ER32 Collet Chuck for Proxxon PD 400

[Wongster]

I completed the recess today. It is a little tight that I wasn't able to remove the gauge after tapping it in with my hand. It wasn't that it is too small but I wasn't able to get it to seat due to air pocket within. Once in, it refused to come out...

Allen key was used to carefully pry it out.

I started by centre drilling and drill to about 4mm deep with a 5mm drill. An endmill was used so that the inside of the hole is flat. I felt silly after that as it will be bored away later... The Sherline boring bar was used to enlarge the shallow hole bit by bit till it reached about 63mm in diameter. No reason for that diameter but wanted to leave some "meat" in case of error. Unless I know of a way to add metal back...







After I get to about 63mm, I started enlarging the recess further by boring the side wall of the recess bit by bit till the gauge fits. The gauge stuck in the recess...





The "floor" of the recess was then clean off as best as I could but I couldn't make it shine like what Rob and Dave did.

I'm letting it cool off right now and will test with the gauge again to see if I need to open it up a little more. Will sand it then using the boring bar if it need be.

Update:
It still fits but the air pocket still prevent the gauge from sitting in properly. Should I do anything more? Also, I just remembered that I forgot to scribe the PCD for the bolt holes!!! All is not lost, me think. I've on order, from Little Machine Shop in US, a set of M6 Transfer Screws. The recess will help to locate the collet chuck while I tapped the part to transfer the hole locations.

Regards,
Wong