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Thread: New (to me) WM30 mill.

  1. #25
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    Default Re: New (to me) WM30 mill.

    Well today was a bust day. After I finished the spindle pulley bore for the upper spindle I was a little disappointed with the fit. Came out loose likely because I lack a 2-3" micrometer and I'd have to unmount to test fit since that part is anchored in the head casting. It's not a disaster or anything but more on the loose end of slip-fit than I wanted. I decided that it was time to get the

    I finally worked up the nerve to tear the spindle down. I wanted to properly model at least the upper spindle and lower spindle cartridge as well as more accurately map out the the head casting. After trying a bit last night to use some brass stock and a dead blow to work the upper spindle out I quickly gave up that route. This morning I headed out the the 'ol Horror Freight to get what I should have grabbed years ago. I picked up a 12 ton shop press. Put it together and got to work pressing out the upper spindle.

    There is a snap ring that must be removed in order to push the spindle out and it's a bear of ring to squeeze too. My snap ring pliers were not sturdy enough for the job. I was able to get it out with a pair of needle nose that just happened to fit. Breaking the upper spindle loose for the first time took a good bit of force. More than I really liked. After that it popped out in a few seconds. I could have beat on that till morning with the dead blow and probably wold not have budged it. From there I used Ye 'Ole Trusty Flat head to remove the 6207 lower bearing from the upper spindle. I got the upper 6211 bearing started like that but could not work it all the way off. I also couldn't just press it out because the gear is just about the same diameter so no way to get ahold of the bearing. So.... I decided to go ahead and fully commit. I chucked it up in the lathe and turned off the gear teeth and as much as I could past that with my tool clearance. This allowed me to get ahold of the big bearing in the press and get that end free too. From there I went ahead and removed all the gear teeth on the upper spindle body.

    I think I'll go ahead and get new bearings for this part too. To me they felt like they had a hint of notchiness to me. Like the faint feel of a stepper motor. Last time I changed them on the small mill they felt like butter, not like this. Possible my attempt to drive them out with the hammer did it.

    Attached Thumbnails Attached Thumbnails New (to me) WM30 mill.-img_1177-jpg   New (to me) WM30 mill.-img_1179-jpg   New (to me) WM30 mill.-img_1182-jpg   New (to me) WM30 mill.-img_1183-jpg  

    New (to me) WM30 mill.-img_1184-jpg   New (to me) WM30 mill.-img_1185-jpg   New (to me) WM30 mill.-img_1186-jpg   New (to me) WM30 mill.-img_1188-jpg  

    CNC: Making incorrect parts and breaking stuff, faster and with greater precision.


  2. #26
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    Default Re: New (to me) WM30 mill.

    Using 2 4 6 blocks in a press?



  3. #27
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    Default Re: New (to me) WM30 mill.

    Needed the elevation. The plates were not tall enough and the gap in the press base would have interfered. They still measure 4"

    CNC: Making incorrect parts and breaking stuff, faster and with greater precision.


  4. #28
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    Default Re: New (to me) WM30 mill.

    With the casting now empty I am correcting the 3D model I obtained online. There are some discrepancies that were obvious now so I'm doing my best to measure out and correct those. A tedious process of refilling the solid and then adding the corrected features. I'm noticing that measuring and modeling a finished casting is... well... imprecise. Paint goop thickness, rough internal spaces, cavities with sloped walls. I'm trying to work out the best position I can for the important features like the bearing bore and quill bore. The other thing I need to very carefully check is the position and spacing of the bolt holes used to hold the old motor plate on the top. Those are re-used in my design for the motor stands and I don't want to find out they are 0.020" just too far apart to work.

    I've modeled up the upper spindle completely (minus actual gear teeth). For now the lower spindle is a functioning 'black box' model. I have the external features represented and jointed correctly, but the inside is not represented. Since I don't plan to crack that open beyond resetting the pre-load and maybe replacing the grease, It's likely going to remain that way.

    Nachi bearings are on their way for the 6211 and 6207 deep groove ball bearings of the upper spindle. Once they arrive I'll get them pressed on and replace the upper spindle back into the head once I am confident of the measurements.

    CNC: Making incorrect parts and breaking stuff, faster and with greater precision.


  5. #29
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    Default Re: New (to me) WM30 mill.

    Completed the hole circle around the upper spindle body. I decided to make them flat bottom holes rather than drill so I milled them with a 3/16" endmill as 0.240" holes to make them a fairly close fit for an M6 grub screw. Used that crappy little indexer I made for this job. I keep thinking I'll make a vertical mount for my rotary table to replace that but for most jobs it works 'good enough'. With a ring of 6 of them I don't think the smaller hardware will be a strength issue. This will mean that my placement of the holes in the spindle pulley blank will need to be very accurate as well. I'm measuring and re-measuring for that operation next.

    New (to me) WM30 mill.-img_1192-jpg


    New (to me) WM30 mill.-img_1193-jpg

    Attached Thumbnails Attached Thumbnails New (to me) WM30 mill.-img_1192-jpg   New (to me) WM30 mill.-img_1193-jpg  
    CNC: Making incorrect parts and breaking stuff, faster and with greater precision.


  6. #30
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    Default Re: New (to me) WM30 mill.

    Job #2 is now done with the 'spindexer'. I got the tapped holes on the spindle pulley finished tonight. Fairly simple, 60* spacing, a spot drill to set the location followed by a 5mm drill for the grub screw holes and then a manual kiss with the spot drill to chamfer after tapping. It all went pretty well. I was concerned about my holes mating up correctly because I made the holes on the upper spindle a close fit clearance. There would not be a lot of wiggle room for misalignment and I'm doing this in 2 separate operations. I checked, double checked, triple checked the distance to the inner wall on the pulley to be sure I was positioning for the operation correctly. It all went off without a hitch really. I used a guide with my tap handle to keep the threads from wallowing around. When it slid on and seated on the upper spindle the holes lined up perfectly and the set screws are just long enough to bury down just below the chamfer in pulley wall. It feels completely solid once they are all torqued down.

    New (to me) WM30 mill.-img_1194-jpg

    New (to me) WM30 mill.-img_1195-jpg

    New (to me) WM30 mill.-img_1196-jpg



    Next I put it on the lathe to see if my results on run-out would be disappointing. At first it showed about 0.004" TIR on the pulley blank section. I know my chuck is good for about 0.0005" of that. The upper bearing journal was reading right at 0.001" so. With a bit of careful tightening of the grubs I was able to knock the pulley blank down to 0.0015". I'm pretty pleased with that. Once that is set then I can work my way around snugging all the bolts up till they are locked on tight and maintain that reading. For once I am happy with my results on a job like this. The pulley is sitting 6" from the chuck so I consider that pretty darn good.

    New (to me) WM30 mill.-img_1201-jpg

    New (to me) WM30 mill.-img_1199-jpg

    Next job is M8 grub screws on the motor pulley hub.


    In this build I am not going to repeat the mistake of using imperial sized hardware on my custom stuff. That became a real pain in the keaster on the PM-25, when you had to have every size of metric and imperial allen wrench and box wrench to work on it. This will be done in all metric since China made that choice for me

    Attached Thumbnails Attached Thumbnails New (to me) WM30 mill.-img_1194-jpg   New (to me) WM30 mill.-img_1195-jpg   New (to me) WM30 mill.-img_1196-jpg   New (to me) WM30 mill.-img_1201-jpg  

    New (to me) WM30 mill.-img_1199-jpg  
    CNC: Making incorrect parts and breaking stuff, faster and with greater precision.


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New (to me) WM30 mill.
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