified non-contact sealing

'

4.000inchhousing

- ...,i '

1.500''

.f

Makewheelplatestosuit
yourwheels. Matchthe
blotterpanelsOnWheels.

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68

q
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Among these are a numberof spindles time and cannot usually have conven-

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.... q. .. .
$ . .,
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'

W e now shift to making two high-speed make it w orthw hile describing the two
grinding spindies.
units separately.
M y interest in ciock making created a
Tool-post grinderspindles have to run
need for a w hole host of new tools. at relati
vel
y high speeds fora sustained

''

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*

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0.468 in

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.

2'000x2inches

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Figure 8.4 Pullev dimensions.

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0.094 in

n:2sindu

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Figure 8.3 Spindle dimensions.

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y.'
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69

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arrangem en:bu1 mist coolants are outof grinding spindle used by an am ateurengi-

w orks is acceptable for our ''one of a

the question. Not having seals really neer to be about 240 uses (twice a
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causestoo many problems to thinkabout

(im m ediatebearing failure forone)sow e
w illopt for sealed bearings and accept
the factthat we cannothave long grinding sessions w ith this spindle.
The spindle described by Professor
Chaddock forthe Quorn toolgrinderis an
excellent spindle.for our
applications
wi
th one except
lon - .
It uses. spr.
sng
.
Ioaded bearlngs that are essentl
ally (as
faras w e are concerned,and forourapplications)Ioose in one direction.Ifw e
coul
d
guarant
ee .that we w illnever
grind
.
.
.
. -'
ln thls one dlrectlon (as@he coul
d
w
l
h 1he
.
auorn)w e could use h1ssplndle butthat
we cannotdo.
The modi
fications Ihave m ade overcom e the above problem as sl
'm pIy as
'ble '
$.e. this w as the sim plest
possl
schem e that Icould com e up w .lth. The
scheme is not idealbut the design does
allow the bearings to be feplaced with
ease in the future if undue w ear should
occur. l estim ated the usefullife of a

m onth for1O years)ofabout 1O m inutes

each,of2400 m lnutes(about40 hours).
W lth a Ilttle care thls splndle should do
that.
The spindle is desi
gned to use a 4.000
inch orsmallerdiam eterw heeland to run
at between 3000 and 5000 rpm .These
Iim its are pl
ced m ore by the grindi
ng
.a
.ndl
w heel
s aval
sable t.han by &he spl
e
.
.
bearlngs. The m axlm um safe operatlng
speed for each w heelis marked on the
w heelbythe m anufacturer.
The spindle is designe
d so that the
.
.
gr.lndl
ng
wheel
l
s
as
cl
os
e to pthe front
.
.
.
bearlng as possl
ble. Thl
s .Is .l
mportant
both forrigidity and forkeeping the bearings clean. The Iam inar air flow at the
wheel'
Is intended to sweep the air from
the nearbearing and up to the w heelpe.
.
rlphery.Thls feature should be preserved
by builders.

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M aterialsneeded
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to make this spindle. As alw ays alIsleel
should be purchased as free m achining
steel.

(Aty nescription

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Thisis nothow w e manufacture spindles

jaw and centreasaccurately asyou can.

bearing

butin 1he am ateur's w orkshop whatever

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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
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houslng ls Identlcalat eltherend, each
end holding a bearing that is clam ped by
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a beari
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The housl
Is made from a piece of
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s
tee!1.500 Inc jes.
ln d.
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lnches Iong. Hold the housl
In the 4-

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1n tw o parts and then one ofthe parts i

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rnade
srnal
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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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2. Bearing caps.

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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

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1 Outerhous.lng (1aa
.50k
Jinch 4.
inc.u
mm)
(11
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omm)
2 Bearing caps 1.500 inch 0.375 '
Inch
(a8mm) (lomm)
1
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1.000
inc
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nc
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l26mm)
(165mm)
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2 Bearingspacers 0.625Inch 2.000lnch
116mm)
' (50mm)
1 PulleY
1.B00 inch 0,900 inch
t38mm) (25mm)
o,x.-.
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1 NUtfOrpull
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brass i
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Bearing selections
The bearings selected are as follow s:

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1.380,,dia

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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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0.375 inches Iong are needed. M easure
Nextbore and thread thesection that the housing and make the cap wi
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Figure9.4 Beanhg cap dimensions -two are needed.

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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
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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

'

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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leY to be m ounted. See also the pulley ofthe outerraces lnto a recess m achined

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- - - ''- - - - - - - - - -

- 0.500ID ream

seetextforI
engthnot
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gigures.6 aean'hg spacerdimensions.

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indeed be in Iuck here. Ifnot.justbefore

j;e mad
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your
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your
whi
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et
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o take
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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
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atteri
alaIittlebitatatimeuntilwegeti
t withyourhands.Runthespindlefortwo
M ak
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seat
to
he
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Thatishow togetthebearingsjust timed minutes at 3500 rpm. It should

4. Bearing spacers

bottom of the recess. Pass the spindle

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e theoreticaldistance between the
i
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throughthisbearingandplacethetwo i

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

'

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

'

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

Clean up and check forproperfit.You m oved.

need the spindle, the bearings, the . . .
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74

;. .

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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

'

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 -

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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to that information fordetails ofcon-

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.

*R C
j

* 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

to the design of the O D grinding spindle

described in the Iastchapter.Please refer

Holdthespindlehousinj inthe4-jaw

aclosefitonthespindleslaaft,

j
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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
.

.' '

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

os00inch

j.

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8.Finishing operations

chuck and centreit.M achlnethe face of

the bearing cap to give you a flange

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be done on a boltheld in the 3-or4-jaw

. ,. . .

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gure9.7 Pullevdlmensions. .
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1.500inch

Ream 0.500 in.

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y

M oto Toolofferings.These pre-m ounted

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match the draw ings.M achine the recess

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Figure9.9 Kevdimensions.F/
7, to f/
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f
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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/
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.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.
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lls you w ould
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ne the recess in the spindle for
'fy your
thachi
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o
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qui
lls.
'ng to use.
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* 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.
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J
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f
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t
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collets. Hold the Splnd e .
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m einternalgrinding spindle.The extraspace
atthedriving pullevisforasecondbelt
fOf
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hi
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efnovethe
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quillsl
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(50m m) (30m m)
1 NutforpuIIey* 12 x 20 tp114 x 1.5mm
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$. Figure 10.2 Spindlenose detallsand qulllmountlng recess. .
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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

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

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

0.750

.........- .----

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a dialindicator to centre the part accu- w ill get deform ed during these operarately - this is to allow us to replace the tions. Carefully clean the threads out

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Ream to 0.312

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Figure10.3 Crosssectlonoftwoqulllholdlngfi
xtures.
.

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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 hees
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.)

'

81

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.37inchdia

o.2s0 inohdia

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a12inchdia

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Y
ROCOSStomatch

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yourcoll
ets

1/8i
nchreamed

ls inchreamed

.
..

fixtureyoujustmade.

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

'

bechamferedverylijhtlyateachend

It is worth repeatlng that if you have

t
j
.
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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
asma'Cefore dfill.Bring up the tailstock
wi
th a ballbearing centre in i
t and w ork

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1)*re
2aBds

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-

.
.

'

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.

I
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between the centre and 1he holding jig pleted quill

s,and m aybe ruin one,itwill

82

exteosive internagrindng 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
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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

t.

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1$ '

ream totherightsizetofi
ttheshanks

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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voucandeterminewhatwentwrong.>0

it,find the problem and fix it.

83

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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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es
rea
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w
he
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I
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ner
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e
ha
l
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st
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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.,

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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

C
'

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.
'

4.250 inch overall

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1MorseTaper-- - -

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certain smalllathes (Sherline)use this Bearingseleclions (

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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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thanbeari
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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:

.

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

z,i,

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
.
.
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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.

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bearings cannot be replaced,the spindle 5. Sizing the spacers.
.
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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.

C
'

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

, .

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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--- --- ---- -

b. .

0.7s0 inch dia

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()6gsx 18toi

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drawbarusedbyyourcolets
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Figure 11.3 Splndle dlmensions.

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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'
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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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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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tailstockand headstockali
gnment.

that they w illbolt up true betw een the

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betw een the bearings.The length willbe

carefully reduced to fit between the
bearings.

lg2'000di
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Wewillmachinethepulleyendfirst. b
earing.Again,thyeIt
wospacerstogether '
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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

jncjjes wide at its widest (US size 3L).

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

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

'

spaedojtNemotorandijleSiZOOftlle

W henmakingthesespacers,the4-jaw you wlllbeusing.

shThe
ouldsma
tchyourdrawbar.
eucuhes
ivale
ntythrea'
ds on-the Iast0.67q
pindle geom etry is suitable foraI- in'
ofthe snindle

jo=c.
6z5.00.0.750

nch,c.z,2inc,
Ho'e can be o.2soi
or0.375 inch depending on

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seetextori
normati
ononspacerl
engtus
0,875 inch dia

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625inch
.

4- ?tl11*#
xjja qujjsy sjjoujd ye made to Stlit the
a;)jkcations that yOu have in m ind, the

0625 inchesdia

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nch

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overallLengthc3.!25inchestostart

0.250 inch

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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 runningpuley.

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.

,
'

'

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.

..

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

'

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

.
.

..

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

UsingLoctite
The adhesive should be applfed only aftef
youare absolutelysurethatyouw illnever
wanttotake thespindleapartagain.

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available atthe back fOrthe washerand
nut.

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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
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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
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CHA PTER 12

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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.

tj

Iife i
s too shortto use any ''hard to use'
'
m aterials except when absolutely neces-

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

oi
recti
on)f

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.

92

93

y-

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

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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0.250 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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jnternaldiameter
yhickness
seals

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

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

* 2 pieces 2.000 inches Iong for the

top and bottom .

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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-

another.

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
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the face plate and drilltw o holes in the
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ac
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Pl
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Cent
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but
ton at
one end ofthe bar.
on
::A)clearholesthatareto bedrilled '
Uk Iathe Centreand bojttjae barfixture tight
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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

1.2soi
nch

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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
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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
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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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needtObojarallelandsquaresothatthe

g 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
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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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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
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lti
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Once you have a nice fit on the

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1.500i
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orillandtap 10.:,2
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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 nches 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.
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bearing should be a snug fitinthe recess.

plateandmaketwomorethreadedcups

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

Figure 12.7 Cl
amping rings - fourringsarerequired.
96

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

Figure 12.6 Backplate.

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determiflcd ffom yotlrtOOIpost

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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
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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

sstiffaspossible.Thisrequirementalso hal
fthethicknessofthebearingsothat

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
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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.

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.

98
'

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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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 onstructk
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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Iocation,Centerintheframe

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
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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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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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Clean and prepare the parts for finaj
Unscrew the tw o hal
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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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M ake the pulley on a piece of free

maclainingsteelstock1zsoi
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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 ?
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thick and w ill have a pulley groove to adhesive and m ake absolutely sure that
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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

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

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

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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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inch ground silversteel(drillrod).
Now thread the Iower clam for the
Do a test assem bly with aII com po- upperbearing into the upperplate untilit

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tight,Everything Iinesup and runs true,i
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not,fix i1.
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into the spindle. Do not tighten yet.

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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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engineering needs.
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0 .750 in (20m m )

this as the basic design in the book. Outside diameter

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Length
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If using M yford chucks on these highspeed spindles itisw ellto remem berthat
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nose threads are gl
the 2.250 inch diam eterspindle.
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on the Iathe spindle. M ount and centre
spindle on the second face plate as

OverallI
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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.
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Foltow ing a logicalsequence?
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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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they w illbe very hard to getthem out.
W e need to work hard to keep thatfrom
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1w illdescribe '
the w ork needed to be

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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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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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'
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The blank forthe m ain housing is a piece

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diam eter and 4.375 inches Iong.This is
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obtainedthiswillsaveaIotofwork.If
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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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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
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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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thisoutto 0

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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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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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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the bearings to be absolutel
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bearings, it is best if this assem bly is
neverdisturbed afterthis operation.
Clean and grease everything.

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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.
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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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5.Finalassembly
bepossibletherotatethenutbyhand.
ginalassemblytakesplaceonceweare Atthispointplacea'
Piinchrodinacollet
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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
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seat has to be protected ataIItim es,any
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hurrv.Do notuse thissurface to hold the The purpose of the test assem blv is to

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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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This nut is the same as the nut forthe

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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the chuck,alw ays chamferaIIedges and

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speed spindles do rem em ber that cast

iron chuck bodies have a finite rotational
speed before they burst.
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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

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.
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applications.Tiny mills willneed a
higherspeed.
spi
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Im ade the motordrive formy cartridge
Mot
or spindle using the follow ing raw m ateri.

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

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nrrangem ent.

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* Somescrapsfrom thescrapbin

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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.

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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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,

jjgjjtenthedrivebelt.Thismeanswehave windings.Usually a plate on the motor

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doi
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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

.,

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
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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

Ona4.000inchdiametergrindingwheel mountedatthesameheightasthelathe

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uoto wheels cannotreally be spun as

Firstwewillcreateamounting forthe

fastasthey need to be foroptim um cut- spindle and then add the motorand drive.
Fi0Llre 14.5 ShOWS the periphery Ofa 4
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USethem - wejusthaveto bemorecau- inch wheelmounted on the OD grinder.

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tiousabouthow wedoit.

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

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have to be Used ataIItimes.This in turn to buiId an overhead drive.

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these questions is '
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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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the pivot shafton the cross slide.This ported eitherfrom the roofjoists ifthey
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ajjow the side plates to clear the com pound slide on yourparticularIathe. Tl
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the com pound because the entire comrlpound Car)be rotatcd ORlr
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The m otor for the tool-post grinde
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* M ove w ith thespi
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* Notbe in the way ofthe w ork
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. Notbe in the w ay ofthe operat
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* Beltd
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. Allow rf
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As w e did with the cross slide m
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that
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m otor. A new belt of a sui
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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
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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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m ounted m otoris thatit is easil
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end forend in a few m inutes ifitis in the
w ay ofthe w ork.The arrangem entis also

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13/4 by4-1/4 by

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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

to cut aIIthe teeth before you can really

The gear outline is first form ed accu- see w hatyou did,therefore few erteeth
rately on a pieceof0.500 inch brass held m ake for a Iess painfulexperience. It is

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Form bolh sides of 1he gear '
o finished divide so lhatyou do not have to w orry

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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theinsideholejustyet,weneedthestiff- Twenty is a good choice butit will,of

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:
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There is a considerable Iearning curve
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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 bank 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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ing.W e are not going to discuss how to

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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such thatthe spindle willnotdropdown

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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.
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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

0.500 in

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slide and plugtheholeitwasin.

theexactcentre.Lockthe crossslide by
W earenow readyto mountthespindl
e tighleningoneofthescrewsthatadjusts

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The mostimportantthing to keep in

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Iimaginethatthegeneralfeelingisthatif directions. It makes nice 0.200 inch

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Loosen the gib and do not allow the

spindle0.005inches,Ioweritsay0.055

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down the dialreading - this i

s the reading
we w ill w ork from the next tim e.
Retighten the gib and take a cut.
M ove &he gear over to cut the next
t00th and take another cut. lf the Iand

t
he verticalslide and makeoa
cut.Turn whati
twasattheIastt00th,youareat
the gearby one t00th positi
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andtheholehasbeendrilledandreamed.

skillsisthetarget.

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the teeth are not touched

and nut and provided wi

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you may getagood gearifyou follow

Fi
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these instructions, butbe w illing to do it

over ifyou have to.It is surprising how

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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M achine the front butdo not touch the

teeth.Then part the gear off a wee bit

. Rub the
excess off on a piece of 40O grit em ery

affectsheIand.

much you learn from cutling yourfirst

gear.I made four before I was happy

Nowwi
thamagni
fyi
nggl
asstakea wi
t
hilo
e.and ream ingthehole isthe Iast
Dr
lin
ng

geareverytime.Oncewegetthatdown

lthWyr
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tte
rn
equ
dj
o
pW
mn
enp
tllled
yo
uu
ro
r

Gears m ade from plates have to be

mounted to an accurately turned arbor

backing plates on both sides to allow

them to be cut.The backing should com e

Ooooloooooo

Jooolooo

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1oo
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sgure 15.4 Dividingplate.

Ifthe opportuni
ty arises and ifyou can

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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errors.Largeracksneedto becuton the drilled in the plate,itis notimportantto

carriage withpacking asneeded because have the spindle atthe same height as
a large cutterwillnot clearthe vertical the Iathe nose.Ifmorethen one row has

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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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save been cu..

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a jjave ueen cut

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to m achine itin place,w ithoutm oving it,

w hen doing precision w ork.This m eans
W e have to set up the dividing gear on
the back ofthe lathe head.
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urn
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moving forward and pick the last few

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timeswhen you willhave to Ieaveextra

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were notgoing to discusshow this was should just barely disappear when the

Nevergobacktodeepena100th.Keep

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to m ake a special plate for a dividing

extra material wears away yourexpensive gearcutter.How ever,there w illbe

etc.).

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jjeak
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and cut the rest of the teeth.The Iand

anothercut.You w illremem berthat w e

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vave
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tima
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wndbe
eepdone
the i
nches
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heoat
nly
wa
yto
es.
limi
aitte
teet
her
ha
toes
be
cut
.Thi
backl
ash
nt
oper
ion
like
thi
Wnr
e
with a pairof calipers and a m agnifying
glass. Be conservative and w rile this
value dow n too. Low er the spindle by
lhis am ount plus 0.050 inches and then
back i
t up the 0.050 inches.This takes

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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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nkeywillbe Cuttingaslotinascrew head
usS
ed.
te
he
model
neo
er

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
,

elmosteveryapplication that1he model cancutyerfectscrew slotsevertime.

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

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m ade. This can be done bY Iocking the

spindle by engaging the back gear and

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.

Ie# back onto the key and shaft.

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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

Now that w e have a Sp

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

t
ha
i
sie
xaea
ctl
yatIathecentreheight, Youwillal
soneedIongermountingstuds
wi
tt
hi
rt
el
at
ve
se

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s.arp
* M ake sure that you have a S'
centre drillthatleaves a true centre.
* Drillslowly, i.e. With a s1OW

feed

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rate.

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. wi
thdraw the drillfrequently to
cl
eanandIubricatethedrill.
. Itis very hard to drilideep-small,

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re-oilevery surface profus
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oiI(sw or 1ow is oood)to wash awnw

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ID grinding
m ust be secure and wellbalanced at a1I
W hen considerin: an internalgrinding high speeds.

every lastoiece ofQrit.Heavv oils ar'l

ureaseswJuldtendt
-otranthe'cri
t. -<'
- wi
th smallarindino sp-lndles.onlw =
very smallamo
-unt Jf ma
U terial'can'be'

Operation,we are talking abouttaking

verysmallamountsofmaterialoff.Internalgrinding often Ieaves the material
removedintheparthollow beingground.

holes.(Thi
sisbestdone byelectrical taken offbv arindino.therefore aIlnar..

dischargemachining(EoM)bysome- shouldbema
'deasJlo'setosi
zeasp'
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ble with only the slightest am ount of

terialI
eftto beremoved by grinding.
ma

Drilling-lholes under 0.020 inches in

W e have one otherproblem thathas to

diameterrequiresconsiderableskillifthe be keptin mind - wehave to keeothe

w ork is to be done right. These holes
should be avoided by the beginner. If
they m ust be drilled in any number,the
m aterialthey are to be drilled into m ust
be selected carefully.
'.

threads on ourgrinding arbors in mi'

nd as
w e grind so that we do not loosen the
threads and have the w heelcom e loose
as we grind.This means we have to grind
in at
such
di
ion
that
the
Ioad
he ara
bor
srect
ont
o the
spi
ndles
ant
dight
the-

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G rindin9

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w heels onto the arbors

Alm ost allgrinding w illbe done with
the spindle at Iathe centre heicht. ,

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Setting up

W ehavetotakethetimetoshutdownto timeortwobeforethejobisdone.

removethismaterialeverysooften.

long,just a few passes and they are inch arbors on which the wheels are
feadY to be replaced.

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facilitiesneedtousethelatheforgrind- t
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ostmo
W Jn
lna
inq the occasionalpart,so we need a pro- grinderon a Iathe.
'----cedure to m inim ise the dam age to the
w hen very Iight cuts are to be taken,
lathe
feeding the w heelinto the w orkbecom es
Before undertaking any grinding,m ake a problem .Thiscan be alleviated by feedsure thatthe Iathe is as protected as you ing in w ith the com pound set at 5.739

can make it. strangely enough this degrees.Atthisangle,movingtbecommeansyouhavetocleantheIathebefore pound along the lathe axisby 0.0010
you start.Doing so makes iteasierto inchesmovesitacrossthe axlso.oool
C'ean up afterw ards.

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After you get done, do a thorough anditshandle.Grindingatan angW

letothe

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newspapersand some scotch tape and 5.739degreestothe'

JnalebeinJnround.

Iar attention to the w ays. W ipe every racy is param ount (w'hich it is or w e

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covereverything on the Iathe and around This means thatthe axial
the setup w ith the paper.
to be done w i
th the thread cuttinn screw

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Movements atotherangles can be

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this can be done in the hom e shop w'
lth
mixed results.Itis bestto considerthese
wheels to be throwaway item s.

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d achieved by mountinu the comoound at

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Firstsetupyourgrindingoperationbut thewheelby0.0001inches.

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tion for 1he spindfe. Splnde speeds of

betWeen 4,000 and 30,000 rpm are
desirable.A certain amount of care has
to be exercised at these speeds.Things

m ounted.

lnternalgrindingisahijh-speedopera-

Asarul
eofthumb,itisbestifnogrinding OD grinding

2.
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Take extremely Iightcuts and work

Sm allgrinding w heelsdo notIastvery w ith greatcare to avoid bending the l/a

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care.SmallwheelsdonotIastIongandit
may be necessary to replace a wheela

necessity,smallandmustbeusedwi
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twoIocati
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3* Cutting Iargethreadsin two passes. The buttons do nothave to be hard4. centring apartin a4-jaw chuck.
ened, but hardenino them willmake a

5.A mandrelforIockingthespindleand better,more Ionaer-lastinotoolforvour

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collection.

a plateforsimpledivisions.

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Figure 16.1 Machlwsts button.

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then600gritwithadropofoil).Leavea downontoa0.375inchmandrelwitha

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trinj buttoninyourtoolcollection.Itis versteel(if you are going to harden

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'0 .070 inch base flange and part offthe 6-32 tapped hole in it,held in a 0.375

deslrableto have asetofone Iongerone them )orm ild steel.

and fourshorterones.Ifw e are aboutto
Take a close Iook atthe draw ings.

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fertheface edge.Polish alIfinished sur- of/lethickbrass(orsteelifyou Iike)and

faceswith emery paper(200,then 400, clean them up with a file.Screw them

It
j1rt

startoutwithsomevainchdiameter

stock.Ipicked this because itis the size

6
'.,

.
.

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xactly 0.500 inches in diameter for a Thickerwashers may be m ade ifyou pre1length of 0.500 inches.Just barely bore fer.These are best m ade ofscraps.Drill
rtheholeto cleanitup.VeryIightly cham- 6-32 clearance holes(No28)in 5 pieces

ItisessentialtohaveatIeastonecen- ofthebaseonthebuttons.Useeithersil-

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make.

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625.1dia

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these wijlbe easierfora beg'innerto

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DremelMoto spindle nose dimensions.

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Makingasetofcentringbuttons*

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Iam goingtodescribebuttonsthatare
slightlylargerthanthoseusuallvseenas

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0.375'.dia

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osoo d'-

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the diameters of choice.W e w illm ake

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them w ith a diameterforo.soo inches
because we probablydo nothavea o.4oo
inch collet for the Iathe. M aking them
thus allow s you to subtracteither0.400
1. M aking a setofcentring buttons.
or0.500 from the measured dim ension to
2 Aligning a la&he headstock and get1he centre-lo-centre dim ension ofthe

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the spindles thatare to be built.

As usualtl
nese notes are intended for
beginners.
The follow ing item s are covered:

tailstock.

(
;piece.Make three more pieces atthis
,sizeandonemorethatisy'
.inchIonger
onlhe0.500inchuiameterpart.
setup yourcolletfor yz inch work.
P
l
a
ceoneofthebuttonsinthecolletwith
.
:the base end out and face the base to

inch collet.Turn the outside diameter

downto0.450inches.Lightl
ychamfer
1Iedges.
S
crews
Purchase these as socket head cap

jive a finished dimension of 0.063 screwsifyoucan.They lookso nice.If

EInches.With a boring toolopen the W not, five 6-32 (approximately 4BA)
,inch hole outto0.375inchesindiameter screws w ould be ideal(sm allersizes are
and 0.437 inches deep. Very lightly hardertowork with)so we willmakeour

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onts
'one at .!p
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ndthatoneuni
ti
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BAscr
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ed
4sc
rewsw%ei
n
chl
oYs
ngia
nd
wn
id
thm
them
.s
Mu
ake
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ae fourshortbuttons first,
Ionger
one
ewn
xe
inch
Iong.
need
nch
Itisqreferablethatthebuttonsbeofan atime.Makethem withthebasetothe
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ev
s
hO
on
uld'la
me
veteer
xd
ai
cmtl
e
yntshie
ons.
aAme
Iltd
hi
eame
buttte
or
ns lathechuck.placetl
newinchbarinthe 5washers
outofxinchmildsteelstock.Cutthe

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The purpose ofthese notes isto support either0.400 inches or0.500 inches are

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ckwasher

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CHAPTER 16

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*Knownastoolmakers'buttonsintheUK.

chamfef alledges.Do this to al1five hold downscrews 6-32 (approximately

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law
has
or
be
4so
inc
las
ew
ti
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rai
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par
the
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r
e
jad
wri
ani
l
d.c
t
o
er
ni
tre
l
a.x
Fac
i
e
nc
th
uel
ao
ul
ae
ra
1n
wdc
i
n
ec
nh
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.but
w
etn
eedEac
fi
ve
ashte
s
foo.
rt
heto
phes
ofthine get
threatd
theaadsdi
eshte
l
dght
i
nt
e
tatil
softofck
to
deep into the bar.Turn the bardow n to
diam eter and 0.063 (716) inches thick. heads slightly overY1s inch thick.Turn
.

124

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around in the chuck and carefully face

t
)$sinch high.Cham fhe screw heads to :
her edges.Cu1 1he screw head slots by
olding the screws in yourtoolholderset
u
atthieIathecentreheightandusea
op
oa2
nch w ide saw to cut the sl
ot.
S
crew slot
s
ar
e
t
o
be
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Z
a
2
i
nches
deep.
Remove a11burrs. Carefully cham fer alI
edges. ' ..
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.
Base
A base is not essentialbut is a greatdevice for keeping your buttons, washers
and screw s together. M ake the base
from W inch brass (orm ild steel).Brass
w
b illmake the thread cutting easier.The
iase is going to be W inch thick by %
nch
ve 632
thw ide by 2% inches long.The fi
t readed holes are 3/0inchfrom cenlre
o centre and 0.438 inches from each

on a Ie
Ivelsurface (ora surface thathas
been evelled). I
t should indicate a Ievel
condilion in alldirections.
Next we need to m ake sure that the

headoftheIatheisexactl
yparallelwith
the Iathe bed.Thism eans thata straight,
preferably ground rod held in the chuck
w ill be com pletel
y parallel to the lathe
bed at aIIpoints on its surface.This can
be checked by traversing adialindicaAor
m ounted on the lathe carriage back and
forth from one end of the bar to the
other.W e are assum ing thatthe chuck or
collets used hold true.
The same should be true of the
tail
stock - its barrelshould travelexactly
parallelto the lathe bed.
The Ialhe spindle and 1he lathe
lailstock quill should be at the same
heightabove the bed.This m ay notactu-

end.Makesurethethreadsareexactlyat allybethecasebutisoftenassumedto
r
ight angles to the base. File to slze.
Ch
am feraIItop edges w ith a sm ooth file
an
d
M polish w ith emery paper.Lightly oil.
ount the buttons on the base and they

be because there is no easy way to fix

this problem . It is a matter of scraping
the bottom of the headstock or the
tail
stock and as this often does m ore

are readyforyourfirstproject.

harm than good itisleftalone.(The fac-

2.Aligning a Iathe headstockand

tailstock

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Ali
gning theheadstockoftheIathetotbe
tailstock is m ore com plicated than it
sdeems at first sight. I willdescribe the
i
ealsetup and you can decide w hatyou
want
A to do on yourm achine.
h s a rule itis considered desirable to
avethe bed ofthe Iathe absolutely Ievel.
Thi
s is done to take the twistout ofthe
Iathebed.On a sm allIathethis isnotvery
im portant because a short bed is not
Iikely to twistvery far,bu1 on a 40 foot
bed this mightbe a big problem . A bed is
usually levelled w i
'
th an accufate spirit
I
evel,often referred to as machinist's lev-

anotherand this can cause a misalignm ent).

Theonlyadjustmentwenormallyhave

avail
abte to us is the ability to m ove the
tailstock atright angles to the Iongitudina1 axis of the athe. For this reason,
m ost am ateurs concentrate on this

adjustment.However, it is worth your

w hile to know exactly how your lathe is
setup.
The cross slide should m ove at right
angIes to the Iathe bed and exactly so. If
there is to be a deviation,it should cu1
the part being faced slightl
y concave.
This willallow partsto sitone on another
without w obbling and m achined shoul-

els.A levelcanbecalibr4tedbyplacingit derstoseattight

.

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perfect/ypara//e/cuns;(b)/f.youmgsthavea

taperthlsJ theacceptabjs tvpes/.taper;(c)

Llndernocircumstancesdo you wanta taper
gke rs:s- t.ta totaqv unacceptable.

t
routb
eg
et
ingpar1h
bng
ear
ng
anand
d otthen
her
par
sl
on
to
tt
he
te
bei
ti
ur
ned

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they w ill ge1 Ioose right aw ay. This is

totally''u'nacceptable. ,

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3. Cutting large threadsin two or

m ore passes

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Ifyou are cutting few erthan 16 threads,

you m ay w ant to consider cutting the
threads in two passes.This is done to
redute the cutting forces on the toolby
reducing the length of the flank that the
Cutting toolhasto cut.
Letus assum ethatw e are going to cut
8 threads perinch fora Iarge screw .For

ease ofdiscussion Iet us assume that

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usuallynecessarytotakeafinishing cut.
to finish the threads.
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Under no circum stances do you want

your lathe lo cut a taper like &he one
show n in Figure 16.2c - you w illhave

these threads have a 60 degree form .

The pitch of these threads is 0.125
inches which m eans'
thatthethread flank
is 0.125 inches wide.On the Iast pass,
,
the thread and tool m eet along a full
o. 125 inches.This is hard to cut and a
(a)
very sharp tool taking very sm all cuts
wouldhave to be used.
l A bettermethodistodivi
dethework
up betw een two or, better yet, three
' ' . , ,
(b)
,
.
pas
s.The firstpass cuts only a third of
these
fulldepth ofthe tbread,then the :ooj
is m oved over one third of a 'hread and
the nextthird of the threads is cut.This
cu'
tends tw o thirds ofthe way into the
(o)
, ,
,
thread w hen the flank starts '
to m eetthe
firstthird of1he w ork.
Movethetooloveragain andmakethe
third setofpasses.Thesew illend al1he
.
fulldepth of the thread and will again
.
.
. .
Figure 16.2 (a)Thl
meet the flank cut previously.lt is now
s FStheIdealcondltlon -

126
.

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, studv the follow ing diagram s. These
.
'show t'
hree ways thata lathe m ight cut.
jjere w e are talking about taking a cut
ith th
w
o'n
gitumanual
dinalaut
omaticfeedfeed.
and
not wie
thI
the
compound
w jjen m aking these cuts:try to position
t
n
tool
cl
oste
coser
entrelohecig
ht.
isin
ot
jtica
cj
re
lbu
t
hetocl
ent
relthe
ght
vou get the better. If you m iss centre
j
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ei
ght tjae hyperboliccutyou w ould get
i
s very,sl
ightand m ost amateurs w illnot
even be able to m easure it.
yfyou can getthe Iathe to cutperfectly
1)arallelas show n in Figure 16.2a, you
yave the perfec1 condilion.This is w hat
w e are striving for,but ifyou are unable
to attain this condition perfectly do not
wor
y unduly.
jfr
you m ustbe Ieftw ith a taper,then a
taperttlatgets fatteras you go tow ards
theheadslockis1hepreferredcondilion
ykgure 16.2b).Thism eansthatthebear(
jngs
w illget tighter as you push them
onto the shaftthathas been turned.This
is tolerable.

tory usually provides m atched units but

an old latbe m ight have the headstock
from one Iathe and the tailstock from

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once you get within about 0.002 dI

e rotation. It w illbe accurate enough
inches ofcentre,you can starttightening for m ost applications though not, of

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down onthejawsselectivelyto bring the course,as accurate as a properdivi

ding

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nrstpass

seconupass

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' ', Figure 16.3 Takingthethree setsofpassesto cutcoarsethreads.

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4.Centring apartin a4-jaw chuck

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Approach the work slowly. Do not

tighten anything down too tight too

The 4-jaw chuck is probably the most early.Rough centrethepartin thechuck
versatile part holding in the arsenalof by eye.You shogld be able to getw ithin
m ost am ateur engineers.As such, the about /1e of an inch of being on centre
m astering ofits properuse is a Iong-term w ith a Ii
ttle practice.
undertaking.This m os'
tbasic skillto be
M ount a dialindicatorat lathe centre

part to the exact centre. lf the part is head.

sticking outofthejawsIessthananinch

Ifyou are going to do work on a part

or tw o,the part i
s centred and you can held in the Iathe spindle,it willbe necesproceed w ith the turning.
sary to hold the spindle very firm ly w hile
j
you do the w ork.It would also be an ad.
.
Note . . ,
vantage if the spindle could be indexed
no notstrike the partw hen the dialindi- through 60 divisions. This is a useful
catoris in contact w ith the part oryou num berand allows you to divide a circle
are likel
y dam age the indicator.M ove the into 2,3,4,5,6,10,12,15,20,30 and
t
.

Sindicatorbackoffthepartwiththecross 60 divisions.Themostobviousomission
qslideand then make the adjustment.

is 8 divisions.Sixtyholescan be accom-

m odated quite com fortably on a plate 6

lfthepartiss'
ticking outm ore than a cou- inches in diam eter. This is by far the
P1e Of inches,the outer end of the paft m ostflexible and usefuldivi
ding plate for
should be centred also.This is done by you to have in yourshop.
m oving back and for'
th betw een 1he tw o
Note '
the follow ing:

endsoftjaepartancjmaking adjustments
'tOtheoutsideend withaIightmallet.The

1 There is a Iarge gearbox coverthat

the highestpoin'
ton the shaft and loosen

idea is notso much to centre the outside

extends pastthe back ofthe spindle

Itisoftenimportantthatthepartbeing the jaw on the side opposite it and

'Ofthepartasiti
stokeep i
tparalleltothe

on mostIathesto accommodatethe

made becentred in the chuck as accu- tightenthejaw atthedialindicator- but

ratelyaspossible.Older3-jaw chucksare not too tijht justyet.Work between
notoriously inaccurateholdersso the4- thesetwo Iawsuntllthe oartiscentred

Fartnearthejaws.Inthatway,asthe
'IaWSarecentred,theoutsideswillmove
,wi
'
ththem andthepartwillbecomecen-

changegears.Theindexing assembly hasto extend pastthisso that

thecoverwillnotinterfere wi
ththe

mastered isthecentringofajartinthe height and make itapproach the work

4-jaw chuck so thatthe part Is centred from the side you are standing on.Find
along its entire Iength.

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t to the other
jaw chuck is used when parts must be between them , then shif-

h
ee
ldp
a
ca
ut
ra
Hc
ok
we
r
jun
st
en
no
tr
th
acrt
ttheelyc.hu
isvoef
t,en
otce
uinggh ttwo
l
aemjawsandcentrethepartbetween

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dow n to
, j
s louj: jx

to get the job done right.w e have to partwillbe wi

thin about0.010 inchesof

.ti
ghtening willcentre everything.

ke sure that it is centred along i

ts
ma
entire length.On a smallIathe like the

At tlae end of this exercise, the

being centred.

hold down arm . You w ill need to

tjo
hm
te
pnj
i
e
n
tg
ej
y
thp
ea/aj
w
j
ss
j
.
,y
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j
hj
ej
s
p
j
o
aa
rt
j c
tj
h
ce
uc
j
a
krt
j
a
ht
ls
di
a
mse
dna
sjo
ju
n;f
t
o
jj
r
sy
j
s
os
ujtp
jj
ao
r;

Now rotate the part slowly by hand

the expanding shaft that extends

Theand
reisget
atc
erttaoinknow
amouyour
ntof
exper
ence
ing
chuck
ii
n-

ntot
heIahth
etma
dre
ccordar
inmgly
.
2i
The
lengt
of
hen
hol
dla
down
has

thesecentringprocedures.onceyouget

to be adjusted to suit the Iathe

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atl
ae andstopateachjaw.Makeanoteofthe

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meeo
au
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sst
k
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he
atm
ueucb
uu
oc
fktb
oe
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ueo
tr
wke
ln
e.
fO
t
ou
rr
orlld
ei
n
tll'ju
or
s
l'
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s
b
je
j
dd
ei
a
so
'Ot
la
th
tO
tk
t
n
ed
zi
cr
e
l lof
u
er
lof
u
lli
alW
,
er
uY
ro
j
y
tgroc
o
I
au
scp
kre
rt
et
sy
pf
oa
ns
dt
s
.to

mhoun
s
l
d
ti
n
bg
ed
ae
ns
di
gt
n
ae
bd
l
eto
i
ngo
yo
duo
rwsn
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ap
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degrees as shown to minimise the

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digital 14
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cap forfrontbearings 15
double sealed 86
carriage stop 107
front 13,15,17,20,25, cartridge spindles 3,10,46,
2:,31,34e39,*7,4%,
47,111,121
49,53,56,91,1O6
designand construction

nose end 14
rear 15,2O,52
sealed 15.29.70
selection of 14
spindle 7.90
spring Ioaded 70
tailend 14
taper 16
tapered 3
tapered roller 1O2

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centredrill 120
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centring buttons 42.95, 124
Chaddock, Professor 70
chuck 2,13,14,18,19,20e
21,25,26,28,29,32.
33,35,40,44,46,48,
.; $9,59,61,73,81e84e
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',.. 85e90,97,108, 111,
' 117, 118e119,121,

back pulley 15
ballbearing centre 21,23
ballbearings 1, 2,6,9, 49,
52,83,98,105, 1O6
sealed 92

bearing catalogues 14
bearing seals 16,33,47,61
belt drive arrangement 93
beltgroove 33,38
block spacer 44

131
chuck back plate 49
clam shellm ount 41
clam shells 46,100
clam ping device 7

barstock 32

boltdownji
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basic spindle 10
bearings 1, 3, 7,8, 10, 13,
14, 1s,16,20,47,sa,
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7O, 74,76,78,85,88e
89e92,104,107,1O9
angular contact 15

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85Fg1F11yz.
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123, 131
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autom atic feed 127
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axis 15,20,3% 33e34,44g
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anaerobic 64, 67
aluminium 38
free maotnsng 63
anaerobic adhesive 87

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boringtool 125
brass 2,38,58,76, 101,
117,121,126
clock gears 116

gears 94

.
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clam ping surfaces 29

clam ps 7
clams 100,107.120
clock cutters 2
clockgears 13,85e92, 113,
116
clockm aking 69e92,98, .
116
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ocks 12,83

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coBetclosers 2,8,9,13e36,
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59 83 99,109,117,
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124,125,126, 132
home-made split 28
Morsetaper 9
M yford 9
spIit 30
com ponents 2,6,8,58
spindle 16
standard 3
compound slide 35,92,/14
concentricrotation 25
construction 13,47,58.62
conversions 15
Coolant 113
copper 38
cross slide 13, 38,40.43,
44 60, 111,113, 114,
117
. 120,126, 128
,
cross slide tabse J2O
cutters 2,7
precision 2
cuttinggears 116
'
cutting Ioad 15
cuttingtools 48, 111
cylinders 45
depth gauge 28
design 8 13
.
smallspindle 8
dialindicator 26, 51,75,79,
126e 128
nickson type 58
di italcalipers 14
dim ensions 5,13,14
imperial 3, 8,14
m etric 4
Sl 3 8,14
uivitjing,bead
116e 11:-:19129e131
dividing plate 116.119.129
m aking 116
dog 4.: ss- 88
dogdrivi
.ngplate 22
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doublepolesw itch 111
drawbar 85e 88.91
drawings 3,5,6,8,11,13,
14,15 64
,

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draw ingsandinstructions 15
Drem elM oto 2,59,73,77,
83
, 84
coltetcloser 59,62,83
colletsystem nose 81
gri
nding wheelarbor 83
tooI 2. 57e7. 83
wheels 113
drillpress 34,120,131
drilling 21,22,25,40e 118
drive
high-speed 110
bigh-speed grinding 113
milling 110
overhead 113
'
drivebelt 15,61,111
drivepulley 32,33,47,61,
67, 108

0D 116
z
grinding spindle 72
tool-postmounted 77
qrinding wheels 2

electricaldischarge mechining
122
end cutting mill 120
end m ill 1B, 121
faceplates 19, 20,21,22,
24, 48'81e94,95,
103, 105,106,117
fiIe 25w34,41,53,60e 128
filing 34
fi
nishing ream er 37
flange face 47
free machining steel 13
frontbearing cap 13

industrialapplications 69
industrialm illing m achines 7
intefnalm orse taper 20
iron,soft 121

halfm oon key 121

headstock 20,6O,88,124,
126,127
high-speed grinding drive 110
housing 6, 7,13,1B,20,23,
24,25,26.28e33e46,
53,54,55,58.61,62e
64,67,71e75,79'8B,
86,87,9O,97,102,
104, 106,107,109,
' 113, 117
blockstyle 51
outer 78
round 51' 54

Jacobschuck 69,67

jigs,holdi
ng 80
key stock 15
keyslot 34
:.' ..
keyw ay 2O,24e33,34,48,
51, 55,71,76,90,
1O6e108,116, 121
keyway cutting 40

gearcutting 116,117, //9

labyrinth seals 69 ,
gearcutting frame 1, 92
laminarairflow 70
gearteeth 12
tathe 12, 19,20.22,33,35,
gearboxcover 129
40,94
. .
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gears,brass 94
accessori
es z
GeorgeThomasdividing head
bed 13
120
carriage 110
gibs 1:7,121
centreheight 44.
grid 6
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chuck 1O,33
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'7'''
cross slide 13, 34
grinderspinde 79
culting lools 92
Io 1la
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oo J33 '. . ', '
M vford super78 1, 3,5,
grinding
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spindle 22,38,40,119,
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.
verticalslide 13
w ork 20
lead shortness 59
,
jeadloy 58
' '.
jjtjajum grease 109 '.
load,axjal 7,15
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joading 7
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1oo
Iubrication 15 .
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tion 27,29,41,
magn 1ca
17 118
mandrel 121,124, 129
alcompoundfeed 127
manu
markingbl
ue 117, 118
material
s
41 2,
783,6,13,14,40,
# . 11.j
free machining 2,25e58,
ss
. metrictooling 132
micro spindse 2,57
microm eter 18.21.28
mi
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olders 2
m llshank
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milling, basic 11
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m ng applications 32,111
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m ng machine 10,41e53
millingoperations 3.10
. mijlingspindle 7,10,12,14,
r
111
,
m isling 1k)reads 13
m isalignment 126
'

mistcoolantsystems 69
M odelEnglheer 12,42e113
modelengineering applications 86
Morse 8
Morsetapers 33,35,36e37,
85, 103, 1O9
collets 9
hol
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36
.
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No 1 spindle 85
No 2 13,14, 15,16,19,
21 as,a7,46,47,48,
,
51,56,91,104,106
u
o 2 collet 56
No 2 milling holders 38
No 2 spindle 46
reamer 36e37
m otor
hjgh-speed 113
shaftm ounted 115
m otordrive 111
m otorm ount 111
.
m otorpulley 113 .
'
motors 111
.m ount
.
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m ounting 6,2O,43,44'46,
94,110,J/3.114,
117,12:
m ounting bolts 6,53
mounting grid 6
m ountingplates 3,14
m ounting slots 6,54
,
m ountinastuds 7
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mounting tang 101
m ountings 40
.
Myfaccessor
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chuck 83
collets 36, 46,74
Iathe collets 58
nose chucks 10
Myfplates lo
u ord S7-B 124
yford SB7 79
spindle nosethreads 13
Myford Super7 2, 3,8,13e
99, 104,128
tablesand slides 6
Myford Super78 le 3, 5e 12
Myford system 42
.

154

'
needle bearings 9
Nexus Plans Service 3
nose bearing 35
noseend bearings 14 . ;,
noseflange 62
nose notes 19
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nose register 20, 21
nose threads 2
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nuts 7
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oilseal 106.108
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overhead drive 113
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parts 10
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plate, m ild steel 41
platelhreads 22
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plates,m ounting 14
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'.. ,
puddling 59
f''
pulleys 6, 13,20e23.29,
32,56, 58,61,64,67,
71'7#,84, 86,89'93,
98e100,101, 104,
106, 108,109,111,
121
commercial 33
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flanges 55
grooves 33,35,38,48e
55, 62,100,109
.
nuts 61, 64,67
.
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slandard 33
.
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stock 33
'
quills 77, 81,82e83'84
spindle 77
.
quorn 75
.'
quorntoolgrindef 70 '

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races 7, 15, 58, 64

'
inner 7, 17,23.29,33.
34, 47.7O,74,9O'

106,109
outer 7.29,33e53, 58,
64, 66,67,75,86,9O,
107,1O9
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ream ers 2
M orse No 2 finishing 15
ream ing 118
recesses 53,58'62,97,
100, 107
ring clam p 31
risers 120
'
rotation
concentric 25
roughing reamer 37
rust prevention 34
..
'
safety 115
sealed bearings 15
. .'
seals

bearing 15
integral 15 '

Sherline 86

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shop Iog 1/&e120

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sketches 5,6,8

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slots,mounting 6

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SouthBendI
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spacers 1, 4 /,43, 58,61,

62, 64,67e 71'74, 75,
78, 86,89, 120
spannernotches 37
spannerslots 55
spigots 120
Spindles 10
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cartridge 2,3, 10, 111,

121
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ampedbearing 2

Myford 6
nose 6,7,14,15,19,
22,40, 46,49, 64, 58,
59'85,104,1OB, 1O9
nose threads 13
OD grinder 79
shaft 18,33, 51, 97, 1O0
sizes 1
threads 17
toolpostgrinder 69 '
using 116
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vertical 92
spirit Ievel 126
splitcollet 72
splitplates 40,43
square key 121

thread cuttingtool 82
thread flank 18
threading tool 23, 49, 50,
72, 82, 97e 106
threads 18,23,48,50e53,
54, 72,85, 88, 91,93,
94, 95, 96e 97, 106,
125, 127
crow ns 18
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external 17
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spindle 17
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steel 58e59'71,73

thrustbeari
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96,1O6

urethanebeltingstock 84

components 16

53,59,60,62,75,82,

construction 2, 3

83,88, 104, 105, 106. ''V''belt 89

design 5,14
driving 45 :
face 23
flange 23, 31
front cap 29

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1O9e124e 126
tapers 2,8,127
M orse 2
E . . M orse No 1 8
M orse No 2 2, 8

grinding 1,2,69,72
highspeed 13,32

taperbearings 15
tapercoll
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27,29,30,33,47

taperedbearings 3

housing 14,15,24,26,
industrial 25
micro 2,57
milling 1.7, 10

M rseNo1taper 85
Mo
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mounting 2,40

tellurium 58
Thom as,George 57
dividing head 57,82,120

Thornton 99
t
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thread cutting screw

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verticalslide 13,34, 38e40,
43,44, 47,48,55e 72,
92s 111, 113, 117,
118, 119, 120. 12/

Morse No 2 8

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verticalspindl
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vice 34

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toolholdertang 94

tai
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33 34 35 37 49 52

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T nuts 40,44,120
T slots 47
tailend bearing 14

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toolpost 51, 57,69

tool-postgrinderspindles 113
tool-postmounted grinder
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tool-poststud 101
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tooling 2,85
metric 132
totalindicated runout 24
turning skills 12

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sheet 131

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silver 94' 99, 324

studs 6, 7,4O,44
mounting 7
sw arf 15, 31, 53, 98
sw ivelling verticalslide 44

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free m achining 13,20,

tommy bar 81e83
24, 29,37' 48, 51, 59e tools 2,69, 85
78e80,81,87,89.93,
boring 80
mild 124

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