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Start with a 4 inch square by 5/8+ inch cast iron casting. |
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Mill the edges square (removing casting scale). The first cut needs to be at least 0.030 inch to cut under the scale. Then mill to finished dimension of 3.953 inches. |
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Then flycut the top surface flat (removing casting scale). The first cut needs to be about 0.030 in to cut under the scale. |
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Center the piece in the 4-jaw chuck. I mark where the diagonals intersect. Then I use the point of a center in the tailstock to help me find when it is centered. |
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Center drill to start the hole. |
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Drill a 1/4 inch through hole. |
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Step drill the hole until it is big enough to allow entry of your boring tool. |
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Bore the hole out to 1.892 inch diameter (completely thru plate). You want a nice turning fit for the base of the compound pivot. |
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Step the hole out to a diameter of 2.007 for a depth of 0.301. The next step cut will leave this diameter for only 0.100 inch. |
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Step the hold out to a diameter of 2.520 for a depth of 0.201 inch for the protractor ring. This will leave about 0.030 inch of the protractor ring below the plate for clamping pressure. Dimensions are for a Grizzly G4000. |
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Then drill 1/4" holes in the four corners for the T-bolts in the crossfeed T-slots. The hole pattern is 2.930 inches square. This is about 0.500 inches in from the ends and sides. |
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Finish the clamp of by milling or turning the corners of the clamp plate to a depth of 0.250 inch for the nuts on the T-bolts. This will allow you to get a wrench on the nut when it is under the compound. |
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Here you can see the finished piece mounted on the crossfeed. |
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And here is a picture of the clamp by itself. |
| Part Identification | Compound Measurements |
Clamp Measurements |
| Cross-slide width | 3.957 | 3.957 |
| Compound Base length | 3.925 | 3.925 |
| T-slot center distance | 2.930 | 2.930 (hole to hole center) |
| Clamp Thickness | ||
| Original Clamp | 0.315 | |
| New Clamp | 0.625 | |
| Pivot (round part of compound base) | ||
| Diameter | 1.890 | 1.892 |
| Depth | 0.324 | 0.324 |
| Protractor Dimensions | 0.315 (total thickness) | |
| Protractor Small Circle Diameter | 2.006 | 2.007 |
| Protractor Small Circle Depth | 0.100 | 0.100 |
| Protractor Ring Diameter | 2.519 | 2.520 |
| Protractor Ring Thickness | 0.227 | 0.201 (allows for clamping) |