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New mill Wells-Index 745

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dmittz

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It looks like you have the same style of way wipers I have. I bought new rubber strips from W-I. I got 3 feet of it and it was about $35.

Here's a suggestion regarding lubrication. I have one of these little oil guns and it is great for pushing oil into those zerks.

https://www.machinerypartsdepot.com/product/12PB20

My routine is to put one pump into each zerk, except for the back zerk on the left side of the saddle, which gets two pumps. (It supplies a larger area than the others)
Thanks for the tip T.J that is great info, much appreciated.
 

TerryH

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Excellent work and documentation of the process! I enjoyed reading the thread very much. Looking forward to more.
 

dmittz

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Excellent work and documentation of the process! I enjoyed reading the thread very much. Looking forward to more.
Thank you TerryH, that is very kind of you to say. I am enjoying the process of fixing this old machine up. Thanks for following along.
 

dmittz

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Hey Guys, so I did a little more work on the Mill yesterday.

Since I haven't heard back from Wells index about the parts and haven't had a chance to call Shane during his business hours I figured I would get started referbishing some of the smaller parts sitting in boxes.

I was able to punch out the rivets or what ever they are called to take the Index information plaque off the door.

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I media blasted the coloum door, quill crank and the hand wheels.

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I used the same paint process as for everything else. It was a nice day so I painted the parts outside then let everything bake outside in the sun for few hours before bringing them inside. I'll let them cure for several days before I take them down.

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Forgot to mention... Before painting I masked all the parts off:

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You'll notice I didn't paint the hand wheels as I have something different planned for them.

Instead of paint I decided to powder coat the handwheels low gloss black, should make the finish very wear resistant.

First step was to painstakingly mask off the wheels with high temp tape.

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Then I powder coated and baked the hand wheels.
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Next came polishing the handwheels:
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Hand wheels all done...

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I don't really like the original plastic spinner knobs on the hand wheels... I might replace them with some nicer metal ones. Anyone know what size bolt hole is in the hand wheels?
the holes are larger than 1/4 and smaller the 5/16, seems like Metric 8mm but had an unusal thread pitch. Worst case I can drill them out and tap to a standard size I guess.

That's all I've got for now guys, I'll update when I've done more work.
 

T. J.

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Anyone know what size bolt hole is in the hand wheels?
the holes are larger than 1/4 and smaller the 5/16, seems like Metric 8mm but had an unusal thread pitch. Worst case I can drill them out and tap to a standard size I guess.
Mine aren't threaded at all - the rod is pressed into the wheel. Replacing them is on my to do list as well.
 

dmittz

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Mine aren't threaded at all - the rod is pressed into the wheel. Replacing them is on my to do list as well.
Interesting, thanks T.J. ya mine are just a bolt with a nut on it and the plastic spinner piece just sits between the nut and the bolt head. I wonder if someone just jerry-rigged up the spinner knobs on my machine after breaking the originals.... Maybe I will just drill and re-tap the holes if that's the case.
 

dmittz

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Hi everyone, this is just a very small update.

So I took down all the parts I had recently painted and unmasked them...
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I also put the information plaque back on thr colum door. I used a brass hammer to punch the little pins back in on the 4 corners.

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I also polished up the hinge hardware.
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The door reinstalled on the colum.

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That's about all I have for now.
 

NorseDave

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Man, that is some epic restoration work. I'd love to get my 645 looking like that, but based on the progress of my other projects, I'm not sure I want it in parts for like 3 years :rolleyes:

On a related note, on your Miller 211, are you using a 10 lb spool of wire? I have a 211 and it welds great, but it took me a while to figure out that the plastic "nut" that they give you for securing the 10 lb spool onto the axle is terrible. It's either too loose and starts to fall off, or too tight and it causes the wire to slip in the drive roll. Once I finally figured it out, I ditched the nut and, drilled a couple of small holes 180* apart on the axle, and just use a piece of solid 12ga wire to keep the spool from walking to the outside of the machine. Curious if you (or anyone else) has run into this. I made that change like 18 months ago and never thought about it since. /thread hijack over
 

dmittz

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Thanks NorseDave, I'm enjoying working on the Mill but it sure does take a fair bit of time.

In regards to the Miller 211. So far I've just been using small (2lbs) spools of .030 wire. I have quite a few small spools left over from my old welder I want to use up first. I haven't had any issues with them. I'll keep in mind that I may need to modify the 'axle' if I want to run the 10lbs spool at some point. Thanks for the tip.
 

dmittz

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Hey Guys, While the 745 is all apart I have been contemplating if I should retrofit a 1 shot oiler system for it. I found a kit online for series 1 bridgeport... Would it be almost the same as the my index 745 or are they a totally different number of ports etc?

Trying to decide if the expense and effort is worth while...
 

T. J.

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I think those systems are fairly easily adapted to different mills - just count up the ports and make sure you get enough parts. I've never installed one though, so hopefully someone who has will chime in.

I had originally thought about installing one on my 645. I have since discarded that idea since finding the little oil gun I referenced earlier. It takes maybe 15 or 20 seconds to oil all the zerks and leaves zero mess.
 

dmittz

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Thanks for the info T.J

It looks like my 745 has more oiling points than a comparable bridgeport, so adapting a one shot oiler kit (for a bridgeport) may be not as strait forward as I had hoped. Since you say it is very quick to just use an oil gun I think for now I'll just get the mill up an running as is and I can take on adding a one shot oiler down the road sometime.
 

dmittz

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Hi Guys, I did a little more work on the Mill.

I figured it was time to get started dealing with the turret and over ram.

I flipped it upside...
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The chain on the underside of the turret can be disconnected at both ends which allows the over ram to be removed from the turret.

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Next I removed the worm gear head nod mechanism.
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Next I removed the gear mechanism on the turret...The gear is retained with a set screw and a pin which both have to be removed.

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Now the Turret, over ram and head knob mechanism were all separated.
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More updates to come...
 

dmittz

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Just a small update:

I decided the next thing I would do was restore one of the bags of small parts. I decided on the over ram slide mechanism.

It was a bit grungy and the 'bolt head' part of the handle that you put a socket on to move the over ram forward and back has some surface rust on it.

I polished up the gear and shaft, than I sand blasted and re-did the black oxide part of the handle. I think it came out nice...
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The chain part of the slide mechanism had a lot of dried out grease, caked on dust and metal chips. So i scrubbed it clean in the parts washer and then lubricated it with some mobile Valcera.

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The mechanism is now all ready to go when I start putting everything back together.

More updates to come.
 

T. J.

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That looks like one place where they made improvements over the Model 645. That shaft on a 645 isn't near as beefy. There must have been more 200 pound gorillas like me who broke theirs trying to get it unstuck with the big wrench!:cower::p
 

dmittz

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That looks like one place where they made improvements over the Model 645. That shaft on a 645 isn't near as beefy. There must have been more 200 pound gorillas like me who broke theirs trying to get it unstuck with the big wrench!:cower::p
Interesting, yes I believe the model 745 is a bit different from the turret upwards but everything below that is more or less the same as the model 645. That shaft actually requires a 1 inch socket or wrench to fit the head on it. It moved pretty easy on my mill but as you say it might be a place they did a redesign on the 745. Sorry to hear yours broke, hope you were able to get it unstuck...
 

dmittz

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Next I started working on cleaning up and stripping the paint on the turret, over ram and head knod assemablly. It took quite a few hours but eventually I got them all down to bare metal.

I first cleaned them with purple power and scrubbed off all the hardened old grease, next I used aircraft paint stripper to remove as much paint and filler as possible. What was left was then removed with a wire wheel on a 7in angle grinder.

After paint stripping...
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Finally down to bare metal....

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It probably goes without saying but I was very careful around the precision machined surfaces....

Also, just a note about safety, since the original coat of paint might have lead in it, I used a supplied air system and did the whole process out doors.

Next up will be start painting and filling, more updates to come...
 

dmittz

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I got a little more work done on the Mill recently.

I spent a bit of time painstakingly taping off the turret and over ram parts in peparation for paint.

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After the taping was done I applied 2 coats of epoxy primer, followed by 2 coats of 2k high build primer.

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I'm going to let the paint cure for a bit, then it will be time to start the process of filling. sanding and applying more high build primer until the surface in acceptably smooth.
 

dmittz

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I made a little bit of progress today on the Mill. I managed to complete the first round of sanding on the turret and over ram. I was actually able to get it to a fairly smooth finish, just a few spots where I need to fill some casting flaws then hopefully I can epoxy primer and topcoat.

Parts after first round of primer and sanding:

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dmittz

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Next I filled all the rough spots on the casting with filler and sanded them smooth.20181105_142426.jpg

I started to do another coat of epoxy primer but unfortunately my spray gun broke part way through so I will have to re-sand and redo the epoxy primer next time.


I also managed to get the table cleaned up. I just used paper towel and WD40 to remove some stains and rust. The table is in really great shape, not even one drill or cutter mark one it.

20181105_135207.jpg
 

dmittz

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I got the pieces I started to paint re-sanded and ready to be painted once I get another paint gun.

I also took a bit of time to clean up the bronze XY nut. I had assumed it would be well worn given the age, but after getting the grime off it doesn't look bad at all. In fact I doubt there is much to be gained by replacing it. And I think the 20 thousands backlash I observed when I first inspected the machine is reasonable for my intended uses.

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dmittz

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So work on the mill is moving forward.

I finally finished painting the turret and over ram parts.

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Next was to install the slide mechanism.

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Then I wrestled the over ram back into the turret.
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The next step is of course to install the turret and over ram back on top of the mill. I briefly considered trying to power hoist/lift them on the mill by hand but since the 4 bolts on the turret have to line up with the holes in the mill colum I figured I best use a hoist to install it.

That ended up being a big production as the engine hoist would not fit past the rolling stand the mill is now on. So I had to put it up on blocks so the engine hoist's forward wheels could 'straddle' the mill without running into the mill's stand. Anyway to was not the way I wanted to install the turret but in the end it worked.

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And finally the mill back in its proper place with the turret/over ram installed.

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middle.road

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Were you ever able to hook up with Shane?
 

dmittz

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Were you ever able to hook up with Shane?
Not yet, but that's why I haven't installed the table and just have the cross slide sitting on the knee, so I can easily remove it. I don't think I will be getting anything re-scraped but I'll ask him about re-flaking (to help with oil retention).
 
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Superburban

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NO! do not take the chop saw to the table!

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Just kidding. Great job. I wish I had the time and dedication to fully rebuild a machine. I'm doing about 1/4 on my 16"SB, but I need to get it going to get some other stuff done.

Good to see the bronze nut is good. I have seen it in the parts diagrams, but did not realize its size. I bet it would not be cheap to replace.

Great job with the pics, thanks.
 

dmittz

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NO! do not take the chop saw to the table!

View attachment 279674

Just kidding. Great job. I wish I had the time and dedication to fully rebuild a machine. I'm doing about 1/4 on my 16"SB, but I need to get it going to get some other stuff done.

Good to see the bronze nut is good. I have seen it in the parts diagrams, but did not realize its size. I bet it would not be cheap to replace.

Great job with the pics, thanks.
haha ya I guess it does look like that in the picture.

Thanks, ya its a bit of work for sure but I'm having fun. I will say the size and weight of the components has made it challenging at times, much harder than the South bend 9a I redid. That's cool you have a south bend 16. I also have a South bend 13 that I'm planning to restore after the mill is done, I have seriously considered leaving the patenia on the SB13 and just getting it functional as referbishing these machines is lots of work!

Ya I was happy to not replace the bronze nut. I called Wells-Index 3 times about it and e-mailed them once. They were very pleseant on the phone, they said they were out of stock on the, but still have the moulds and could have thier foundry cast some new nuts if I was willing to wait...they were going to call me back with a price but I never did hear back about pricing. However, I assume if they were casting one and machining it just for me it wouldn't be cheap.
 

dmittz

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Just a very small update. I removed the studs on the turret and cleaned up /polished them. 20181113_190223.jpg

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All the studs replaced...

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I also polished the nuts and washer too..

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I really like the look of the polished hardware, adds a nice little detail IMHO.
 

ACHiPo

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Looking great!
 
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