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Ossessionato
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Ossessionato
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pheasant plucker wrote:
No wire brushes for the Dremel so used scotchbrite (which worked very well..!)
Fu@@ing hell, that is brilliant. I think I need to buy a lathe.
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Molto Verboso
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nomadinsiam wrote:
Fu@@ing hell, that is brilliant. I think I need to buy a lathe.
It's a deep rabbit home to fall down. Haven't even made anything for the Vespa yet!
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So… I needed some stock to turn and hopefully make a backing plate for the 4-jaw chuck. Have some 8mm aluminum plate but prefer not to use that. Called my mum up who hordes everything.

She did indeed have some steel plate thingy (old water meter cover?)

She also mentioned she found a chuck key that I might want…
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Molto Verboso
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Hmmm…. These things really don't look like they belong together.
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Molto Verboso
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3 cutting discs later…

Solid 8mm plate under that crust. I figure it is cast but seems like legit steel.
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UTC quote
pheasant plucker wrote:
It's a deep rabbit home to fall down. Haven't even made anything for the Vespa yet!
No rabbit could dig this deep.
Chuck key make me chuckle.
Thanks mom!
Your back plate is some craziness - but what better project to take on in learning the machine? Dig a bit deeper...
Enjoying the ride.
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Threw some chips
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Starting to look respectable
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Molto Verboso
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Figuring out the spigot
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Cutting the recess for it
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Arghh taping steel. Think I need to drill the holes out a shade bigger. Tomorrow.
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Finally got it tapped. Had to drill out to 5.4mm and even then still brutal to tap. Sitting firm and flat.
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Time to sort the second face. Cut the new spigot in for the chuck.
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Really slow process - have to use the compound and cross slide, while running at 100rpm. This face and spigot should ensure the chuck is square and running concentric. Very slowly snuck up on the spigot and fits with no play.
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Finish line in sight! Just have to drill and tap the plate to mount the chuck. Possibly have run out of appropriate bolts to mount it with tho…
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Johnny Two Tone
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UTC quote
Can't you mail order some? Nice progress!
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sdjohn wrote:
Can't you mail order some? Nice progress!
Not really - finding an adaptor plate for these specific dimensions is likely impossible. You need to cut the back plate on the lathe itself anyway as it is the means of truing the chuck. More important for 3 jaw chucks. By leaving the mounting plate on for the 3 jaw, and attaching my 4-jaw to that, I can swap back to the 3 jaw without too much drama.
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sdjohn wrote:
Can't you mail order some? Nice progress!
Ahhh - you might mean the bolts? Yeah - will be able to source some easy enough.
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Johnny Two Tone
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Yeah I meant the bolts. You got it.
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Scrounged some.
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The chuck seems to be running true. Spraying oil from the cleaning. But somehow have acquired a wobble somewhere. Put a piece in because I've heard you shouldn't run the lathe with nothing in the chuck (not sure why, perhaps the centrifugal force on startup isn't good for the jaws). I know the piece isn't centered, but the wobble stays if I close all the jaws and no piece. Hmmmm…. will have to back track to figure it.

https://youtu.be/sqUAtKbYMuE
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I'd even checked the backplate and it was rock solid.

Although I did loose the orientation… so perhaps I need to rotate the backplate and see if that helps.
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Well it's not the chuck - pulled that off and still wobbling. CM22 was right… the motor pulley is the problem. Guessing my bodge shim gave out dealing with the cast iron plate. Typical bodge shim life expectancy I guess.
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Puzzling over how to sort the motor pulley. Can't find a new one to order that will fit. Can't precision machine the old one because I need it to run the lathe!

The lathe came with a what appears to be a spare home made pulley that kinda looks right except the shaft diameter is a plain 24mm not the keyed 14mm I need. Not sure if I can modify it enough to be a perfect solution.

Thinking I will have to sort the old one as best I can (another, hopefully better shim) and use that to get the spare one to fit, and then perhaps really sort the old one properly. Thinking I need to rebore the pulleys, interference/press fit a much larger shaft, and then rebore that and cut a new keyway.

I'm thinking I need to sort all the belt pulleys at some stage. The pulley on the lead screw is well askew also - but doesn't seem to itself cause much drama. Guessing the motor pulley is the most important because it delivers all the force - any small wobble there turns into an oscillating force and bigger wobble.

This lathe 'restoration' business has some parallels to fixing up a Vespa. Still - nothing close to fitting a mudguard!
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UTC quote
1. shim the old one
2.1 use that setup to bore the home made one
2.1 file in a key way
3. swap to the home made one and use that setup to make a tapered split hub for the old pulley.
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Well I hit a roadblock. Can't get the old one to shim and not vibrate like a mofo. Motor spindle is 100%. The ID of the old pulley is torn up inconsistently and tightening the grub pulls it off axis. Vibrating on 2-axes so really nasty.

Found a cast one locally. It is between my 2 speed sizes and way cheaper than chasing my tail. Ordered some stock and a boring bar. Hoping a 12mm bar can work from a 13mm pilot. But need to upgrade my twist drills. Big ones are $$$.

Found a home for the old drill press tho. Caught up with an old friend - turns put he has had the worst luck this year. Among other things - been fighting with his landlords for 4.5years to fix up the house. A couple of days before we went into lockdown broken asbestos was found all through the house. His partner and he had to move out immediately with 2 changes of clothes and what they could carry - he took his guitar amp and a bmx (restores/customizes them). Had to even give those clothes back to get destroyed. All their stuff - if it couldn't be deep cleaned, got put in heavy duty bags and taken to be destroyed. Dust was all through the heat pump… then straight into >1 month lockdown. Luckily in a mates man-cave.

I asked him about a custom guitar he was doing up (was gonna help him with the finish) He thought they wouldn't clean it - but they did and he had just got it back. Stoked! But he needed to find a drill press to finish the job.

Boom. There's a bloke who deserves a drill press. And he will be all over sorting the motor if it needs it. Dude extracts precious metals from circuit boards for shits and giggles.

And yeah - they got lawyers working on it. But here in NZ it won't be a crazy payday like in the US. Even though they should b/c it sounds like their asbestos exposure could be terrible.
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Pheas' - think you have sussed it - but couple things you could always put the 3 jaw back on and run it to see if you have same results.

Hole in the bucket problem with the pully - if that rhyme translates.
I know you are world renown at working the internet to find things - so assume there isn't an off the shelf solution.

One thing you could consider - have a machine shop drill and press in a brass bushing that fits perfectly to your existing pulley. That is such a straight forward process you might get it done about as inexpensively as buying a new pulley. They just need to be capable of truly centering it.

Amazing job creating that back plate from nothing.
Your lathe skills must have gone up 10 points alone on that one.
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I ran the lathe without any chuck, without the idler to spindle belt, and other configurations. Just the pulley on the motor shows the problem is that pulley. Seems I got lucky on my first shim attempt. Looking back it must have failed during the backplate machining because I was getting a strange wobble when working on it. Cast iron isn't a great material to lathe - and I intermittent cut it plenty. Lots of pressure on the lathe. Was well aware that it would be the case but wanted to see how far I could push it.

Still under decent covid lockdown restrictions so trying to sort it via a machine shop will be tricky. And that's cheating anyway! Plus they would likely charge too much for my miserly self. Needs a keyway broached in too. Just talking to those guys would cost more than I'd want to pay.

I have ordered a pulley with intermediate speed/diameter that should fit. Hopefully give me enough speed range to then properly fix up one of the correct 2-speed pulleys I have. Needed a boring bar and stock to proceed anyway.

It's worth pausing at this stage to get this right. As you pointed out early in the piece - that pulley is pretty critical for smooth running. Definitely don't want to damage the motor spindle or bearings trying to polish a turd.
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Looked up lathing cast iron after I had machined it. It turned out I did what I was meant to and it behaved like expected.

Turn it as slow as possible, use HSS to get through the 'crust' that casting causes, be prepared to sharpen said HSS lots, and then finish with carbide tips.
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pheasant plucker wrote:
Looked up lathing cast iron after I had machined it.
Hahaha - my natural approach!
Looking good.
Remarkable outcome from a shank of cast iron.
Like the go it alone spirit...
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charlieman22 wrote:
Like the go it alone spirit...
I'm guessing you are like me - get frustrated when 'professionals' do a job that doesn't end up as good as you would've done it yourself. Wife gets frustrated that I want to fix everything around the house rather than pay someone to do it. At least if I mess it up or it's not up to par then it's on me.

Plus - I haven't ever used a broaching technique (or much of what I'm planning to do) so plenty to learn right.

Cutting the backplate was as much about learning as getting the 4-jaw in action. Very similar concepts to what I'm planning for the flywheel. Figured if it goes ok with horrid cast iron then should be much easier with aluminium.
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Boring bar, stock, cast pulley, and a few other bits arrived. Damn cast pulley was more like 13.9mm shaft size. Boring bar won't fit in 14mm - so had to sand it to fit the motor. And heat it to get it on tight - isn't an ideal pulley but working well enough to move on.

Finally can adjust a piece for concentricity. 4 jaw is awesome. Here's the old pulley dialed in and ready. Just need a smaller boring bar and some decent big twist drills now.

https://youtu.be/LYkcwQ0MKSk
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Not perfect but not bad. Broaching the keyway was tricky. Ended up tapping the pulley on - nice and tight, doesn't need a grub screw. Think ever getting it off may be a problem.

Tried to straighten the lead screw pulley - it had been knocked well off centre. The gear spindle tip (the pulley mounts on) was bent. Chucked it up in the 4 jaw - centered the tip just exposed from the chuck. Then put the micrometer on the far end - directly underneath. Smacked it with a hammer (gently) and straightened that to 0.1. Hard to get it any straighter. Think the shimmy is from the pulley itself now.

Not sure what rpm this is, but can't run on the one higher setting as the belts start jumping. Not quite sure the cause. Shed's a mess so need to fully sort it.

https://youtu.be/guXHItLMI4U
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You should make yourself one of these automatic lathe oilers next.

https://youtu.be/-W3S-sh490Q?t=142

It was the video that came up to auto-play after yours so I had to watch it.
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Cleaned up and ready to roll. Time to move on to the flywheel(s). Will start a new thread…

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