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  1. #46
    Join Date
    Sep 2009
    Location
    Sydney
    Posts
    399

    Default Rockwell Bandsaw Identification, Help and Conversion

    Went to a local fab shop during the week and bought some 32mm round and 10mm plate. The intention is to push ahead with the reduction drive parts so I can finally get this bandsaw working. I have a real need for it, so want to get it up and running, but loads of other projects keep popping up and taking priority.

    The problems with making all these parts is:

    1. They take quite a bit of time
    2. Some of them are 5Ē which fits in my lathe but the flat belts keep slipping and so I really need to upgrade the lathe to a belts (Hercus C), so I have to chat to Mal about whatís involved.
    3. Cutting plate is a pig. I only have an angle grinder which works, but a plasma cutter would make it much less of a chore.

    First up I turned the bush. Itís a stepped arrangement so the larger step will take the plate to mount the larger sprocket to. The smaller step will have a 10t sprocket welded straight to the bush. To mount the larger sprocket I need a carrier. So I cut one out of plate and then had to make it round on the lathe. Interrupted cut and I only had threaded rod to attach it to the chuck. Didnít work well but was able to slowly take cuts and get it round.



    Next up I put it on the bush and welded the rear section. Time for some holes. Got to try out my new DRO and bolt hole function. Wow how easy. Not only drilled mega easy but the fit is exceptional!



    Hereís the side that will take the small sprocket. I need to turn this shoulder further in, but thatís a job for next time.



    Other side. This will be drilled for a set screw to lock it to the 17mm jack shaft:



    The holes lined up perfectly. Have to say the DRO makes a huge difference here. I need to buy some cap headed bolts with a shorter length and nylocks (this was a test fit with what I had on hand):





    This smaller sprocket needs to be drilled out to 22mm but Iím not sure how to do that yet. I suspect Iíll need to mount it in the 4 jaw chuck or maybe buy a boring head for the mill.

    Then I just need to make 3 more Rockwell Bandsaw Identification, Help and Conversion

  2. #47
    Join Date
    Sep 2009
    Location
    Sydney
    Posts
    399

    Default

    The sprockets are hardened, so boring out the centres to 22mm is going to be a challenge. Anyone have any advice on how to manage?

    I was going to give to a mate and have him chuck all 4 in his wood burner and leave them overnight.

    Thought was it would anneal them ready for machining, before I try and harden/temper the teeth again.

  3. #48
    Join Date
    Sep 2009
    Location
    Sydney
    Posts
    399

    Default

    I came up with a solution for the sprockets. Had a mate take them home and chuck them in his wood burner overnight. It definitely seemed to anneal them and made boring them much easier. To bore them out I put them in my 4 jaw chuck and eyeballed them straight. 2 jaws on the lower part of the teeth and 2 on the upper. Carbide inserts seemed to go ok but interrupted cut so I went very delicate on the depth of cut.

    Unfortunately I didnít get any pics of the process.

    Today I made another sprocket carrier, the one on the jack shaft that has a large sprocket only. Same process as before but much easier now I have gotten rid of the flat belts on my Hercus 9C. I have the opposite problem now which is the cut depth can be so good and I need to keep a good DOC on carbide anyway, that I nearly overshot on 2 parts. Luckily it fit exactly both times Rockwell Bandsaw Identification, Help and Conversion

    So most of my jackshaft parts are done. This is the motor driven arrangement. The setup on the right is driven by the motor and the sprocket on the left is driven by the small sprocket on the right.





    They will be attached to the shaft by a couple of set screws on the backs.

    Here is a mock up of how it will all connect:



    Whatís left?

    I need to make another sprocket carrier for the bandsaw, another one for the small sprocket on the end of the jackshaft, plus one for the motor itself. 3 total and itís mostly done.

    The big sprockets are bolted together, so an easy replacement. However to get the right reduction ratio Iíve had to use 10T sprockets as the smaller ones and so these will have to be welded. I donít want to weld them unless I can try and re-harden them.

    I tried to harden them yesterday but I canít get them hot enough. Not sure if itís actually a problem give how little theyíll be run, but Iíd prefer to if I can.

  4. #49
    Join Date
    Sep 2009
    Location
    Sydney
    Posts
    399

    Default Rockwell Bandsaw Identification, Help and Conversion

    In the shed for an hour or two this afternoon and I have the majority of the jackshaft finished. Fingers crossed it fits under the saw as I built it up on the bench, but Iím quietly hopeful.





    I was going to put an adjustable slot for one of the shafts but havenít yet, might see how I go first as the rotation of the chain seem to self tighten a little anyway.

    Itís super smooth and works beautifully.

    https://youtu.be/VNgfWyCKVZ8

    Just need to make another couple of carriers for the sprocket at the rear, one for the rear of the jackshaft and the one for the saw itself.

    I had a 10T on the motor but will change it out for a 13T as it didnít have enough meat for me to be comfortable with the setup. I have the 10T welded to a carrier already but would prefer to have more meat on it and look to slow the motor down instead.

    Before anyone says anything. The bolts are temporary. I have 1 set screw in each carrier at the moment but will probably fit 2 on each.

    Annoyingly I should have put some registers in the sprocket carriers (large ones) to centre the sprockets. Might still do it so I can get them nice and centred.

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