Master Mill is nearly ready to test

The pulley is complete with the exception of set screws aka grub screws.

To cut the keyway I mounted a sharpened woodruff key in a boring bar and broached it by moving the lathe carriage. Lathe motor off.

There are a few blemishes where I did not machine deep enough to get past the aluminum casting shrinkage.  It is better to have the pulley strong and massive than have a perfect complexion.

The plan is to try it without cutting grooves for the poly V belt.  This is the one borrow from the air compressor.  The pulley was sized to make the belt work.  It is approximately 10 inches.

The belt is riding a bit to the inward side of the pulley.  I think I can fix that by moving the motor a bit left.

The motor pulley is also a flywheel and a cooling fan.    It may look funny but without it the motor may overheat.

What's left is this.

• Drill and tap pulley for 2 set screws
• Clean up the flash in the 6 holes.  Sadly it is too large to bolt to the faceplate on the lathe.  It will hit the ways.
• Cut and mount wood to cover the top of the electronics mount cast earlier.   I read that the heat sink should not be grounded.
• Tighten up the column bolts.  Check all bolts.
• 2X check that everything is rotating in the right direction and will not unscrew itself.  I may have to reverse the input shaft in the mill so it comes out the other side.  That or put a set screw in the motor pulley/flywheel.   
• Cable strain reliefs.

Past that everything is cosmetic but the electronics may benefit from a cover and a fan.