My tool post turned out to be a few thousands too short, but I was able to remedy this easily by shimming the cutting tool. Once the cap is cut off, the tool can be removed from the lathe and placed on the assembled tool base (which has been mounted on the lathe) to determine the appropriate length needed to get the cutting tool at the proper height. The bolts should have a 0.45" shank (un-threaded portion) I used bolts with a longer shank and added additional threads with a die, then cut the bolts to length. They are made from 1/4" bolts hack-sawed to length, and drilled brass rod. Countersink the holes in the coupling, and tap the holes in the top plate. Use a center punch to punch a couple of witness marks in both the coupling and the top plate to show the original alignment, so the parts can be re-aligned later.Īfter drilling the pilot holes, disassemble the "sandwich" and finish drilling the holes to the required sizes. The coupling, top, and bottom plates are then clamped together in a "sandwich" and four pilot holes are drilled through both the coupling and the top plate. The coupling holes are drilled by marking out the locations on the coupling. The top plate was faced on both sides the bottom plate was faced on the top surface only. I used an indexable carbide tool for this, although I am sure that an HHS tool would work as well (possibly better, as this is an interrupted cut, which can cause chipping with carbide tools). The plate surfaces were then "smoothed" by mounting the plate in a four jaw chuck on the lathe, and then facing the surface. The other two edges were left as they were on the original piece of steel.
I cleaned up the cut edges as noted earlier. Next, measure and cut two pieces 3 inches long.