So thanks to Murray I have received a single speed 'Pancake Motor' for my poor old Bridgeport.
It's spindle is 22 mm but my pulley is 19 mm so the first job was to bore it out on the lathe - sorry no pictures.
Then it has a 7 mm key way and my (Imperial) broach set obviously doesn't include 7 mm so the next job was to file up a 7 mm key and grind a shaping cutter to fit in a boring bar to shape a suitable key way in the pulley using the lathe and manual long feed - again sorry no pictures.
Then my Bridgeport mounts the motor on two 1/2" UNC studs, one as a pivot and the second in a slot for belt tightening, so having first offered up the front plate of my original to the mounting holes on Murray's motor (which are plain 10 mm holes) to check absolutely that they have the same mounting centres I drilled and tapped them out to 1/2" UNC to fit my studs - I then placed the motor on the machine to prove all fits - it does!
OK now I need to sort out the electrics - my original motor had a housing for a 5 way switch (fast fwd/slow fwd /off slow rev / fast rev) - this one just has a pressed terminal box - the switch must have been elsewhere on the machine and only sadly needs to be three way being single speed.
RSComponents provided a suitable three phase reversing switch and I drew up a suitable box to house the new switch and replace the terminal box. Cutting it out on the Plasma Cutter proved a bit of a pain - I've still not got it fully configured since my Windows 7 debacle - but at last I ended up with a 'flat box' just needing bending.
Like a twit I failed to realise that my narrowest finger on my folder was wider than the narrow dimension of my box - no problem if you bend the narrow bit first, but if you don't . . . . .
![:bang:](https://madmodder.net/Smileys/default/BangHead.gif)
As an attempt to recover the situation I tried sawing a 'bend here' cut but rather as I expected the result wasn't acceptable. Never mind - cut another 'flat box' on the CNC plasma and do it right this time - which I did
![:ddb:](https://madmodder.net/Smileys/default/dancenana.gif)
OK Box and lid bent up, all the right holes drilled for mounting it on the motor, and to take the switch and the 20 mm entry grommet - time for a trial assembly. It all fits but the wiring is going to be a bit tight but should work oOK.
I've dis-assembled it for painting - (tasteful shade of satin black) and will try and fit it all together tomorrow.