Nice job Zee, you'll be "teach'in the class" before long !
Thanks. My 'long' is measured in eons.
Or something a little less.
Did some more work on the crosshead guide. So far...so pretty good.
1st pic shows set up for marking. I don't have a chuck for my spindexer.
So marking went great but then I had to put it in the vise and lost all reference. I used the height gauge and went back and forth from one side to another until I rotate it to 'close enough'.
2nd pic shows the milling out of one side.
3rd pic shows milling the rounded corner. The downside of doing it this way (as I found out) is the metal gets pushed out and over the line I was going for. It was hard to know when to stop. I could have done one of two things. a) Milled from the other side so the cutter goes 'into' the mark. I would have needed a mirror to see that. b) I could have set the mill to just touch and used the DRO. But I'd still have a bunch of metal pushed out that would need filing.
4th pic shows this step done. A little filing and things cleaned up pretty well. I don't know if I reached the target for the rounded corner but it looks pretty close and it won't matter.
You might notice I redid the transition from the smaller outer diameter to the larger outer diameter. It really bugged me but it was pretty easy to correct.
You might also notice a step change, rather than a smooth transition, from the smaller inner diameter to the larger inner diameter. I didn't have an appropriate cutter to do that but more importantly I couldn't see it and didn't want to rely on my measuring. I'm probably going to leave as is but there's a chance I might be able to improve it later.
Whether this goes bad or not...at least I know how to get this far.
[EDIT] You'll also see the far end's inner diameter looks much smaller. I got there drilling but the boring bar couldn't and didn't need to. All of that gets milled away later.