Project Frankenmill – Part 10, Boss Hawg

Back at it on Sunday morning. My first order of business was to work out how to capture that 35mm round boss that protrudes out of the Z slide. I decided to machine in a recess to hold a .250″ aluminum plate.

Onto making the plate. Made it out chunk out of a scrap of the world’s gummiest aluminum. But hey, it was free and I’ve done a half dozen different projects with it.

Transfer punched the holes through onto the casting and drilled them out on my drill press. I was out of Z on the X3, so I had to do it offline. I keep finding handy things to do with 123 blocks – here, I propped up the plate using a couple of parallels, then held the transfer punch square to the plate using two 123 blocks in a corner configuration. I’m sure I didn’t invent it, but it was a nice discovery.

Here is the plate all buttoned up. Four flat head cap screws hold it down. I cursed to myself quietly because I only had imperial (10-24 1/2″) screws in stock, instead of metric. Then I got over it and got’r done. Everything on the plate sub-assembly sits below the plane that mates to the flat surfaces on the Z slide, as you can see in the second photo.

Time to commit and lock in these plugs.

I zeroed on one of the holes using my little center finder gizmo before I bonded the plugs in place. I figured it would be wise while it was zeroed to drill a new center in that same plug so I have the same point of reference if I want to do later work.

And here we go, really committing now. Helical boring the new X3-spaced mounting holes. 3/8″ four flute carbide endmill, which was alternating taking bites of Chinese cast iron and 1215 steel. I couldn’t really hear or see much difference. And the last CNC operation of the day, profiling an undersized version of the center hole to accept the boss on the Z slide.

Next up, slung the four jaw onto my lathe for the first time ever, and dialed in the CNC cut bore as closely as I could. Took it out to just under 35mm with a boring bar, and then took it the rest of the way with sandpaper. This was mostly because I don’t yet own a set of telescoping gages and mics, and I knew I couldn’t trust halfass caliper readings, so I played it safe and did several test fits until it just slipped over the boss. Accidentally bumped the non-cutting part of a tool holder into the face when I was trying to turn in a chamfer, that’s what that mess is on the face. Oops. Good thing this part is buried in the machine.

Here are some of the sights and sounds of today…

Machining the casing and boss receptor plate (video).

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