Miscellaneous stages in the making...


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I haven't had time to colour match or adjust the exposures of these shots so the quality varies considerably. Some were shot outside at night with flash, some with natural light, some indoors with tungsten or window light - so the colours are very variable. Still, I thought someone might find them useful so here they are.

[Left] Each pocket was cut initially with slot drill chosen to suit the corner radius and then finished with a bull-nosed cutter to match the original pocket's bottom profile.

All the table machining had to be completed outdoors as the machine wouldn't fit inside in its current form. (If you think your shed is cold, you should try machining outside in the yard in the middle of winter with just a bit tarpaulin for a roof.)
   Tom Senior Major ELT milling machine, cutting new table pocket

[Left] Drilling three extra fixing holes in the bottom of the upturned body to combat the extra overhung weight/leverage of the head.

[Right] Drilling corresponding holes in the base using a drill press clamped in place to obtain the necessary leverage and alignment. Although these holes were tapped, security nuts were also added underneath at assembly time for extra peace of mind.
   Tom Senior Major ELT milling machine, base drilling    Tom Senior Major ELT milling machine, stand drilling

[Left] Craning the completed body into position on the finished base. Notice how the chip tray corners have been chamfered at the rear to get the base tight into the corner. (For more info on the crane, see the article featured on the homepage.)

[Right] A test to confirm that horizontal operations would be practical with the head still in-situ on the overarm.
   Tom Senior Major ELT milling machine, assembling body to base    Tom Senior Major/Bridgeport head, horizontal milling test

More pics to come when I have them.




Neil Fazakerley, 2010.

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