Building a milling machine

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NormanV:
Pekka, you should give it a try, it is not really all that difficult. Once you've done your first one you will wonder what all the fuss is about. The most important part is getting the patterns right, I am not very patient and my patterns are not particularly neat or accurate but they are just about good enough.
Not yet Andrew, but my stocks are getting low!

NormanV:
The bearings for the drive pulley arrived this morning and it was a pleasure to do some work on the lathe for a change. I have machined the castings to mount the bearings and this afternoon I will get the castings mounted on the bracket that I made last week. I'm still waiting for the splined shaft to arrive so that I can get the backet fixed to the top of the machine.

NormanV:
I'm cheesed off with suppliers, the bearings that I mounted today were ordered yesterday and arrived by post today, postage cost £1.50. Great! Thank you www.simplybearings.co.uk
On Friday morning I ordered and paid for the splined shaft I had to pay £9.50 for next day delivery (that is all they offered, they would not post them), today is Tuesday and they still haven't arrived. When I tried to chase them up the supplier wasn't interested. Aargh!!!

NormanV:
I made a great leap forward today! The splined shaft had caused me problems, it needed to have one end turned down and threaded 12mm. I have an imperial lathe so I tried to thread it with a die, of course it turned out crooked! I admitted defeat and went to a local engineering firm who quoted me £15 to thread it for me. It sounded a bargain so I left it with them. I collected it today and rushed home to fit it, perfection!!!!!
I have now mounted the castings that support the top pulley and everything is turning freely.
The next job is to machine the pulleys, I have decided to use poly V belt as the thinness gives me more clearance around the top casting.
After much searching I managed to find the dimensions for the pulley grooves, now I have to grind a tool to cut them. Does anybody have suggestions on how I can grind it accurately enough to fit the belt?

NormanV:
You may notice the "flywheel" looking object above the head casting. That is a bit of the design of which I am rather pleased. The main spindle is a 25mm spindle with an E32 collet chuck built in. It is mounted in taper roller bearings and needs some way to preload the bearings.
I bought a taperlock bush and pulley. I drilled and tapped the bush to take 4 grub screws that bear on the rim of the top bearing, this enables me to adjust the preload precisely. I turned the flanges off the pulley as they were getting in the way.

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