ROCKWELL 21-122 milling machine REBUILD

Discussion on all milling machines vertical & horizontal, including but not limited to Bridgeports, Hardinge, South Bend, Clausing, Van Norman, including imports.

Moderators: GlennW, Harold_V

wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

This next one is for all the guys in the Rockwell group that were discussing
how to repair the aluminum gear for the head tilt with a new keyway.
I used a steel ring with a 3 inch ID for a demo mock up, so just slightly smaller.
Raised it on 1 inch blocks and clamped. Pic 3 shows just enough clearance to complete
the cut.
The attachment is a Bridgeport No.2 right angle head which is designed for a
2.563: dia. quill and has been bored out to 2.95" and has a drive shaft extension
that is 3/4" dia.
A No.4 head could also be adapted would still need and extension drive shaft
but no boring just a steel or aluminum sleeve to adapt from 3.376" to 2.95"
A No.2 head is m ore versatile it has a 1 inch longer reach.
These heads can be bought used on Ebay. Sometimes you can find a deal.
The 1/4 inch endmill has a shortened shank section.
There are specialized endmills out there with even shorted cutting flutes that
would allow access to even tighter situations.
Attachments
P1040464.JPG
P1040465.JPG
P1040466.JPG
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

Well this is the next accessory that I made up for the mill.
A faceplate and a topslide adaptor bracket to be able to
turn and bore items too large to put on a faceplate on my
Chipmaster. Face plate on that is 10-7/8" and 11-1/2 " swing
The face plate here is 12-1/8" and can swing over 19 inches x
4-1/2" deep. I found the faceplate on Ebay for 100 to 125.00
and the machined it and made an adaptor brkt for the horizontal spindle.
Not that you would put a solid hunk of metal that large
on the faceplate. But there may come situations where an awkward
shaped part may be well served with larger faceplate turning ability.
By de-rating my speeds on the horizontal spindle I have a 38 or 39 rpm
low speed, well suited to spinning larger items.
The topslide comes off my Chipmaster with 2 nuts and bolts onto the
adaptor plate and then onto the mill table with 4 bolts.
There are 2 alignment pins to register the 0 degree point.
While I have the mockup in situ to showcase this accessory,
I think I true up the faceplate .
Attachments
P1040467.JPG
P1040467.JPG (68.72 KiB) Viewed 3777 times
P1040468.JPG
P1040468.JPG (82.79 KiB) Viewed 3777 times
P1040469.JPG
P1040469.JPG (73.22 KiB) Viewed 3777 times
P1040470.JPG
P1040470.JPG (74.07 KiB) Viewed 3777 times
P1040471.JPG
P1040471.JPG (77.65 KiB) Viewed 3777 times
P1040472.JPG
P1040472.JPG (69.22 KiB) Viewed 3777 times
User avatar
NP317
Posts: 4557
Joined: Tue Jun 24, 2014 2:57 pm
Location: Northern Oregon, USA

Re: ROCKWELL 21-122 milling machine REBUILD

Post by NP317 »

Creative!
RussN
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

Well the faceplate is trued up.
When I was checking fit and runout I got .055 on the face
and .015 on the circumference.
Seemed way too high considering the back of the faceplate
was turned at work on a lathe mounted to a faceplate that
was true.
So I started by remov ing the drive key and remounting it.
That got me to .030 and .014".
I thought about that and decided to take off the faceplate
and face the end of the spindle.
That got me to .011" and .001 on the circ.
Couple skim cuts and the face was true to within .0005"
and the .001 on the circ. not worth worrying about.
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

Here is the newest accessory, I just finished the other day.
Power feed for the knee.
2" dia. hub with 1/4" dowel pins and 1/2 inch hex stock
set screwed to the hub.
Put into a cordless drill and use as needed when there
is lots of up and down. Works as good as the power feed
for the longditudal. But not in the way when you don't
need it/and banging your knee on it.
Stay tuned-I have lots more accessories to debut.
Just haven't had time to set them up and post.
Attachments
P1040473.JPG
P1040473.JPG (76.47 KiB) Viewed 3488 times
P1040474.JPG
P1040474.JPG (74.43 KiB) Viewed 3488 times
Last edited by wally318 on Sat Mar 04, 2023 9:38 pm, edited 1 time in total.
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

Tomorrow I with with pics my solutions for cutter sharpening.
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

Several yrs ago I bought a Darex endmill sharpener.
Paid 700 US for it on ebay and put it in storage.
Fall of 21 my company was getting ready for a move
and among other things won a silent auction for the
almost new(old but almost never used) for 53.00 CDN
We paid about 5000.00 CDN for it with the CBN wheel.
So I gave the older one to a friend from work for the
53.00 I paid for the new one-so cost me 53.00 to upgrade.
Attachments
P1040475.JPG
P1040475.JPG (84.56 KiB) Viewed 3200 times
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

So I came up with the idea(s) to make this sharpener/grinder
be able to sharpen most of the cutters in the shop. Or-be
self sufficient.
Pic 1 is of the stock stylus used to guide the sharpening
of the side teeth(helical) on endmills.
It has a .010" dia tip. Not very suitable for dealing with the weight
of helical slab cutters.
PIc 2 is of my mod with an adjustable ball bearing sylus.
Pic.4 are the 1" and 1-1/4 dia arbors to hold the cutters
in a 5C collet.
Pic. 5 is the stylus set up(mock up) on a 4 inch long 3: dia. cutter.
Attachments
P1040476.JPG
P1040476.JPG (66.72 KiB) Viewed 3199 times
P1040477.JPG
P1040477.JPG (79.61 KiB) Viewed 3199 times
P1040479.JPG
P1040479.JPG (82.04 KiB) Viewed 3199 times
P1040478.JPG
P1040478.JPG (78.07 KiB) Viewed 3199 times
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

For plain horz. milling cutters I bought an Eagle Rock milling
cutter grinding fixture on Ebay. It is designed for putting on
the table of a surface grinder.
And modified it to present to the Darex wheel
in a horizontal fashion instead of the vertical position
that would be used on a tool and cutter/surface grinder.
Attachments
P1040481.JPG
P1040481.JPG (63.22 KiB) Viewed 3198 times
wally318
Posts: 260
Joined: Sun Jun 05, 2011 1:06 am
Location: Kelowna, British Columbia

Re: ROCKWELL 21-122 milling machine REBUILD

Post by wally318 »

I found a deal on the ball mill/radius grinding attachment for the Darex.
They typically sell for 600-900.00 US, I got this one for 300.00
I had to make the 5C collet drawbar and give it a good going over.
Pic.2 shows it in a mock set-up using a square 5C collet to sharpen
a HSS threading tool. I also plan to use it to sharpen slotting cutters
to use in the Parkson slotting head that I adapted to the horizontal spindle.
More on that later.
Attachments
P1040483.JPG
P1040483.JPG (88.23 KiB) Viewed 3198 times
P1040482.JPG
P1040482.JPG (81.27 KiB) Viewed 3198 times
User avatar
NP317
Posts: 4557
Joined: Tue Jun 24, 2014 2:57 pm
Location: Northern Oregon, USA

Re: ROCKWELL 21-122 milling machine REBUILD

Post by NP317 »

Enviable tooling!
RussN
User avatar
Bill Shields
Posts: 10461
Joined: Fri Dec 21, 2007 4:57 am
Location: 39.367, -75.765
Contact:

Re: ROCKWELL 21-122 milling machine REBUILD

Post by Bill Shields »

I have one of those darex grinders and really like it.

I you come across another ball mill attachment...let me know
Too many things going on to bother listing them.
Post Reply