Fit of HLV-H tailstock clamp?

Jim S. said:

My newly acquired HLV-H came with a broken tailstock clamp. I can easily make a new part but am not sure how much clearance to allow on the square portion that fits through the tailstock body.

The square portion of the clamp is .395" but the broached hole in the tailstock is about .440" square. It's not clear to my why so much clearance and it seems that amount of play may contribute to bending of the plunger and tendency to break. There's no evidence of damage to either part, male or female.

View attachment 225626

My inclination is to make the new plunger with just a few thousandths clearance on the square portion. Can anyone think of a reason to have more clearance than that?
Thanks,
Jim

Click to expand...

rons said:

You can never be sure what was done before you became the caretaker.

It is a interesting mechanism. When you turn the lever the wedge's small thread retracts back into the hole on the larger threaded piece attached to the lever. But the larger thread moves the assembly in the opposite direction at a faster rate. So the anvil eventually stops on the dovetail. When installing back on the tail stock it takes a few tries before you get the anvil placed just right (# turns) in the hole of the larger threaded piece. If I'm wrong then enlighten me...

Click to expand...

rons said:

When installing back on the tail stock it takes a few tries before you get the anvil placed just right (# turns) in the hole of the larger threaded piece. If I'm wrong then enlighten me...

Click to expand...