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The way I saved material was to make the chuck adapter a separate part allowing a much smaller piece of prehard 4140 for the shaft.

You can use the shank of small drills to measure threads. If you know the size of the drill shanks it can be inputted into the formula to get the correct measurement. I have used this method in the past with good results.

Nice ATC i have made two of this design. The lathe that I am currently working in is a updated Enco compact5. Just a note many modern spindles use ball bearings, two at the chuck end and one at the drive end. The two ball bearings at the chuck end are preloaded and the one at the drive end is...

Looks like you have a plan. The L in 12L14 is for lead which has been added to enhance its free machining. I worked in the experimental machine shop (prototype parts) where we used Harrison lathes and Bridgeport mills to produce one of a kind parts.

12l14 is a free machining steel. Where I worked we used cemented carbide or insert tools to machine this material. It should be possible to take final cuts of as little as .0005" using a sharp tool with a small radius.

I use LinuxCNC which is free and community supported. With LCNC you can control simple steppers to state of the art servos. There is a stepper leaning curve but well worth the effort. Note: PathPilot is an extension of LCNC.

It is really looking good I see you won the piece of cast iron I was watching on Ebay. I bought a bar from McMaster Carr to make a 20mm ring lap.

This is F E Read turning prehardened 4140. A too deep of a cut can deflect the cutter or the material and will eventually spring back resulting in chatter.

Here are a couple of screen shots of my 3d model.

I will upload a drawing when I get a chance. The driver works similar to there 1K+ driver. There is a shuttle supported by springs with a adjuster screw to move the rod which is also spring loaded.

Just thought someone might be interested in the mandrel driver I made. The driver is mounted on an Atlas bench miller.

If you are still having trouble I would suggest using an express tap. Express taps do not cut but form the thread. You can power tap an M4 thread with these.

Trevor, Just thought you would be interested in what I am making for cam and crank grinding. This is CNC with a CNC controlled dresser. Mark PS yes I am also working on a Quorn

From your sketch it looks like you can just plug the wrong hole using locktite and an aluminum plug and redrill on the correct location. There seems to be a sufficient amount of stock remaining.

One of the hardest things to learn is how to square a block. I do think that you should find a better vice because it is making you work way too hard.

Just read the entire post. Great work on the shaper and the drawings. I would love to get a 3d Cad model of the shaper if possible. A Cad model would make it easier to substitute available materials. I would like to reiterate that the shaper is some awesome work

creating an non serviceable assembly is not a good idea. is there another way to install the bearing and shaft as an assembly from the other side (pressed to a shoulder)? A sketch of the assembly would help making suggestions.

What we used for our race cars was very simple just tubing and bent disc to create a spin in the exhaust.

It would make sense to temper the material to HRC 28 to 32 which is the hardness of stress proof. At this hardness 4140 machines extremely well with good surface finish. I would expect similar results with 1045.

I have created a couple of CNC machines with LinuxCNC for the controller. To facilitate other projects I am contemplating a CNC ID OD grinder. The attachment is where my design is at the moment.