Really not content with how the headstock is working out, so time to take stock of what went wrong, and how I plan on not making those mistakes over again.
Very reasonable to scrap it given the wear pad issues. With regard to doing things in one setup, it's not critical (but can be convenient) while you're just roughing the part in, but where it really matters a lot is in the final passes. The boring bar can clean up the non-concentricity, but it has to be cutting at least a shallow chip all the way around and all the way down both bores in the same setup to do it.
ah flapper discs..my m8 at work learnt that lesson recently aswell, he wanted to remove the paint from his bonnet on his car to repaint it, flapper discs look innocent, and like they will flex when used to not take big amounts of metal away but in reality they take big gouges out of thin metal and soft metal faster than a grinding disc. bloody things are aweful for cleaning anything cept thick rust scale off thick metal.
The draft was not the problem, the amount of extra material on the casting that was not necessary (and meant extra work to remove it) was why I reworked my existing pattern.
Very reasonable to scrap it given the wear pad issues. With regard to doing things in one setup, it's not critical (but can be convenient) while you're just roughing the part in, but where it really matters a lot is in the final passes. The boring bar can clean up the non-concentricity, but it has to be cutting at least a shallow chip all the way around and all the way down both bores in the same setup to do it.
ah flapper discs..my m8 at work learnt that lesson recently aswell, he wanted to remove the paint from his bonnet on his car to repaint it, flapper discs look innocent, and like they will flex when used to not take big amounts of metal away but in reality they take big gouges out of thin metal and soft metal faster than a grinding disc.
bloody things are aweful for cleaning anything cept thick rust scale off thick metal.
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A failure that you learn a few things from isn’t really a failure at all. Looking forward to the new and improved head stock.
Sods law. Yes sir. My style. Take a few steps back and make it to your satisfaction. You are doing nice work.
If I were me I would ditch the paten make a complete new paten with better draft angles to give allow a better cast head stock.
The draft was not the problem, the amount of extra material on the casting that was not necessary (and meant extra work to remove it) was why I reworked my existing pattern.