I’ve always liked the zero-set indicators sold in the tooling catalogs, but don’t like the price. So I thought that I would try and build one. Here are the results. This won’t be a step by step construction write up. The pictures can tell so much more than typing all those words. So with that in mind if there are any questions on how I did something or why did I do it a certain way, don’t hesitate to ask. I’ll try to explain fully. With almost each picture I’ll give a brief explanation as to what I am doing or going to do. So here we go.
This is what a zero-set indicator looks like.
The raw stock for the first parts.
On the Sherline turning the arbor.
The two pieces of ally plate have been machined to except the arbor.
The two holes for the two small bars are drilled and reamed.
Here they are assembled to the arbor for a trial fit.
A quick skim cut with the fly cutter on both side to clean them up a bit.
A thumb screw has been made to hold the bars in place.
A quick check on the Grizzly mini mill revealed a problem. I had made the arbor .500” dia. The drill chuck only opens to .375”. So I had to use the .500” collet
A quick check in the Bridgeport showed Ok. Larger drill chuck, that’s why.
The raw stock for the next portion, plus a paper template drawn in AutoSketch.
Line the piece up to drill the two holes for the support bars. Notice that there are two pieces of aluminum in the vise. You’ll get the idea in the next couple of pictures.
The two holes have been drilled and reamed.
Lining up to drill and tap for the clamp screw.
Temporary screw holding it all together.
Again a quick check in the machine to see how it looks.
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Setting up to drill the two holes that will holder the indicator holder.
The hole in between the other two holes is off it’s location. This hole is for the adjustment screw so no big worry.
Fixed by using an end mill larger than the hole. Looks like a busing is in order here.
Hole has been fixed.
Bushings have been added for the two bars that will hold the indicator holder.
The center hole has been bushed and the adjustment screw made and inserted.
Things are starting to come together and look like the first picture. The indicator holder has been milled and is ready for some drilling.
Here the slot is being cut so the indicator can be clamped.
Next job is to make a dovetail groove in the block. The black part is part of the original holder that came with the indicator.
The main slot has been milled. Now to cut the dovetail. I had to make a cutter and will post that in another thread.
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The dovetail has been cut. All that is left to do is make the clamp nut and drill and tap the holder.
But first a quick test in the Grizzly mill. Note that I’ve turned the OD down to .375” so it will fit in the drill chuck.
And it’s reversible too.
Yup, looks good to in the Bridgeport.
Here’s everything assembled, just missing the springs in the two bars between the indicator holder and the end support piece.
I found a spring that’ll work for now. I’ll need to make two springs later on.
As I said this wasn’t meant to be a construction article. Also I came up with the sizes on the fly. If I had sat down and tried to come up with a drawing and dimensions I’d still be sitting there and drawing.
The smaller bars that were press fit into the indicator holder part came from old disk drives. The bars supported the read head. The only problem using them was there diameter size. The sizes didn’t match imperial or metric.
Ok, I’m ready for the questions now.
Bernd
