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The spindle has an ER 40 internal taper and and ER40 external thread. Behind the external thread there is a shoulder register allowing the backplates to fit in the same way as Myford backplates fit, just bigger, and using an ER40 thread. This allows an ER40 collet and collet nut to fit...

For reasons no one ever explained Myford never embraced the native ER40 spindle nose in their big bore model (still only 1" clearance through capacity)

Which means it has far less energy to transfer, you don't get anything for nothing here, your logic is indeed flawed and using something with a lower boiling point and a lower latent heat of vaporization has no advantage in this application, in fact there are significant disadvantages.

I donate my scrap and chips to a school, the teacher says he likes it because it's oil free and casts better than anything else he's had, it's all 6082, but there are many different grades of "Extruded" and referring to them all as one is not a smart move

I am endlessly amused by you, please do keep it up :D

The only relevance of that statement is that a reamer is not a drill.

10mm pilot for 11mm final? :D That's most of your problem right there, running it at 500rpm with 0.5mm engagement compounds the mistake as it will rip the edges off a drill bit more often than not, a 5mm pilot would be better. This is not a case of a drill fault, it's tool abuse ;-)

Every ME with a Myford thinks his Sow's Ear is a Silk Purse, they're mostly over priced for what they are. Funny that, since as a breed MEs tend to be tighter than a gnat's chuff :D

The conical Super 7 bearing system is also good for over 2000 rpm. ;-)

Get a tube flaring kit or have it done professionally.

It's an easily misunderstood system but the tapered Hydrodynamic bearing on the Super 7 spindle nose is very good and can deliver remarkable accuracy even by modern standards.

I was at the Doncaster show, I kept expecting to see Tumbleweed roll across the hall! If they weren't the "Big Bore" they weren't "New", the base price for the new big bore is over double that! ;-) Add to that the fact that the "Big Bore" has a very disappointing headstock through capacity of...

www.lathes.co.uk

It is, with a collet chuck on a back plate it gives you capacity up to and over the standard Myford spindle capacity, I use ER40 which gives me capacity up to and above my custom Super 7 30.5mm through capacity. It's good when a man knows his limitations, even when he falsely foists them upon...

I buy from a commercial tooling supplier who supplies machine shops, they don't carry anything but good quality.

I have CBN Welcome to reality............... :D

Buy based on quality and support, you'll actually be better off in the long run. I just had a Siemens Micromaster Vector VFD fail, it's about 20 years old and was ex-industrial when I bought it about 15 years ago, Siemens still offer all the documentation for it in good, clear, comprehensive...

How long is the gear? I've seen split spring steel rings which can be manipulated over/past large items on a shaft, think "Slightly less than one turn of a Slinky", you can get such a thing in nearly anywhere and your only critical dimensions are then ring OD and thickness.

That looks like there is no groove for a circlip?

Bend a wavy circle from spring wire.