ROCKWELL 21-122 milling machine REBUILD

[wally318]

This next one is for all the guys in the Rockwell group that were discussing
how to repair the aluminum gear for the head tilt with a new keyway.
I used a steel ring with a 3 inch ID for a demo mock up, so just slightly smaller.
Raised it on 1 inch blocks and clamped. Pic 3 shows just enough clearance to complete
the cut.
The attachment is a Bridgeport No.2 right angle head which is designed for a
2.563: dia. quill and has been bored out to 2.95" and has a drive shaft extension
that is 3/4" dia.
A No.4 head could also be adapted would still need and extension drive shaft
but no boring just a steel or aluminum sleeve to adapt from 3.376" to 2.95"
A No.2 head is m ore versatile it has a 1 inch longer reach.
These heads can be bought used on Ebay. Sometimes you can find a deal.
The 1/4 inch endmill has a shortened shank section.
There are specialized endmills out there with even shorted cutting flutes that
would allow access to even tighter situations.

[wally318]

Well this is the next accessory that I made up for the mill.
A faceplate and a topslide adaptor bracket to be able to
turn and bore items too large to put on a faceplate on my
Chipmaster. Face plate on that is 10-7/8" and 11-1/2 " swing
The face plate here is 12-1/8" and can swing over 19 inches x
4-1/2" deep. I found the faceplate on Ebay for 100 to 125.00
and the machined it and made an adaptor brkt for the horizontal spindle.
Not that you would put a solid hunk of metal that large
on the faceplate. But there may come situations where an awkward
shaped part may be well served with larger faceplate turning ability.
By de-rating my speeds on the horizontal spindle I have a 38 or 39 rpm
low speed, well suited to spinning larger items.
The topslide comes off my Chipmaster with 2 nuts and bolts onto the
adaptor plate and then onto the mill table with 4 bolts.
There are 2 alignment pins to register the 0 degree point.
While I have the mockup in situ to showcase this accessory,
I think I true up the faceplate .

[NP317]

Creative!
RussN

[wally318]

Well the faceplate is trued up.
When I was checking fit and runout I got .055 on the face
and .015 on the circumference.
Seemed way too high considering the back of the faceplate
was turned at work on a lathe mounted to a faceplate that
was true.
So I started by remov ing the drive key and remounting it.
That got me to .030 and .014".
I thought about that and decided to take off the faceplate
and face the end of the spindle.
That got me to .011" and .001 on the circ.
Couple skim cuts and the face was true to within .0005"
and the .001 on the circ. not worth worrying about.

[wally318]

Here is the newest accessory, I just finished the other day.
Power feed for the knee.
2" dia. hub with 1/4" dowel pins and 1/2 inch hex stock
set screwed to the hub.
Put into a cordless drill and use as needed when there
is lots of up and down. Works as good as the power feed
for the longditudal. But not in the way when you don't
need it/and banging your knee on it.
Stay tuned-I have lots more accessories to debut.
Just haven't had time to set them up and post.

[wally318]

Tomorrow I with with pics my solutions for cutter sharpening.

[wally318]

Several yrs ago I bought a Darex endmill sharpener.
Paid 700 US for it on ebay and put it in storage.
Fall of 21 my company was getting ready for a move
and among other things won a silent auction for the
almost new(old but almost never used) for 53.00 CDN
We paid about 5000.00 CDN for it with the CBN wheel.
So I gave the older one to a friend from work for the
53.00 I paid for the new one-so cost me 53.00 to upgrade.

[wally318]

So I came up with the idea(s) to make this sharpener/grinder
be able to sharpen most of the cutters in the shop. Or-be
self sufficient.
Pic 1 is of the stock stylus used to guide the sharpening
of the side teeth(helical) on endmills.
It has a .010" dia tip. Not very suitable for dealing with the weight
of helical slab cutters.
PIc 2 is of my mod with an adjustable ball bearing sylus.
Pic.4 are the 1" and 1-1/4 dia arbors to hold the cutters
in a 5C collet.
Pic. 5 is the stylus set up(mock up) on a 4 inch long 3: dia. cutter.

[wally318]

For plain horz. milling cutters I bought an Eagle Rock milling
cutter grinding fixture on Ebay. It is designed for putting on
the table of a surface grinder.
And modified it to present to the Darex wheel
in a horizontal fashion instead of the vertical position
that would be used on a tool and cutter/surface grinder.

[wally318]

I found a deal on the ball mill/radius grinding attachment for the Darex.
They typically sell for 600-900.00 US, I got this one for 300.00
I had to make the 5C collet drawbar and give it a good going over.
Pic.2 shows it in a mock set-up using a square 5C collet to sharpen
a HSS threading tool. I also plan to use it to sharpen slotting cutters
to use in the Parkson slotting head that I adapted to the horizontal spindle.
More on that later.

[NP317]

Enviable tooling!
RussN

[Bill Shields]

I have one of those darex grinders and really like it.

I you come across another ball mill attachment...let me know