After getting my new(old) lathe, 101.07381 I discovered that the big 2-step drive had a crack clear through one of the spokes. When I found a replacement on Ebay the fellow wanted nearly as much as I paid for the whole lathe so decided to do it myself.
Starting with a 1.5"x9.5"x12" slab of 6061 AL I cut it square with the table saw and knocked off the corners. I roughly laid it out using DyeChem, compass and rule then went to the drill press to drill and tap 3/8-16 holes for mounting to a faceplate and drilled/tapped holes for set screws to lock it to the counter shaft. While there I used a holesaw to knock out 1.75" holes defining the spokes. This was a big mistake causing interrupted cuts in most of the facing cuts and really slowing things down. Sometimes I'm penny wise and pound foolish but I did end up with four 1.5" long x 1.5" diameter chunks of AL to use somewhere else.
I bolted to a face plate to rough it out, getting near finish diameter, thinning the web to within a 1/16" and drilling the center hole then flipped it over and thinned the web on the other side.
To finish it to size and cut the grooves I mounted it to a shaft and turned it between centers.
After balancing and mounting the lathe runs a lot smoother
I took about 2 dozen picks if anyone wants to see them.
MikeMc
Starting with a 1.5"x9.5"x12" slab of 6061 AL I cut it square with the table saw and knocked off the corners. I roughly laid it out using DyeChem, compass and rule then went to the drill press to drill and tap 3/8-16 holes for mounting to a faceplate and drilled/tapped holes for set screws to lock it to the counter shaft. While there I used a holesaw to knock out 1.75" holes defining the spokes. This was a big mistake causing interrupted cuts in most of the facing cuts and really slowing things down. Sometimes I'm penny wise and pound foolish but I did end up with four 1.5" long x 1.5" diameter chunks of AL to use somewhere else.
I bolted to a face plate to rough it out, getting near finish diameter, thinning the web to within a 1/16" and drilling the center hole then flipped it over and thinned the web on the other side.
To finish it to size and cut the grooves I mounted it to a shaft and turned it between centers.
After balancing and mounting the lathe runs a lot smoother
I took about 2 dozen picks if anyone wants to see them.
MikeMc
