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Portable milling/grinding machine for machine way reconditioning

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PekkaNF:
I my biggest surface plate is about 600*400 mm and another 400*400 mm. Then I have three camelbacks 400, 600, and 1000 mm. I have pretty good 600 mm straight edge and 1000 mm straight edge is in order.

Table is easiest and hardest....it has few original surfaces, machined that can't have any wear, because they are no bearing surfaces, but they are on the same plane than bearing surfaces. On the other hand, it has a longitudal dovetail, that is going to need some attention and it is not trivial to measure.

Knee is hardest part....it has Z-axis bearing planes luckily on on plane (or should have) but Y-axis bearing surfaces have offset by design and it is going to complicate measurement. Good news is that it just about fits on my big surface plate - I can verify it and then check it against the knee ways.

I can borrow longer straight edges of varrying (known accuracy).

I will not try to attemp of scraping to shift the most of metal, there is simply too much of it.

I have been reading of Connelly's Machine tool reconditioning, rather nice reading if you can't sleep...It is very matter of the fact of course and I much liked it. However, I haven't mannaged to google anybody first timer that has tackeled this size project solely on scarping and has a proof of succeeding.

I need whole more controlled method of removing metal than angle grinder or such and faster than scraping.

Pekka

awemawson:
Get a Biax and use it with a carbide scraper insert, you'll be surprised how quickly you can remove cast iron. (Steel is a different matter)

RotarySMP:
Sounds like you are well tooled up to do the job. Any welded frame supporting a grinder is going to take off metal fast,with The Risk of rapidly destroying the remaining accuracy of the mill. How many surfaces are really that worn that you need to take off tenths of mm? For those you are going to have problems with leadscrew alignment, and should consider milling out and moglicing them.

chipenter:
I used a flat file ground the teeth off the edges and cleaned the file with a brass brush , still took a fortnight to remove ten thou from my lathe bed , and my hands were so black the kitchen sink went rusty .

RotarySMP:
There are a few guys on the Net who have hacked cheap saber saw's to reduce the stroke and mounted carbide scraping blades a cheap Biax. The feedback from those who have done it is that it works quite well, with a significant reduction of effort verse hand scraping.

http://www.cncecke.de/forum/showthread.php?59092-Schab-O-Mat&highlight=S%E4bels%E4ge+biax

http://www.practicalmachinist.com/vb/general/power-scraping-anyone-tried-convert-makita-hk0500-metal-161099/index2.html

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"My own Aldi variable speed recipro saw adaptation which I call "Aldix" is not quite as good, too light and too much play in the blade guide, but I've used it a lot over the past 4 years and its still going well...."

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