Next task, the frame. Laying out a drawing, adapted from the prototype, was easy:

I decided to make the frame from rectangular steel bar, "key stock". Another possibility would have been to have it torch or laser cut from12mm thick steel plate - something I'd loathe to do myself...

The best way for me to get absolutely square ends and exact dimensions for the pieces was to cut them a bit oversize with an angular grinder, and then square up the parts to exact dimesions in the lathe. There is no need for accurate centering here - that's why a 3-jaw chuck is OK. (I've still to get a 4-jaw...) NOTE dated 2000-11-25: Bought a 4-jaw today!

Next step was the milling of the slots for the pedestals. This will ensure a perfect fit for the journal bearings. Here I have bolted the two main frame parts together, in order to get exactly the same dimensions on both halves of the frame. I'm using another, smaller lathe (2 1/2" height, 8" centers) that has a milling attachment for this - but it's all too small for the rest of the works...

The more massive part of the frame would have been impossible to silver solder with my own small propane burner, so I borrowed an oxy-acetylene torch and welded the joints between the front & back parts of the frame halves.

Here are the assembled frame halves. You can see that the lower part, with the pedestal binders, have screw joints - I must be able to open up the frame to get the bearing blocks into it... So that you can get an idea of the size, I've included ordinary 150mm (6") calipers in the picture.

A couple of weeks later, the frame stretchers are added, and the chassis is finally taking a definite form...



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