. jAlbum 9 Machining bearings.<br><br> slides/009.html# Tue, 25 Sep 2012 01:50:08 -0400 Milling the sleeve to a "half-pipe". The outside diameter of this casting has already been machined, and the locating nipples filed to match the holes in the crossbox. With these two tasks done, the bronze was clamped into the crossbox and lines were scribed to define the required height of the finished half-pipe. After leveling up according to the layout lines, the casting was strapped down to the V-blocks, and milled down to these layout lines. Three cuts on each side is the usual order of business: two bigger cuts, and one light finishing pass. Could most likely be done in two, but why take the chance in ruining many hours of work, and a good casting?<br><br>Photo by Rick Brigger. Milling the sleeve to a "half-pipe". The outside diameter of this casting has already been machined, and the locating nipples filed to match the holes in the crossbox. With these two tasks done, the bronze was clamped into the crossbox and lines were scribed to define the required height of the finished half-pipe. After leveling up according to the layout lines, the casting was strapped down to the V-blocks, and milled down to these layout lines. Three cuts on each side is the usual order of business: two bigger cuts, and one light finishing pass. Could most likely be done in two, but why take the chance in ruining many hours of work, and a good casting?<br><br>Photo by Rick Brigger. slides/009.jpg slides/011.html# Tue, 25 Sep 2012 01:50:08 -0400 Top half of axle sleeve being coped (grooved) so that the bottom gear shaft sleeve can be stacked upon it like a Lincoln Log. Single-point cutter is set to swing a 2.625 radius, to make the saddle come out correctly for the 5 1/4 inch diameter gear shaft sleeve to nest nicely into place. Several cuts were taken, each about .050 in depth. Between cuts, the head of the machine was lowered straight down to deepen the groove. <br><br>Photo by Rick Brigger. Top half of axle sleeve being coped (grooved) so that the bottom gear shaft sleeve can be stacked upon it like a Lincoln Log. Single-point cutter is set to swing a 2.625 radius, to make the saddle come out correctly for the 5 1/4 inch diameter gear shaft sleeve to nest nicely into place. Several cuts were taken, each about .050 in depth. Between cuts, the head of the machine was lowered straight down to deepen the groove. <br><br>Photo by Rick Brigger. slides/011.jpg slides/012.html# Tue, 25 Sep 2012 01:50:08 -0400 A closer look. The placement of the cut was determined by placing the sleeve in the crossbox, and scribing an oval, with a scriber being guided by the opening between the two opposite saddles on the crossbox. <br><br>Photo by Rick Brigger. A closer look. The placement of the cut was determined by placing the sleeve in the crossbox, and scribing an oval, with a scriber being guided by the opening between the two opposite saddles on the crossbox. <br><br>Photo by Rick Brigger. slides/012.jpg slides/018.html# Tue, 25 Sep 2012 01:50:08 -0400 Cross box indicated true, with one sleeve in place, along with the boring bar, prior to installing the other half of the assembly. The braze is a repair to secure an ear that was broken, cracked but not missing! <br><br>Photo by Rick Brigger. Cross box indicated true, with one sleeve in place, along with the boring bar, prior to installing the other half of the assembly. The braze is a repair to secure an ear that was broken, cracked but not missing! <br><br>Photo by Rick Brigger. slides/018.jpg slides/027.html# Tue, 25 Sep 2012 01:50:08 -0400 The assembled bearing, with proper shim pack in place, ready for boring. Ain't this crew a real confidence builder? <br><br>Photo by Rick Brigger. The assembled bearing, with proper shim pack in place, ready for boring. Ain't this crew a real confidence builder? <br><br>Photo by Rick Brigger. slides/027.jpg slides/030.html# Tue, 25 Sep 2012 01:50:08 -0400 The first cut, which really could have been heavier without taxing either the machine, or setup. Finish bore will be a smidge over the 5.500 inch axle diameter. The cardboard box is to catch the bronze cuttings. It is unbelievable how much metal comes out of this boring operation. After boring six bearings (three completed cross boxes) two five-gallon pails of shavings have been recovered. <br><br>Photo by Rick Brigger. The first cut, which really could have been heavier without taxing either the machine, or setup. Finish bore will be a smidge over the 5.500 inch axle diameter. The cardboard box is to catch the bronze cuttings. It is unbelievable how much metal comes out of this boring operation. After boring six bearings (three completed cross boxes) two five-gallon pails of shavings have been recovered. <br><br>Photo by Rick Brigger. slides/030.jpg