The Home Machinist!

Check out Martin Model and Pattern. He sells castings of a variety of flywheels and drivers. I do his 3D printing for patterns and he boards the patterns and obtains castings.

http://www.martinmodel.com/MMPpatterns.html

Since you already have a model file, you are half way there.

Original wood screws were often not tapered. I have some mid 1800's muzzleloaders that had wood screws with the wood thread screw form, but a blunt end. The only difference in use was that the hole has to be predrilled at the minor diameter to install the screw and prevent spitting in the wood. It's...

Don't bother. Instead, print a few layers of material under the part. By the time the layers of foundation are printed, the surface is as flat as it will ever get on the printer. The dimension printers use .1" of support material under the part to generate a true, flat surface on which to build...

NOOOOOOOOOOOOOO!!!!!! If you double up the wheels, the gap between the wheels makes a nice spot for swarf to pack. If anything packs in there, the wheels are side loaded and they go bang. Same thing if the corner of the wheel chips out between the two wheels. The chip can easily wedge and again go b...

I have made flats, straight edges and small surface plates from granite counter top. Generally they were within about .005". You either need reference surface or three pieces of granite. If using 3 pieces, get some diamond lapping compound and work the three pieces by lapping 2 at a time while ...

Occasionally you luck out. Generally HF tools need some rework, but the quality is generally getting better, but the prices are going up at a good pace.

Easy with the right orientation, a shaper and an offset cutting tool.

Can a single pin go through? If so, the pin holes in both the hinge and Base could be rearmed and honed if necessary for a fit and then snap ringed into place. If the center must remain clear, then threads with anaerobic locking compound would work. If radial adjustment is needed, four-way split the...

I have done several repairs of similar failures in Emmert patternmaking vises. I used Harris-Welco 17FC flux coated brazing rod and additional white paste silver soldering flux. The rod material is essentially monel. I grind and then file both surfaces clean. Grinding alone wipes graphite across the...

drill a wood block to just slightly smaller than the OD of the sphere and make a similar ring of wood. Use some deck screws to pull the two together. Then just cut right through the wood. The spherre is supported close to the outside edge and will be much less likely to roll in the cut.

Lay a steel rule across the top of the pipe and push down with a centerdrill point. Then adjust position until the scale is level. That puts you on center. Then centerdrill and final drill.

First try reducing the OD very slightly on the two pinion gears that contact the spindle gear. Then just live with it or glop it up good with heavy grease to reduce the impact, wiping and rubbing of the gears.

I had one of those lathes and it worked OK. Not stellar, but OK.