No refurbing, just a little borrowing.There are better, more rigid systems than the original Thomson round rod/ ballbushing version.
I understand that you are refurbing a legacy system that is complete, presumably once worked well, and may have other significance to you.
But don't consider the Thomson stuff as either ideal, or as some sort of benchmark for price. It's not used on machining centers, for instance.
1. I removed four of theses Thomson guides from this wood mortise machine. There are four guides on this vertical plate.
2. I used those four Thomson guides to design this wet cutting tile saw. With the internal bronze bushings the alignment is pretty hard
to get the table to slide smoothly for 25". So I started to think about using plastic. Remember there is going to be water and tile residue splashing about.
3. The four Thomson guides are now back on the mortise machine. And that takes it to post 1.
Should I stay with two Thomsons or one long Thomson for the rail slides?
To bore the 1.25" diameter hole in the aluminum housing I think this would work:
Machine scrap aluminum piece to square and cut some slotted holes from the center to the middle of each side.
Attach scrap to face plate and turn true.
Bolt aluminum housing to face plate and use a long boring bar on a lathe.
(The wood piece is acting as the aluminum housing)
The 1" threaded face plate to 1" straight pipe is held in a collet. Has proved invaluable for some operations.
4. Looking into designing a housing to hold 3 rolling wheels. The lower wheel will apply tension on the 3/4" bar. The wheels would be UHMW.
The top two wheels would be easy to mount on some block. It's the bottom wheel that has to apply tension. That is the hard part. The drawing
views are not the standard way. I forgot.
I tried to avoid explaining the story behind the questions in post 1.