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  1. I've had a lot of success using ferro-nickel rods...

    I've had a lot of success using ferro-nickel rods on cast iron. Pure nickel is known to be hot-short, which is the exact opposite property to what you want when welding a crack prone material. But...
  2. Adobe is a constant source of bugs of its own. If...

    Adobe is a constant source of bugs of its own. If you just need to open pdf's, Microsoft's edge might be adequate. (/me ducks and runs for cover :) )
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    I'm surprised that you can get it to run true...

    I'm surprised that you can get it to run true enough at that kind of RPM. Threads are not very good locators unless they are very nicely ground. In this case, you're sucking them down so that the...
  4. About .002" interference. Aluminum wants to gall...

    About .002" interference. Aluminum wants to gall when you press the sleeve in, but at .002" interference, it will go in fairly well. Make the sleeve thin, so it can collapse as it goes in. I'd...
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    I'm not certain that spending all the time...

    I'm not certain that spending all the time modelling the theoretical groove shape actually helps you to machine it. It's a different animal if you are going to use 3d surfacing techniques to machine...
  6. If it were me, I'd lay out the text in OneCNC,...

    If it were me, I'd lay out the text in OneCNC, along the Y axis. Get each character set nicely centered on each degree mark. Vectorize the text to make it machinable. Use one of the simpler functions...
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    Buy a few and try them out, it is not a major...

    Buy a few and try them out, it is not a major gamble to take. The main issue I've had with some Chinese made tooling is the thread quality: they can sometimes be cut extremely loose, as though they...
  8. Never say never: 7 months ago, and some people...

    Never say never: 7 months ago, and some people resist patching their OS

    Critical vulnerability in Microsoft remote desktop services; update now
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    You can get fancy and make the new nut with an...

    You can get fancy and make the new nut with an extended boss sticking out, bored for a clearance fit over the diameter of the main shaft. This will prevent the nut from hitting against the shoulder...
  10. I would just drill the corners and mill the hex,...

    I would just drill the corners and mill the hex, maybe a little bit of file work or could use the slotter to tickle out the remainder.

    For some applications, I'd purchase a deep hex impact socket...
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    When broaching with the hydraulic press, I have a...

    When broaching with the hydraulic press, I have a 6" long spine on my 'pusher'. I put the back of the broach against this when starting out. The objective is 'no daylight wedge' between the back of...
  12. Over the years, using a Peedee thread wire chart,...

    Over the years, using a Peedee thread wire chart, I don't even bother with calculating the theoretical PD. I just take the major nominal diameter of the thread and add the fraction in the ADD column,...
  13. After years of machining, you get used to how a...

    After years of machining, you get used to how a lathe sounds under various cuts. Once in a while, I'd hear one of the guys lathes really hunker down for a hefty cut, and I'd say "There's somebody who...
  14. I would recommend that you dispense with the...

    I would recommend that you dispense with the notion of retrofitting manual machines. You'll literally need that manual mill and lathe to make parts for the retrofits. And you can always make use of...
  15. The nut shown looks like it would lock the gear...

    The nut shown looks like it would lock the gear into place. That makes it just a nut, not a preloading nut. The gear needs a definite location and should be shimmed into position and then locked...
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    Imagine the racket when you have those falling...

    Imagine the racket when you have those falling off the machine: essentially like a stand of pipe falling over :D "Anybody hear where that chip went? I lost one"
  17. CBN might be the answer, although I am not...

    CBN might be the answer, although I am not convinced that an interrupted cut will still not damage it.

    My money is on silicon carbide whisker reinforced ceramics like Greenleaf's WG300 (or maybe...
  18. I think it could be a plus that the OP is not a...

    I think it could be a plus that the OP is not a machinist. Machinist types tend to get mired down in the knitty gritty details too much to effectively manage their staff, if they have one. I'd take a...
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    Ream all the holes, through all the parts, as one...

    Ream all the holes, through all the parts, as one assembly. Mark the parts so that they will always be assembled in the same order. That's being a practical machinist.

    The most tried and true...
  20. I've been using my 1 ton Mahaffy stacker (pallet...

    I've been using my 1 ton Mahaffy stacker (pallet forks) for years. I have my Haas raised up with the feet sitting on 2x8's so that there is enough room beneath the sheet metal for the 4" high...
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    I don't know, but the dead crap from the last...

    I don't know, but the dead crap from the last batch of bugs makes good food for the next batch.
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    Exactly right: double the time making tools...

    Exactly right: double the time making tools traverse the same path is eminently inefficient. On a tool change frequency optimization basis, multiple parts could/should be fixtured to make the tool do...
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    Use one of the manual lathes instead ;)

    Use one of the manual lathes instead ;)
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    T handles are a lot more comfortable to use if...

    T handles are a lot more comfortable to use if you put about a 3/4" diameter tube for the handle. Helps to minimize hand injury.
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    Agree with eKretz: better to harden them in oil...

    Agree with eKretz: better to harden them in oil than to use as is. Make sure you get them hot enough, it is my impression that, compared to a plain carbon steel, it takes just a tad longer at high...
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