Author Topic: Boley 4L  (Read 22971 times)

Offline SteveT

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Re: Boley 4L
« Reply #25 on: December 14, 2015, 05:58:59 PM »
Looks a good find  :beer:
Steven Tyrer
lives in Cardiff South Wales

Offline tom osselton

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Re: Boley 4L
« Reply #26 on: December 15, 2015, 01:15:06 AM »
Nice job!

Offline RotarySMP

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Re: Boley 4L
« Reply #27 on: December 20, 2015, 04:08:38 AM »
Thanks guys.

It is pretty well used, but still a fine tool.

Well, that first moto mount undercoating was crap, so I sanded it back and redid it.

Then I needed to make up an adaptor plate to mount my 4 jaw to my only chuck back plate. The slug of steel was a drop form Fixmetal. It is too thick, but I figured it would be waste to turn 70% into swarf, since I can reuse it for something else once I get the new backplates which are ordered.

The parts I order fro Mädler.de showed up (within two days of ordering - nice), so I bored out the timing belt cogs, and shaped a keyway in the one which goes on the leadscrew. Since my keyway cutter is 3mm I had to do it in two passes.

Regards,
Mark



Offline RotarySMP

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Re: Boley 4L
« Reply #28 on: December 24, 2015, 05:23:52 AM »
Now the top coat has dried, and I could install it.

Offline RotarySMP

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Re: Boley 4L
« Reply #29 on: December 24, 2015, 05:45:03 AM »
Although I am installing the ELS for threading, I am enjoying manual turning, so I would like to tighten up theexcessive play in the saddle drive.

I bought some sintered bronze bushes from Maedler.de, figuring I just need to bore out and bush the handle casting on the apron. The Shaft is also worn 0.25mm, so I'll have to turn that back and sleeve it as well. When I looked at the shaft on the apron, with the pinion which meshes with the rack, it also has 04mm play, so I'll need to pull the apron, bush that hole, sleeve it's shaft, and the add a second busing into the handle casting.

I'll order 11mm and 14mm reamers for this job, and get on with something else in the mean time.

Mark




Offline RotarySMP

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Re: Boley 4L
« Reply #30 on: February 21, 2016, 01:16:04 PM »
Finally got around to making a holder for the Boley's collets.

Mark


Offline RotarySMP

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Re: Boley 4L
« Reply #31 on: February 29, 2016, 08:01:00 AM »
The spindle nipped up on the lathe. I think I'd better tear it down and check that it is not scoring the journal, and probably scrape the plain bearing back in before I use it any more. My lathe had been lubed with grease (except the headstock nose bearing)  when I got it, so I need to make sure that the rear bearings are also correctly lubed.

It is obvious from the hammer and punch marks on the nuts that someone has been here before, who didn't bother with the finer points of maintenance like using the correct tool for the job. Lucky I bought a set of C spanners a few months ago.

The tear down starts on the LH end. Their is a fine thread on the spindle which mounts a split nut as a backstop for the thrust bearing preload nuts to act on. This nut has a conical surface.

On my lathe, their was also a conical washer, but that was located on the other side of the thrust adjuster. I guess that was incorrect assembly.

I need to release the nut on in the gearbox behind the nose bearing, but it has a sheet metal cover.

To get that cover out of the way, it looks like I need to remove the three screws on the bull gear, and shift it to the left. There is also a grub screw on the spacer which has to come out.

The thrust bearing house slid out with a nice tight sliding fit.

The bearings will have to come out, as they are full of grease. Boley specifies VG68 way oil for the rolling element bearings. Martin from the CNCEcke has offered me his dummy bearing so I have a shaft support to locate the spindle for the 100 time you need to install and remove the spindle during scraping.
http://www.cncecke.de/forum/showthread.php?41731-Restauration-Boley-4L-Drehbank&highlight=boley

I am glad that the back gears look in very good condition.

Mark



Offline RotarySMP

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Re: Boley 4L
« Reply #32 on: March 06, 2016, 02:15:31 PM »
I pulled the spindle. Turns out the grubscrew which acts as an anti-rotation stop for the collets, was loose. It had backed out a bit and machine a groove in the plain bearing. I estimate it is at least 1/10mm deep. I hope there is enough meat there to scrape the bearing back to full contact.

Mark

Offline RotarySMP

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Re: Boley 4L
« Reply #33 on: March 13, 2016, 03:00:52 PM »
I've now pulled the three rear bearings. Once the dummy rear bearing arrives, I can start scraping the front bearing back in. I'll have to grind the steel shim in the top of the bronze bearing which controls it's diameter. with the current shim, and the bearing nut tight, the spindle goes all the way into the bearing till it hits the shoulder.

Mark

Offline RotarySMP

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Re: Boley 4L
« Reply #34 on: March 16, 2016, 03:39:55 AM »
I pulled the steel spacer from the slot in the spindle bearing. This roughly sets the bearing bore diameter, then therefore roughly sets the bearing clearance. The fine adjustment is through spindle axial location. Someone has been there before, and broken one end off it. It is currently 2.20mm thick. I'll need to do a few tries with a stack of shims to get a feel for how much need to be grind off.

Offline RotarySMP

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Re: Boley 4L
« Reply #35 on: March 17, 2016, 03:43:31 PM »
Today I was out at my mates doing a casting seesion, and he ground down that bearing shim on his surface grinder. Cool tools those.


Offline RotarySMP

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Re: Boley 4L
« Reply #36 on: March 31, 2016, 03:22:58 AM »
Not sure if this is interesting for anyone...

A Gentleman from a German forum sent me his dummy bearing to support the LH end of the shaft, so I scraped in the main bearing over Easter.

I checked the run out of the spindle. There a couple of tiny defects (which I can't see) which kick the TIR to 0.0004" / 0.01mm at the collet taper.
https://www.youtube.com/watch?v=4zSdoCfkvkY&feature=youtu.be

 The Chuck alignment boss is "perfect" within the limits of my measuring equipment.
https://www.youtube.com/watch?v=Gp8YNbTDCrU&feature=youtu.be

Just waiting for a new seal, and need to surface grind the new shim, and I can put it back together.

Mark




Offline RotarySMP

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Re: Boley 4L
« Reply #37 on: April 04, 2016, 06:26:17 AM »
Ground the new spacer shim yesterday, seal arrived, so I can reassemble that lathe this week. With the forward bearing spacer shim ground to 2.14mm, I have about 0.012mm play in the bearing. This needs to be about 0.02mm, so I'll have to add another 0.02mm shim to increase it.

On Saturday, I plopped the top slide on the surface table to have a look at it. As expected, it has worn a bit hollow, so I started scrapping it.

Mark


Offline smiffy

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Re: Boley 4L
« Reply #38 on: April 04, 2016, 03:48:09 PM »
 Hi nice job you are making of getting your lathe into shape. I think it uses some of the same parts as my 5 LZ .
Do you have the collet chuck . I only have part of mine and would like to make the missing parts
       Mike

Offline RotarySMP

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Re: Boley 4L
« Reply #39 on: April 05, 2016, 04:05:30 AM »
Hi Mike,
Thanks for the encouragement.

I don't have a collet chuck, or do you mean collet closer for the 358E / W23 / A12 collets?

Yesterday I didn't feel like reassembling the spindle, so finished stripping the compound down to piece parts. It is in pretty good condition, except the paint which is almost completely gone, and an extra M12 threaded hole in the top slide.
Mark



Offline smiffy

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Re: Boley 4L
« Reply #40 on: April 05, 2016, 09:07:26 AM »
Sorry its the end cap of the collet closer that I am missing .My spindle is bored 4 MT and at the moment I use a er collet chuck in the spindle but it would be nice to get the proper collet up and running Mike

Offline RotarySMP

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Re: Boley 4L
« Reply #41 on: April 06, 2016, 03:11:36 AM »
Hi Mike,

I have not been able to disassemble  the end of my collet closer. Martin Oliver has had his apart...
http://www.cncecke.de/forum/showthread.php?41731-Restauration-Boley-4L-Drehbank&p=824584&viewfull=1#post824584 He is very helpful and has done a lovely Job of restoring his 4L.

Interesting that the 5LZ spindle is native MT4. The 4L and 4LV are native 358E

Mark

Offline smiffy

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Re: Boley 4L
« Reply #42 on: April 06, 2016, 06:43:40 AM »
 MY 5LZ was only available as 4 mt to special order according  to the  information in the manual .

Offline RotarySMP

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Re: Boley 4L
« Reply #43 on: April 06, 2016, 09:49:24 AM »
How many chuck backing plates do you have? I only have one. Martin did a group order but the CNC shop he contracted to make us a batch let us down.

The 5LZ native backing plates have an locking collar to clamp to the spindle to stop the chuck unscrewing don't they?

Mark

Offline smiffy

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Re: Boley 4L
« Reply #44 on: April 06, 2016, 03:42:48 PM »
 My spindle is din 3 and I can buy bison back plates from rotagrip .The lathe came with 3 and 4 jaw chuck and 1 spare back plate.
The 3 jaw chuck is a Forkardt F125 chuck and a fantastic piece of kit , When I have a bit of time I will photograph it .Its the only 3 jaw chuck that I have ever seen where the jaws are reversable  same as a 4 jaw chuck 
Does anyone have the retractable tool holder for screwcutting as i would like to know how they work ?  Mike

Offline RotarySMP

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Re: Boley 4L
« Reply #45 on: April 07, 2016, 03:22:02 AM »
That really was a special order spindle wasn't it. Din 3? Is it the short taper from Camlock, but clamped up with nuts on the rotating kidney slotted disc? I thought that was DIN 55021 Type B? Nice to have for sure. You really got lucky with this lathe.

Concerning the retracting tool holder, I would suggest you join the Boley subgroup in the CNCEcke.DE Forum, and ask there.
http://www.cncecke.de/forum/group.php?groupid=11
Mine came with the Boley 4 way tool post, but I use a Phase II AXA on it.

I have the original Klopfer 110mm three jaw, which is great with the outside jaws, but someone turned a step on the inside jaws. Good for thin parts, but hopeless of small diameter stuff now. I bought a replacement Klopfer 110mm marked "Weiler" hoping the jaws would be interchangeable, but they aren't, and the second chuck has more wear. Also picked up a low mileage Bison thin lightweight 125mm four jaw independent. Nice chuck. Unfortunately I currently only have one backing plate, so it is about time I get stuck in and make a dummy spindle nose gage with the M40x3.5 x 55° nose thread, and then make some more backing plates, face plate, catch plate etc.

Mark


Offline RotarySMP

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Re: Boley 4L
« Reply #46 on: April 07, 2016, 03:24:52 AM »
Made a little more progress on scraping in the compounds flat ways.

There was a hollow in there which has taken a fair bit of work to get done to.

Mark

Offline smiffy

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Re: Boley 4L
« Reply #47 on: April 07, 2016, 03:20:04 PM »
Some pictures of head stock and chuck
The scroll only moves just under 1/3 turn and then the jaws can be withdrawn , There is a detent to hold each jaw is place for location purposes
The jaws can be fitted to different places in relation to each other .
Each jaw can be independently reversed
There is a small button on the front of the chuck that comes out to indicate when the scroll is fully withdrawn and the jaws can be withdrawn
Forkardt still make this chuck and when I have a few pennies  I will buy a new set of jaws as at the moment I only have soft jaws but at £365 a set it will have to wait
 The chuck is rated at 4000 rpm
A new chuck is eye wateringly expensive 

Offline RotarySMP

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Re: Boley 4L
« Reply #48 on: April 08, 2016, 03:23:27 AM »
Hi Mike. Tasty chuck!

I hate to think what that lathe would have sold for new. A standard 5LZ in 1970 had a list price of 70 000DM, which wasn't far of the price of an average house. Your special order spindle would have pushed that up a fair bit. does it have metric or imperial leadscrews? That would be a wonderful machine to restore.

Edit [Deleted the bit about the spindle]

Might be a good idea for posterity, and future 5LZ owners searching for info, to post all your photos on your 5LZ thread and I'll post the 4LV stuff in this one. There is not much info on either on the net, so it might be helpful to keep it sorted.

Yesterday I cleaned all the compound slide components. They are in very good condition with little wear. The lead screw and nut look as new. The castellated nuts haven't been mangled with a drift like all the other ones on this machine.  Photos are still in the camera sorry.

Mark
« Last Edit: April 08, 2016, 05:03:20 PM by RotarySMP »

Offline RotarySMP

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Re: Boley 4L
« Reply #49 on: April 08, 2016, 05:02:03 PM »
I finished the flat ways of the compound. According to Conelly it should have 10-15 ppi, and I count 14, so I hope it's good enough.

The tool post mount surface is a bit sloped. I'll need to take 0.2-0.3mm off it to get rid of the impact marks.

The cross slide also has a bit of wear. I'll have to do scrape down carefully, as the compound mount boss is pretty good.

Mark