DIY Tool Post Grinder for Emco Maximat V10 Metal Lathe

Project:
Making a tool post grinder for my emco maximat v10 metal lathe

Difficulty Level (Easy, Medium, Hard, Insane):
Medium

Process:
A little while after I got my metal lathe I noticed that the jaws of my self-centring 5" 3-jaw Emco chuck were not running as true as I wanted it to so after some research I found several videos of people who used a tool post grinder to surface grind the hardened jaws down to true centric.

The only problem was that I didn't want to spend $700 on a Dumore tool post grinder. However, I had already bought a die grinder at Harbor Freight a few years back that could handle mounted tip grinding stones with a shank of 1/4".

Now, all I had to figure out is how to make a holder for my die grinder so I could mount it to my compound slide. After checking out a whole bunch of videos and articles I came up with my own design. Since I already had my Home Foundry and my Propane Burner set up I got ready to cast me some parts, then used the mill head on my lathe to mill it to specs.

After it was all finished I was able to mound my grinding stone in the die grinder, attach it to the compound rest, true it up with a 1 carat diamond dresser and grind my lathe jaws. Now I run within 1.5 thousandths runout at about 6" away from the chuck. Not too bad for a 42 year old lathe.

Videos:

Pictures:

Pattern for the tool post grinder base

Another view

All the patterns

Another view

Finished drag for one part

Finished mold

Another mold

Cast bracket with expanded riser

Spreading out the dry green sand

Rehydrating the green sand for the next cast

Mulling the rehydrated green sand by hand

The patterns and the cleaned up casts

Turning the smaller ring

Another view

Cutting a chunk of 3.5" aluminum for the larger circle

Drilling the larger circle with 1" drill

Boring the larger circle to size

Cleaning up the outside of the larger circle

Shiny...

Cleaning up the larger circle

Harbor freight die grinder with larger circle done

Larger circle mounted on the die grinder

Both rings on the die grinder where they'll end up going

Cast of the vertical support bracket

Cleaned up support bracket

Milling the support bracket

Teaching my girl some metal working skills. Can't start them too early!

Milling the base

Another view of the base

Tapping the base for the vertical bracket tie-down bolt

The almost finished bracket base (before the main hole was drilled)

One of the rings mounted on the vertical bracket

Another view

My son tapping the larger ring. He's a pro by now!

Clamping the larger ring for some machining

Milling the slot for the tightening bolt

Another view

Cutting the slot on the band saw

Tapping the larger ring

The finished larger ring

Another view

The finished (vertical) bracket that bolts to the base

Another view

Side view

Slightly different angle

And one more

The mounted grinder on the compound slide

Another angle

Another angle

Close-up of the finish ground jaws

Tools:
Home Foundry & accessories
Propane Burner
Chop saw
Measuring tape
Pencil
Metal scribe
Square
Table saw
Metal lathe & accessories
Mill & accessories
Band sander
Vise
Hammer
Drill
Hand saw
Tap & die set
Air die grinder
Stainless steel rasp
Step drill
Drill bits
Drill press
Electric die grinder
Countersink
Digital calipers

Materials:
10 lbs aluminum
7 bolts
1" of 1" cold rolled steel
Tap magic fluid

Cost:
Less than $10.00

Time:
15 hrs

Savings:
$100

Conclusion:
It's totally amazing

Brake Caliper Rubber Boot

Project:
Replacing the rubber boot for our 2011 Dodge Grand Caravan rear brake caliper

Difficulty Level (Easy, Medium, Hard, Insane):
Easy

Process:
We brought our "new to us" van to get it inspected and they told me that almost $1000 worth of brake work was required (which ended up being COMPLETELY FALSE...that's whole other story). So instead of paying them to do the work, as always I figured I'd do it myself. Even though it legally wasn't necessary to change the pads and rotors, and since I've already bought the parts and had the wheel off, I figured I might as well replace the parts. But, I noticed that whichever bozo put the brake caliper back on the rotor last time got the protective rubber boot stuck between the brake piston and the brake pads (insert censored words here).

Oh, and the mechanic told me he thought the brakes were a bit spongy...duh...

anyways...

So I called the dealership to see if they had any rubber boots in stock. To my shock, they didn't. Neither did NAPA, Canadian Tire or any other specialty store I called. Not only didn't they have it in stock, they didn't have them period. According to the dealership you have to replace the entire brake caliper and they quoted me over $200 bucks for it PLUS installation PLUS bleeding of the brake lines...so yeah, i'm not gonna pay $300 bucks because a $10 part was damaged.

I put it all back together, went on ebay and ordered the

Centric Brake Caliper Repair Kit 143.67013 for $10 bucks plus another $10 for shipping.

Putting it in was as easy as

Driving the van up on my Car Ramps

Jacking up the van

Taking off the rear right wheel

Taking off the brake caliper

Taking off the broken seal

Putting the new seal on the piston

Putting the brake caliper back on

Putting the wheel back on

Taking the van back down

All in all, it cost me $20 and took about 15-20 minutes. Love paying myself $840/hr to do my own work!!!

Pictures:

Yeah, wasn't very happy about this

Wheel's off

The brake in question

The rubber sleeve between the piston and the brake pads

Ugghhh...

The old piston boot

After the rubber boot was removed

The new $10 rubber boot

After it was installed

Tools:
Car Ramps
Jack
Impact driver
Socket set
Screwdriver

Materials:
1 Centric Disc Brake Caliper Repair Kit 143.67013

Cost:
$20.00

Time:
20 minutes

Savings:
$280.00

Conclusion:
Works great!