Part 6- The Index Head Base
UNIVERSAL TOOL AND CUTTER GRINDER
Note: The spring loaded adjustable levers are two sizes. They can be positioned in six positions around their circumference. Many times when taking off the parts it is easier to remove the lever and use a 8mm or 12mm nut driver instead of the lever. That is why in some of my pictures you will see the lever removed.
Unscrew the Base from the Index Drum.
A quadrant is an instrument that is used to measure angles up to 90°.
Now The Main Axle and the Base can be removed (See Part #5 for removing the MA).
The next step can be done on a Lathe or Milling Machine using a Rotary Table.
The method would be pretty much the same, I used a Rotary Table.
The Base must be precisely dialed in. Using the MA as a guide rotate the part until
the height of the axle is the same on both sides. Also, the Base must be exactly on
center of the Rotary Table.
This is a clean-up cut only, take off as little material as possible.
As you can see in the photo I still have a little original green material showing.
Last I put a very small relief using a dovetail cutter to make sure the
Index Drum would not drag on the bottom corner.
Index Base Clamping Lever:
Using the grinder I found that many times the Index Drum Clamping Lever was in the way of moving the Base Lever or worse pinch your fingers. The levers can be re-positioned but this is not always convenient. I made several longer bolts, each longer than the last and ended up with 2” of stick-out to allow the Index Base Clamping Lever enough clearance to completely pass by the Index Drum Lever. I also made a new brass capture nut ½” longer (not shown).
· Chuck a rod in the lathe, I used 3/4" diameter. The new part will be 4” in length including the hex end and the thread.
· Turn down the handle ind to .545” or until it will fit into the lever up to where the hex begins, then turn off about .250" more to allow for the hex.
· Drill and tap the M5-0.8 thread for the Lever Screw.
· Cut it off, reverse the part in the lathe and make the threaded M6-1.0mm screw.
· Chuck it in a Rotary Table, Spindex or whatever you have to machine six sides of the end.
The Axle hole that connects the Index Head and the Index Drum is very poorly made. I set up the Base on the mill and dialed it in to the top shoulder. I used the 10mm axle to find the center of the hole and bored it out for a new bronze bearing. I found the proper size at Ace Hardware. I also made a new, longer brass capture nut. These are standard machinist operations and not detailed. In the next article I will go into more detail about the bronze Bearings. You can see the Base after shots in Photo #009.
* WORK NOTES:
If the nylon bearings come off, or in my case I took them off (don't do it) they may be re-attached with cyanoacrylate (Super Glue).
Terminology of parts Disclaimer:
Several names of the parts have been taken from the Deckel Catalog; to insure you the reader, will always know what part I am referring to. I have applied the identification of parts from other machines, catalogs and some I created for a clear description of the parts function, (eg. Top Slide Tool Holder).