Index Model 645 Mill

I haven't been able to do much with the mill lately due to other obligations and projects. But I did score a used 3 hp rotary phase converter on eBay for a reasonable price, which arrived yesterday. I was able to spare an hour or so this evening and temporarily wired it and the mill up. I am excited to report that IT LIVES! The spindle motor runs smoothly and quietly. The spindle feed works in both directions and all three speeds, although one neutral position on the speed selector seems a little finicky. The table power feed motor shakes quite a bit - I assume due to the belt sitting in one position for years. Also one of the gear selector levers is stuck.

Now I'm even more anxious to get the mill cleaned up and moved into my shop...:grin:
 
......snip....... The table power feed motor shakes quite a bit - I assume due to the belt sitting in one position for years. Also one of the gear selector levers is stuck....:grin:
The stuck gear selector lever is NOT stuck! That is the interlock doing its job. One has to be in the middle or neutral position for the other lever to move and vise-versa. Don't force it! Might be advisable to take the gear box apart, clean, re-assemble. Fill with oil. Ken
 
Good to know. I'll give that a try.

I need some advise/guidance on disassembling the mill for cleaning and moving. I have an engine hoist to help with the heavy parts. This is my rough plan for now:
  1. Remove spindle motor
  2. Remove spindle feed gear box
  3. Remove head from ram
  4. Remove ram
  5. Remove table
  6. Remove saddle
  7. Remove knee
One issue I've identified is that the ram is frozen in place. Unfortunately, I broke the ram positioning shaft while trying to get it to budge:cower:. If I protect the back end of the ram with some wood, can I hammer on it lightly (or heavily) to move it? (All this with the clamping bolts loosened of course)

Also I may or may not remove the knee depending on how much of a pain it's going to be.
 
Go easy on taking things apart. Parts for this old mill are almost untainable today!
Removing the spindle motor is cut and dry. Next thing you want to do is remove the belt drive/guard housing. Should be four 3/8" socket head cap screws accessible from the top flange of the head under the belt guard to remove. Belt guard is heavy, get some help handling it! Once these four bolts are removed, you should be able to remove it without removing the spindle pulley or brake. I'm doing from memory, so correct me if I'm wrong! The spindle feed box is more complicated and will require you to remove the guts from it before you can remove the housing. It's been too many years ago since I removed the one on my mill. In fact, it doesn't exists on my mill today. That's another story for another time. The head is pretty straight forward to remove from the ram. Again, it is slightly heavy. Before removing, pull the spindle pulley from the housing. Once you get it out of the way apply some ATF fluid mixed with Acetone in the top of the spindle quill and let soak. Keep applying for about a week. Don't try to beat the spindle out yet!!! There is a certain sequence of events that you you go thru before beating on it. In fact I don't encourage it at this point. I'll report back on what to do. Got to go look at mine and recollect from memory how I did it on my mill. Ken
 
I had a 645 that was probably the ugliest machine I ever bought. I'm glad that someone painted lime green because nobody was interested in it and I got it for little more than scrap price. I put a lot of work into it but it was a great machine. My advice would be to focus on the gearbox before you run it. When I took mine apart the original grease was hardened and came out like chipping away at a bar of soap. That machine calls for a special grease in the gearbox. I know that I found something compatible at NAPA. I'm sure I still have a tube of it. If you want I can check and give you the info on it. You're going to have a nice mill when you're done with it.​
 
Special Grease? Mine is filled with oil. There is a sight glass at the bottom of my gear box. Can't see anything because of it's awkward location, but it's there. Now up in the head, that gearing is in a bath of grease. Since my head does not have any of that gearing in it anymore, it's no concern to me. But for those that still have the power feed attachment still in tack, I suggest packing it with Lubriplate 630 grease or one of the other Lubriplate products they have for gearing. Ken
 
Yes..I thought we were talking about the gearbox on the left side of the head...maybe I should go back and reread the thread.
 
I may need to go back and re-read it, too Yeiks! :(

Look at his post #11.
 
Ok...I see that the table powerfeed gearbox takes oil. That I'm not familiar with as mine didn't have it. I was looking for a pic of mine but after computer crashes I have lost a lot of pics. I'll have to search on here and see if I ever posted any pics.
 
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