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Jim - I have designed the head spacer to bolt to the back of the spindle head with (6) M6 fasteners. There is an optional M10 tapped hole on the opposite side which aids in drawing the top of the...

Ideally a brass punch....but any kind of drift/round stock/tool would work. If you can get the saddle back where it isn't as tight on the table, would be best. If not, just go easy and work up to...

You said you removed the gib screws, but you need to drive the gib strip out too. Get that out and you'll get the saddle off.

-Mike

During my week "off" for the Christmas Holiday, I spent the majority of the time in the basement machining up another set of 2.5in, 3.5in & 3.5in solid spacers. I didn't quite finish the solid...

Big bolts - big torque. Use a cheater bar (pipe) to break the bolts free and to tighten. Work smart, not hard! ;-)

-Mike

Column spacer is 2", so short answer is 2" longer. However, take a close look at your setup to determine your requirements.

Are you planning to overdrive the y-axis over the front? Now would be...

Finished another spindle and column spacer set over the weekend.

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-Mike

Mike - if I'm following up on an adaptive clearing pass which leaves uneven amounts of stock, I will cosmetically see waves after the finishing pass that match what was left behind from adaptive...

Standard Carbide Non-coated 2F 1/4 Endmill and Tormach SuperFly cutter with a polished insert for aluminum.

I usually take a .005-.010" finish pass followed by a spring pass when using the...

Glad to hear you are making chips and parts are working for ya Mike! Thanks!

-Mike

Made another 2.5" Spindle Head Spacer for a customer.

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-Mike

Hoss's head flip will give you the most z-axis travel with the least amount of work - best bang for your buck!

My proposal implies you don't want to physically flip the z-axis base. It will...

Exactly! I had already milled my oil grooves in the saddle and when I attempted to flip my Z-axis and quickly discovered the my oil grooves hanging in the wind! hahaha

So my fix was to machine...

The other "easy" option to increase the Z-axis travel without flipping the base is to simply copy the ballnut mount feature in the base 180deg. In other words, mount the ballnut BELOW the head...

As I no longer can edit my first post....please let me add in hopes smoothing any hard feelings:

"Credit to Hoss for taking the time to share the hard work and effort he put into his G0704 -...

Mike - your mill looks great....time to get it dirty!!

Thanks for the positive feedback too - I'm glad everything worked out for you!

-Mike

I'm basically following Icvette's trial by fire wisdom and suggestions here:

http://www.cnczone.com/forums/benchtop-machines/290706-g0704-vfd-ac-motor-upgrade-information.html

The motor is...

I think I'm going to go the 1000:1 inverter duty route on my build. I plan on only having one set of pulleys at 2:1 so I can under/overdrive the VFD and motor to get my full spectrum of speed and...

Anyone have an opinion on V-belt vs PolyRib (automotive serpentine style) belt?

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I'm going back and forth between a 3L v-belt and 4-rib J-section belt for my spindle drive. Both...

...just can't leave well enough alone!

Next round of upgrades will be massive so I'm laying it all out before jumping in.

Here a list of items I'm upgrading to:

1. Direct belt drive
2. ...

I checked parallelism at work on a granite inspection table and I'm within .002" across the entire face. I say pretty dang good for coming off a G0704....which also has the spindle spacer installed....

Pippen88 - I size my stock first and hold the parts in parallels in the vice. Most parts are 2 setups; top and bottom or top and side. I only have this one fuzzy pic I took...

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-Mike

Well I decided to try out the Tormach SuperFly Cutter on my G0704 and I'm glad I did! Decent MMR and most importantly to me - excellent finish!! I used a polished SEHT insert for aluminum.
...

...busy couple of weekends. I finished a 2.5" and 3.5" spindle head spacer for a couple fellas on the forum. They turned out nice. Here are a couple pics....

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-Mike

Parallelism should be pretty good. I face both sides after assembly. No reason for it to come apart after that.

I had the head shimmed on the stock mill, so I was prepared to shim with the...

Well I've received a lot of favorable feedback via PM's. Thank you all.

Looks like I have a busy weekend ahead machining a couple of these spacers for you fellas.

If you want one too - PM me...

The local cost for a block of solid 6061 2-1/2" x 5" x 8" is $55.

In my fabricated design I have about $46 worth of material.

I contemplated going billet - but liked the freedom of...

Haha very true - tough crowd. ;-)

I often run different combinations of loading and restraints to check the sensitivity of my models. This part isn't going to the moon nor is it spacing the head...

I don't know how much the head Assy weighs - let's say about 80lbs.

300lbs is just a number I chose to include cutting forces and dynamic loading.

It was just a quick 10min sanity check at...

Well, for giggles I ran an FEA....

I placed 300lbs acting down about 5" off the face of my spacer and see about .0003" max deflection locally at the top while most of the mounting surface is at...