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Registered Member #2099
Joined: Wed Apr 29 2009, 12:22AM
Location: Los Altos, California
Posts: 1714
For the first time in at least 2 years, and first time _ever_ using the faceplate, I made something with my tabletop Sherline lathe. The lathe was a lucky garage sale find, in spite of many missing parts, when I wanted to make rings from uncommon metals.
The little project was a fun way, not a fast way, to get well-centered alignment holes in two electromagnet pole pieces. Their nominal 3" hot-rolled steel came oversize and significantly non-round. In most directions the diameter is about 3.035", but on opposite sides are two relatively low places only 3.015" apart. Lines scribed with a centering square don't all pass through a single point, or even define a tiny circle.
So I made a drilling jig in the form of a shallow cap for a rod end. It has a rim whose lathe-bored inner surface barely fits the rod. A lathe-bored center hole receives a drill bushing -- actually a 3/16 by 3/8 ball bearing. For various reasons the jig is not made from a thick sheet of aluminum or plastic. A jelly-jar lid was epoxied onto some 1/8" hardboard. Its rim, minus jar-sealing compound and paint, was packed with Bondo. Cured Bondo is a delight to machine!
Finishing the center hole was not so easy. My only boring bar, from a six-tool starter set, refused to cut. It was too big. A non-cutting place on the "heel" was indenting the thin steel into the woody sheet material before cutting point could touch it. Fortunately, a 1/4 inch twist drill worked OK as a boring bar. Aluminum spacer brings drill center up to standard level in the simple horizontal toolholder. Another aluminum scrap spreads the tool clamping force over a couple of flutes.
The faceplate position with respect to lathe spindle threads seemed to be repeatable enough, as I removed it a few times for test fits.
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Progress with my little lathe
