Wednesday, October 7, 2009

Some Projects from Stephen Ellacott

Stephen Ellacott sent in pictures of his latest projects.

"I finally got your indexing plate mounted with a simple indent pin arrangement on the top of the tailstock - works great! Thanks! I made a simple jig to help remove the headstock pulley - 6 1/2" of 5/16" steel rod with a counter bore in one end to fit the point of the gear puller and turned down to 1/4" for a length of 1" at the other end. It is inserted through the headstock with the 3 jaw chuck mounted and the jaws tightened on the reduced part of the rod. The gear puller can't push the shaft through the 3 jaw because of the lip of the cut. I also made a simple spindle threaded 1/4-20 at one end and used it and a washer to hold the pulley on top of the vise while I drilled and tapped the three holes. The plate spins very well without any wobble at all.The indent pin is 5/32" in diameter and tapered to ensure it centers every hole in the indexing plate. It doesn't go all the way through the plate and has a slightly rough finish to stop it from dropping out. It is stored in the top right of the indent pin plate when not in use (see the second picture of Dean's center).In the first picture you can also see a small steel plate I use as a magnetic mount point for my test indicator on top of the headstock and the most amazing piece of brass swarf! After a year of dodging sharp little brass needles I finally found the recipe for turning brass! Zero top rake, 7 degree front/side rake and a 20 thou deep cut at 2100 RPM for a 1/4" rod. I was enjoying turning down the brass pin so much I had to scrap the first one!"

"A modification to Keith's excellent sharpening jig (well worth the effort to make!) which allows you to use it on a drill press without a vise by clamping through the center hole or slots on the table. Much easier to reposition! I also use a hard felt wheel and honing compound in the chuck with the jig to get a "scary sharp" edge on my cutters."

"Taig vise clamped to the drill press using a couple of vise clamps. The basic clamp design is on the Little Machine Shop web site, I just scaled it down for this vise."

"A modification to Dean's headstock center using a coupling nut tapered to fit the pulley. This gives you a self-centering rig which cuts down on vibration quite a bit."

Front view.

"3/4-16 spindle for the Taig chucks made from a 2" 3/4-16 bolt. The trick is screwing the bolt into the front of the four jaw chuck (without jaws) or the machinist's plate then parting off the head and turning the shaft down to 3/8 or 1/2". This ensures concentricity between the threads and the newly turned shaft. The nut is split and used to hold the machined spindle in the mill to cut the Weldon flat without damaging the threads."

Posted on as well.

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