Week-long resurrection of a heavy horizontal mill

Oct 21, 2026 Last reply: 3 days ago 4 Replies
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Most shops would send a tired old horizontal mill off to a rebuilder, or quietly let it sit and rust. Here someone who says they are not a machinist took a Cincinnati No 5 that a selling dealer had already been through, found it flexing under the cutter, and simply fixed it themselves in a week. That is not the usual route, and it is impressive to read about.



The path to a working machine ran through several failures at once. The table arched 0.120 inches whenever the cutter bit into the stock after the dealer refurbishment, and a contractor had mounted the fixture as far left as possible to cope with that arch. That mounting strained the lead screw until the backlash eliminator bushings gave out, and their housing was no longer holding the bearings properly. The right side apron also broke out. The maker replaced the bushings, repaired the bearing housing, and welded the apron back together, which was their first time welding cast. They also spent countless hours going through the manual and nearly three cases of brake cleaner getting the machine clean.



The cutting setup stands out to me. The fixture clamps the lawn mower blades down with 2000 psi, and the blades are climb milled. Without climb milling the work would get torn loose and flung, so that choice reads as hard-earned rather than casual. During the heavy pass, smoke rises from the cutter contact area, and the machine genuinely looks like it earns its keep.



One thing still open: no photos of the machined surface finish have surfaced yet, though the maker promised to grab some at work. It also sounds like the freshly cleaned machine looks dirty again after only a couple hours of running, which says a lot about the duty it sees keeping blade production alive.


The climb milling decision is the cleverest detail here. Since the alternative is work tearing free mid-cut, running it that way shows the maker understood the cut direction matters as much as the clamping force. Combined with 2000 psi of hold-down pressure, that setup makes heavy passes possible on a machine that was arching badly not long ago.

I am curious about the table problem that started all this. How much was the table actually arching when the cutter engaged, and was that deflection really what overloaded the lead screw and took out the bushings?

From what the maker shared, the table arched 0.120 inches when the cutter engaged material after the dealer refurbishment. The fixture had been mounted as far left as possible to deal with that arching, and that positioning strained the lead screw and bushings until they failed. So yes, the deflection and the failure were directly connected.

A paint job seems like the obvious next step. The maker mentioned the selling dealer essentially only painted it, so a proper strip and respray while everything is apart would suit a machine that gets dirty again within a couple hours of running. Even a partial cleanup of the castings would make the interior easier to inspect during the next teardown.

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