A bit big for models (again): I need to cut a 'rebate' for a ring gear, about 1" deep & 1" wide, on a 24" dia flywheel weighing about 200 Kg by my calculation. I've had a couple of jobs like this in the past which I've taken away to get them turned, but after someone suggested setting up a rig to mill it in situ (not practical in this case, & the flywheel has to come off anyway), I've been wondering about doing it on my Elliott turret mill. I've got a 14" rotary table, & reckon it's just feasible to do it as far as dimensions of machine etc are concerned. There will be quite a bit of weight overhanging the side of the knee, I can probably rig up some sort of temporary support under the end of the table, as the only table movement needed will be the infeed. Even that I could probably do via the quill, and clamp the table up as solidly as possible. The machine isn't a super duper toolroom job, & not in it's first flush of youth, so I'm not too worried about pushing it to it's limits. Any comments from anyone who'se tried this sort of thing, maybe on a smaller scale, or who can see any obvious pitfalls? (apart from the risk of dropping it on my toe :-( )
I've got another very similar job coming up this winter, if it works it'll save two trips hawking bl**dy heavy lumps around the local machine shops to see who will take the job on! Also, turning it would possibly involve machining up a dummy crankshaft end (this one is a taper fit, the second one is on a bolted flange), unless I can find someone with a big enough chuck to grip the outside. The chap who did them for me before retired some years ago, he did have a nice big Swift lathe but I think that left the district.
Cheers Tim