Today I spent a couple more hours in the shop. I'd hoped to get more done on Neil's project, but progress was made.

I started off with changing the gears on the lathe to be able to single point thread the bolts and axle we'd made. They fit PERFECT and worked great! First up was two M14x1.5 6g threads, one on the long axle (which would later get cross holes for a cotter pin) and the larger bolt for the rear suspension fixing point. Next, change the full profile threading insert to make two M10x1.25 6g threads, and a simple change of a lever handle to change the thread pitch on the lathe.



Using my spindexer on the milling machine, I first spotted the holes with a Ø 1/4" x 90º spot drill at 4 spots 90º apart, then drilled through with a beautiful Titex A1249TFL-1/8IN drill. It looks bright and uncoated in this photo, but it is in fact coated with Titanium Aluminum Oxide. The 135º split point cut like butter! I then had to run a regular No.29, 0.136" (3.45mm) drill though it to match the size to the original part.



The results, though I did use a jeweler's file to clean it up after I took the photo. The mating nut I had on hand spun right on with no hangups.



I also wanted to show a close up of the heads on those bolts which we made yesterday. As stated earlier, a short plunge with a 1" indexable insert ball mill, a touch with a Dremel and a minute or two of polishing to get this result. Note the little chamfers I milled around the hex. Jewelry!



One final shot of the finished parts together with the originals.