ROCKWELL 21-122 milling machine REBUILD

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wally318
Posts: 141
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

ROCKWELL 21-122 milling machine REBUILD

Post by wally318 » Sat Sep 26, 2020 2:39 pm

In my previous thread I got the knee of the mill unjammed.
This was the beginning of the rebuild. In order to go forward
this had to be done first.
The mill is a Rockwell both horizontal and vertical.
I found it on Ebay a few years ago in Riverside, ca.
I live in Kelowna,BC The seller took it to the local
Fastenal and it was shipped to Ferndale,Wa. near
Bellingham. And I came down with a trailer about 250 mi.
and picked it up. In the meantime, I have been stock piling
tooling for it making parts for it, adapting and making
upgrades and accessories for it. Finish rebuilding a
12 x 24" belt drive lathe to make room for a Colchester
Chipmaster, which I will have up and running shortly.
As well as shop tools mics,verniers etc. All of it near the top
of the food chain, find/looking for all this stuff and finding deals
took a considerable amount of time besides working a full time job/
cycling & working on my audio system and time with my kids.
Let me tell you I made a lot of trips from Kelowna to Oroville,Wa
in the last few years to pick up tools and records through customs.
So here goes.

wally318
Posts: 141
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 » Sat Sep 26, 2020 2:52 pm

With the mill column on its back and the base off, I took the opportunity
to put the drum switch for the horizontal spindle inside the column.
Pic 1 is the holes drilled for it.
Pic 2 is an extension on the switch to deal with the column thickness.
Pic 3 is the switch installed.
Pic 4 is the the outside of the column- clean look, only the handle.

The swich is well tested for fit/function and mocked up and tested
for motor running and working.
The switch came in and out of the column many times till
I was happy that everything was as it should be.
Including flipping the mill over to grind the inside of the column
for lumps in the casting so that the switch fit nicely.
Let me tell you that was fun 1 handed angle grinding almost 2 feet
up the column almost totally blind. Except for 2 small holes to see a bit
and shine in some light.
Oops, forgot to add pics.
Attachments
P1040293.JPG
P1040294.JPG
P1040296.JPG
P1040297.JPG
Last edited by wally318 on Sat Sep 26, 2020 3:07 pm, edited 1 time in total.

wally318
Posts: 141
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 » Sat Sep 26, 2020 3:05 pm

Before the base came off, I had already
adapted the slotting head to the mill.
The slotting head is a Parkson that I brought
in from England. I think its from a 1N horizontal mill.
It has up to 2 inches of adjustable stroke.
You can angle the head 360 degrees as well as index the
cutter. It has a graduated holder.
Pic 1 is of the crank housing/block machined to slide
over the horizontal spindle seal cover as well as clearance
for the top of the column ways and mounting holes drilled.
Pic 2 are mounting holes drilled/tapped in the column.

Next I will go over all the vertical ways/dovetails before
putting the base back on.
Attachments
P1040299.JPG
P1040298.JPG

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NP317
Posts: 2693
Joined: Tue Jun 24, 2014 2:57 pm
Location: Northern Oregon

Re: ROCKWELL 21-122 milling machine REBUILD

Post by NP317 » Sat Sep 26, 2020 11:43 pm

Wow! Serious work you are doing.
Making a shop to make a shop. Old time fun.
Thanks for sharing.
RussN

wally318
Posts: 141
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 » Sun Oct 04, 2020 5:06 pm

OK. So I've totally gone over the ways on the column and the vertical ways on the knee.
I used a fine file to clean up any questional burrs at the edges(small chamfer)
and a fine diamond hand lap to touch up any questionable areas and a bit more attention to where the bolt head dug in.
A quick scrub with scotchbrite and varsol.
Then checked all the way surfaces with a parallel and 45 degree angle block.
Couldn't use a 60-angle looks to be about 55 degrees.
Next I put on the knee and then ground off about 7mm from the thin/damaged end of the gib.
Now the bolt head is inside the cavity and more thread grabbing. The top of the lower gib screw
threads seemed quite loose. I checked gib adjustment first, to see how much I could/should grind.
Re-set gib adjustment for a quick check.
Put the base back on the column-hopefully for the last time.
Before the base went back on, I cleaned out all the acumulated crud-oil/grease dirt and metal chips
to get ready for painting. And installed a better drain tube for coolant on the underside.
All the name plates/tags are removed and ready for paint.
When I'm ready to paint, I just have to remove the gearbox parts and spindle.
Then I can slide the knee up and off.
I will lift the mill up on blocks, use paint stripper on the base and then prime before paint.
The column can get paint on top of existing. Paint is still intact.
But for now The mill will sit as is in the corner. I'll put the saddle on loose and slide the table on
just to get it out the way. It'll sit there for now-while I get the Chipmaster up and running and
get the shop organized and tidied.
Attachments
P1040300.JPG
P1040301.JPG

LouStule
Posts: 40
Joined: Fri Sep 11, 2020 7:20 pm
Location: Washington State

Re: ROCKWELL 21-122 milling machine REBUILD

Post by LouStule » Mon Oct 05, 2020 6:24 pm

Kelowna BC is beautiful. Nice job on the mill too.

wally318
Posts: 141
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 » Sun Jan 10, 2021 11:11 pm

OK. Now we're ready to get into the thick of it.
I've removed the gearbox and associated parts, as well as the
spindle/bearings and slide the knee back off.
I weighed the knee just for the heck, its 75 pounds. Just the bare casting.
I've got the base/column up on blocks and the base stand.
Right now I'm stripping the paint off the base only. It was chipped up
quite badly. Also putting threaded fillers into threaded holes, about 10 of them on the
column. There were all sorts of things bolted to it that I didn't need and frankly made
it look quite ugly. The column still has most of paint intact.
So I'll prime the base and a bit of touch up in a few areas of the column and then
paint the final coats on the base and column together.
I'll be using a rust paint type enamel with Valspar enamel hardener mixed in.
I did a bit of research on painting machines a while back and came upon some
info on putting enamel hardener in regular Ace hadware type rust paints.
It was said the paint dryed harder-glossier and quicker than just the
standard rust paints on their own. Sounded like the ticket for getting
a more durable finish on a machine without the mega bucks expense.
and since the colum/base castings aren't real smooth will apply with brush.
Easier than spraying in my small shop area. No concerns about overspray
and covering everything up as well as proper mask for spraying with paint/hardeners
containing isocyanites.
The other smaller parts including the knee will get sprayed at work where we have more
suitable equipment for that, but more suitable to smaller stuff.

When taking off the gearbox and associated parts It was quite a mess inside.
I had a bit of a taste of it when moving the mill to get the lathe in the shop.
I had a couple bolts off the back for the adjustable pulley bracket and when
leaning the mill backwards what came out looked pretty ugly.
So here's a bit of the story as to why.
When I bought the mill back in 2015 the owner said that he took over his fathers shop.
And that his father had bought the mill about 40 years ago 1975. The model number of the
mill is 21-120 a horizontal only. And by looking at the vintage machinery site, was able to figure
out the mill dates to 1968. So the father bought the mill when it was about 7 yrs old and
added or it already had added a Vertical head to it. The son said the father NEVER used
the horizontal spindle in those 40 years. They were using it as a vertical only, specifically
for making some sort of brass/bronze gears, so it hat a small 1/3 hp DC motor/controller with 1 pulley
on the vertical head and the column had some sort of 4th axis controller bolted to it.
I guess for indexing. Both of which I sold right away. The shop lost the contract for the gears and
thats how I got it. So back to the mess in the gearbox. I'm guessing the backgear oil has maybe
never been changed in over 50 YEARS. It was just about as black as any oil you've seen
come out of a car when changing the oil and as thick or thicker than the thickest molasses
that you've ever seen.
I've thrown in a couple pics of column and of gearbox area and parts as well
Attachments
P1040313.JPG
P1040312.JPG
P1040314.JPG
P1040315.JPG

Lazz
Posts: 150
Joined: Sun Jul 29, 2012 11:06 pm
Location: The Warm Arizona Deserts... Phoenix to be precise...

Re: ROCKWELL 21-122 milling machine REBUILD

Post by Lazz » Tue Jan 19, 2021 1:26 pm

Ive got one of those...
I use it exclusively as a horizontal.
These are small foot print machines that can to the job.

My vintage 1968 mill started in the Morenci AZ school system and then spent some time as a sign for Moore Tools here in Phoenix
https://www.google.com/maps/@33.4767792 ... 312!8i6656

Thanks again John....

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liveaboard
Posts: 1337
Joined: Sun Dec 08, 2013 1:40 pm
Location: southern Portugal
Contact:

Re: ROCKWELL 21-122 milling machine REBUILD

Post by liveaboard » Tue Jan 19, 2021 6:09 pm

That should be illegal.

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