DECKEL FP1 REPAIRING THE SLOW FEEDS PAGE 1
REPAIRING THE SLOW FEEDS AND PREPARING THE MACHINE FOR IT`S NEW LIFE
NOW THE MACHINE IS IN MY WORKSHOP AT HOBØL THE WORK IS STARTING ON REPAIRING THE SLOW FEED SYSTEM WHICH WAS NOT WORKING WHEN I BOUGHT IT. HERE ARE SOME PHOTOS OF THE MACHINE BEING DISMANTLED IN ORDER TO DIAGNOSE AND PUT RIGHT THE SLOW FEED PROBLEM.
AFTER CUTTING AWAY PART OF THE PALLET THAT IT WAS DELIVERED ON, THE CRANE WAS ABLE TO BE MANEUVERED TO BE ASTRIDE THE MACHINE AND LIFT IT OFF ONTO THE FLOOR WHERE THERE IS PLENTY OF WORKING SPACE AROUND IT.
THE SADDLE WAS WOUND TO THE RIGHT AS FAR AS IT WOULD GO AND THEN AFTER REMOVING THE RIGHT HAND END PLATE THE TABLE WAS SLID TO THE LEFT SO THAT THE X AXIS LEADSCREW NUT COULD BE REMOVED BY UNSCREWING THE COLLAR HOLDING IT IN PLACE IN THE SADDLE. THEN THE LEADSCREW AND NUT ASSEMBLY WAS REMOVED AND ALSO THE TABLE.
THE ABOVE PHOTOS SHOW THE BODY OF THE SADDLE. WE CAN SEE THAT THE LEADSCREW REVERSING SHAFT AND LEVER THAT SHOULD BE PRESENT IN THE RECESS IN THE CASTING ARE COMPLETELY MISSING!
ABOVE IS THE SADDLE REMOVED AND LAID DOWN ON A TABLE. THE RIGHT HAND PHOTO SHOWS THE FEED GEARS TO THE X AXIS SLOW FEED IN CLOSE UP. THE PROBLEM HERE IS THAT THE SMALL BEVEL GEAR HAS SHED THREE TEETH AND SEIZED TOGETHER WITH THE LARGE BEVELS THAT`S THE REASON FOR THE LACK OF SLOW SPEEDS.
ABOVE, THE FEED REVERSING ASSEMBLY SHOWN WITHOUT THE BEVELS
AFTER THE X AXIS FEED SHAFTS AND BEVELS WERE REMOVED THE REMAINING SMALL BEVEL HAD TO BE EXTRACTED FROM THE DRIVE SHAFT. ABOVE LEFT SHOWS THE SMALL BEVEL IN SITU AND ABOVE RIGHT THE EXTRACTORS THAT I USED TO REMOVE THIS WITH. ON THE RIGHT, A CUT DOWN COMMERCIAL PULLER., THIS WAS A FAILURE AS i COULDN`T GET ENOUGH FORCE TO BUDGE THE BEVEL. NEXT I MADE THE PULLER SHOWN ON THE LEFT HAND SIDE FROM A LENGTH OF 2 INCH PIPE AND BORED IT OUT TO SLIP OVER THE BEVEL OD.
AS I HAD DRILLED OUT THE STUBBORN PIN THAT HAD REFUSED TO BE DRIVEN OUT, I DRILLED OUT THE PIN DIAMETERS TO 8MM IN THE HUB OF THE BEVEL TO MAKE SURE THAT NO REMNANTS OF THE PIN REMAINED TO HINDER THE BEVEL BEING REMOVED FROM THE SHAFT.
THESE HOLES WERE USED TO LOCATE PINS FROM THE PULLER BUT AFTER A LARGE TORQUE WAS APPLIED TO THE PULLER BOLT NO MOVEMENT OF THE GEAR WAS OBSERVED AND THE PIN HOLES IN THE BODY OF THE PULLER WERE BEING DISTORTED, SO AGAIN A FAILURE!
THE NEXT STEP WAS TO TURN A NEW PULLER FROM 2 INCH SOLID BAR AS SHOWN IN THE MIDDLE OF THE ABOVE RIGHT PHOTO.
AS I HAD DRILLED OUT THE STUBBORN PIN THAT HAD REFUSED TO BE DRIVEN OUT, I DRILLED OUT THE PIN DIAMETERS TO 8MM IN THE HUB OF THE BEVEL TO MAKE SURE THAT NO REMNANTS OF THE PIN REMAINED TO HINDER THE BEVEL BEING REMOVED FROM THE SHAFT.
THESE HOLES WERE USED TO LOCATE PINS FROM THE PULLER BUT AFTER A LARGE TORQUE WAS APPLIED TO THE PULLER BOLT NO MOVEMENT OF THE GEAR WAS OBSERVED AND THE PIN HOLES IN THE BODY OF THE PULLER WERE BEING DISTORTED, SO AGAIN A FAILURE!
THE NEXT STEP WAS TO TURN A NEW PULLER FROM 2 INCH SOLID BAR AS SHOWN IN THE MIDDLE OF THE ABOVE RIGHT PHOTO.
ABOVE, AFTER TURNING THE BODY OF THE PULLER ON THE BOXFORD VSL, I USED THE RAGLAN MILL TO MACHINE AWAY THE SIDE OF THE PULLER BODY SO THAT IT WOULD SLIP OVER THE SMALL BEVEL.
ABOVE LEFT, PULLER No. 3 JUST FINISHING THE EXTRACTION OF THE BEVEL FROM THE SHAFT. ACTUALLY I HAD TO MODIFY PULLER No. 2 BY SHORTENING IT AND DRILLING AND TAPPING 3 EQUI SPACED HOLES FOR 8MM GRUB SCREWS THAT ENGAGED BEHIND THE BEVEL, THIS WAS SUCCESSFUL BUT REQUIRED EXCESSIVE TORQUE TO MOVE THE BEVEL ON THE SHAFT.
ABOVE RIGHT IS SHOWN THE REASON FOR THE DIFFICULTY IN REMOVING THE BEVEL, WHICH WAS. DUE TO THE CATASTROPHIC FAILURE OF THREE TEETH ON THE SMALL BEVEL LOCKING UP THE FEED REVERSING ASSEMBLY IN THE SADDLE.
THIS CAUSED THE SHAFT TO ROTATE 360 DEGREES WITHIN THE BEVEL, SHEARING THE PIN AND TEARING THE METAL ON THE SHAFT AND THE BORE OF THE BEVEL.
AS THE ROTATION OF THE SHAFT WAS 360 DEGREES IT GAVE NO EXTERNAL CLUE AS TO WHAT HAD HAPPENED SO THAT`S WHY IT WAS EASY TO ASSUME A WRONG DIAGNOSIS.
ABOVE RIGHT IS SHOWN THE REASON FOR THE DIFFICULTY IN REMOVING THE BEVEL, WHICH WAS. DUE TO THE CATASTROPHIC FAILURE OF THREE TEETH ON THE SMALL BEVEL LOCKING UP THE FEED REVERSING ASSEMBLY IN THE SADDLE.
THIS CAUSED THE SHAFT TO ROTATE 360 DEGREES WITHIN THE BEVEL, SHEARING THE PIN AND TEARING THE METAL ON THE SHAFT AND THE BORE OF THE BEVEL.
AS THE ROTATION OF THE SHAFT WAS 360 DEGREES IT GAVE NO EXTERNAL CLUE AS TO WHAT HAD HAPPENED SO THAT`S WHY IT WAS EASY TO ASSUME A WRONG DIAGNOSIS.
ABOVE LEFT, THE THREE BEVEL SET SHOWING THE THREE BROKEN TEETH ON THE SMALL BEVEL . THE BROKEN AREA HAS A CRYSTALLINE STRUCTURE, INDICATING THAT THE TEETH HAD BEEN HARDENED ALL THE WAY THROUGH WHICH WOULD MAKE THEM BRITTLE. THE TWO LARGER BEVELS SEEM TO BE UNDAMAGED ABOVE RIGHT, THE HARDENED WASHER SITUATED BETWEEN THE BRONZE BUSH AND THE SMALL BEVEL BOSS. UNUSUALLY, THERE ARE TWO 2mm PINS WHICH HOLD THE WASHER CONCENTRIC WITH THE BUSH. BOTH PINS ARE SHEARED AND THE PIN HALVES ARE STILL STUCK IN THE BRONZE BUSH.
HOPEFULLY, THEY WILL NOT BE TOO DIFFICULT TO REMOVE
HOPEFULLY, THEY WILL NOT BE TOO DIFFICULT TO REMOVE
ABOVE, I RECEIVED THE COMPONENTS FROM FRANZ SINGER TO REPLACE THE MISSING PARTS FROM THE X AXIS CHANGE OF DIRECTION ASSEMBLY. THEY COST 460 EUROS AND THE CUSTOMS DUTY WAS 1200 NOK!!!
ALL I NEED NOW ARE A SET OF X AXIS BEVELS TO REPLACE THE BROKEN ONES.
ALL I NEED NOW ARE A SET OF X AXIS BEVELS TO REPLACE THE BROKEN ONES.
ABOVE LEFT IS THE LITTLE GEARBOX FOR THE SLOW FEEDS VERTICAL AND HORIZONTAL CONTROL. IT LOOKS AS GOOD AS NEW. THE RIGHT HAND PHOTO SHOWS THE TOP OF THE COLUMN WITH THE HORIZONTAL HEAD REMOVED. THE GEAR IS HARDENED AND GROUND AND SHOWS NO WEAR AFTER 50 YEARS OF USE.
ABOVE LEFT THE HORIZONTAL HEAD AND THE SADDLE TABLE SLUMBERING ON THE FLOOR AND ON THE RIGHT THE DECKEL CABINET SUPPORTING THE DRILL AND THE MES VERTICAL SURFACE GRINDER.