Acknowledgement
The set of drawings has been verified by the construction of a grinder from them. Any
mistakes or omissions being corrected when found. This grinder is illustrated below and I
would like to thank Laurie Clarke ( Melbourne Australia ) who made it and kept me
informed. The drawings should be reliable but I take full responsibility if this proves not
to be the case.
Don Willis
Bonelle TCG Drawing Revisions
20/2/04
21/02/04
23/02/04
24/02/04
25/02/04
26/02/04
28/02/04
01/03/04
06/03/04
06/03/04
06/03/04
30/03/04
31/03/04
22/05/04
00/00/00
00/00/00
00/00/00
00/00/00
G4 rev 1 dim 2 ½ was 2 3/8, G3 rev 2 notch added
L1 minor changes principally to clarify ‘where used’
C7 Sketch added to show positioning of components.
L2/2 13/13” was 7/8” Rearranged to show slots more clearly.
Cross references to keys & clamps ( Drgs L1 & L2) corrected on drawings :B2, B4, D1, G1, G2, G10, H1, H3, K4.
B2 Shape corrected to correspond with B3
C10/2 scale added
C2/4 added
G11 dim 4 7/16" was 4 5/16"
H2 missing dims added
G5 dim1 5/8" was 1 11/16"
H1 assembly clarified
H7 & H8 added
D1 dim 2 1/2" added
Bonelle TCG
Drawings
A. General Arrangement
B. Base
C. Wheel head
D. Wheel Guard
E. Dust Containment
F. Spindle
G.Workhead
H.Toolholder
J. Front Bar
K.Tooth Rest
L.Miscellaneous
Conventions used.
The drawings are arranged so that detail drawings follow
immediately after the assembly on which they are used and bear the
same drawing prefix letter A,B, etc. Details are usually easily
identifiable on the assembly by their appearance. Specific reference
by detail number is only made when this is not the case.
The drawings do not show tolerances and mating parts have the same
dimensions. The necessary clearances must be considered and
provided during manufacture.
Conventions used continued
Reference to a detail .........
F12
3
= Drawing showing that detail.
= Detail number on that drawing.
Detail Numbers.................
Det 3
(2)
S
B
CI
S
SS
L
Example:- Det3 (2) S.
= Detail number
= Quantity required
= Material.
= Brass
= Cast Iron (Continuously Cast Bar)
= Bright Mild Steel
= Silver Steel
= Leather
Fixings............................
© J.B.D.Willis
Example:- F12/3
The nature of the fixing is shown by the
drawing (cheese head screw, cap head
screw etc) only the size is specified eg.
2BA X 3/8".
Bonelle TCG
30
30
20
20
10
0
10
Half Size
column height not to scale
C
J.B.D.Willis.
Revision
0
Date
22/10/00
General Arrangement (Front Elevation)
Drg No A1
Bonelle TCG
column height not to scale
Half Size
C
J.B.D.Willis.
Revision
Date
0
24/10/00
General Arrangement (Side Elevation)
Drg No A2
Bonelle TCG
Section A - A
40
A
30
20
A
10
0
10
20
30
40
C
J.B.D.Willis.
Revision
2
Date
17/03/03
Base Assembly
Drg No B1
Bonelle TCG
B4/5
secure with Loctite
Ensure that B6/1 & B6/2 are in the
same plane then secure B6/2 with Loctite.
B6/2
1/16
B6/3
12"
B4/6
secure with Loctite
( see note on C7
regarding levelling
screws)
B6/1
C
J.B.D.Willis.
Revision
2
Date
26/02/04
Base Sub Assembly
Drg No B2
Bonelle TCG
11 "
2 1/4 "
3 1/2 "
1 3/8
1 3/8
1 1/8 "
3 1/2 "
1 1/2
F
2in
C
15/16
1 7/8 "
C
C
1 1/2 "
C
1 1/2
60°
1"
1
1 5/8 "
1 3/16
1 7/16
1 3/8 in
15/16 in
3 1/4 in
A
1 1/2
1 1/2
F
CL
1/2 in
3/8 in
1 1/4 in
D
1/4 "
A
E
E
3/8
1 3/8 in
B
F
1 7/16
40mm see note on C4 (cleans up to 1.54" typically)
Tap M4 10mm deep on 1 1/2 " pcd
see note on C4
1 1/4 in
1 3/16
Tap M8 3/4 " deep
2 BA
B
E
9/16 1 1/8
F
E
1 1/4 "
retain offcut
to make K2/1
4BA X 3/8
Tap M4 10mm deep
on 1 1/2 " pcd
120°
F
Det 1 (1) CI
C
J.B.D.Willis.
Ø1 1/4
1 7/8
3 1/2"
Revision
Date
5
20/03/03
41/64"
5/8"
8 mm
Det 2 (1) CI
Notes
1. Lightly machine faces check that they
at 90deg to each other.
2. Bolt together using holes C.
3. Bore holes A to give close slide fit to bar
4. Holes B to be .003" larger than A
5. Hole D to be a push fit on vertical bar
6. Holes E (on underside ) 2BA X 3/8"
7. Holes F 9/32" C'Bore 1/2" X 1/2"
Base Details (A)
Drg No B3
Bonelle TCG
1 1/2"
1/4"
1 1/8"
1/4"
1/2"
1/4" *
1/2"
1/2"
1/4"
1/2"
Ø3/16"
1/4" knurl
Det 2 (1) S
A"
1/4" knurl
7/8"
3/8"
1"
5/8"
5/8"
2 BA"
5/8"
Det 3 (1) S
J.B.D.Willis.
Revision
1
1 1/4"
1"
Det 4 (1) S
Date
17/03/03
1/2"
9/32" dia
* adjust these dimensions to suite actual sizes of B3/1 & B3/2
C
3/8"
2 BA"
Det 1 (1) S
Base Details (B)
Det 5 (2) S A = 1 3/4"
Det 6 (1) S A = 2"*
If levelling screws are to be
incorporated as shown in
Z2 or Z3 then det 5 and 6
to be modified accordingly.
Drg No B4
12 7/8""
3/8"
Bonelle TCG
3 Holes
5/8" knurl
Tap 2 BA 3/8" deep
Det 1 (1) S
1"
3/16"
1/4"
5/8"
5/8"
1"
5/8"
11 3/4""
1/4"
13 3/4""
13 1/4""
1 3/16 "
3/8"
Det 2 (1) S
3/8"
1 1/2"
1/8"
3/8"
3/16" dia
3 3/8"
1 1/2"
1/16"
11/16" "
1/8"
1/2"
1/2"
5/8"
C
J.B.D.Willis.
Revision
1
Date
16/12/03
Det 3 (1) S
3/16" dia
Base Details (C)
3/4"
2 BA
Det 4 (1) S
Drg No B5
3 1/4"
3/8"
3/8"
1/2"
1"
15 3/4" "
Bonelle TCG
Det 1 (1) S
!/32" chamfer
1"
Det 2 (1) S
1 1/4"
Det 3 (1) S
15 5/8" "
13 /1/2" "
C
J.B.D.Willis.
Revision
0
Date
29/10/00
Bar Details
Drg No B6
Bonelle TCG
C
J.B.D.Willis.
Revision
1
Date
28/02/04
Wheelhead Assembly
Drg No C1
5 7/8
Bonelle TCG
3/8" holes fitted with
bushes tapped 1/4 BSF
1.96 see note
3/16
5/16
1/8
5 1/2
3
2
7/16
1/4
2
C
L
2 3/4
2
4 3/8
CL
1 3/8
5
7/32
4.5 mm
Det 2 (1) S 1/16" thick
8.5 mm
3/8
1/2
5/16
4 BA c'sk
1 3/4
3 1/8
M5
1/4 " c'sk (for Parvalux SD13 Motor)
Det 3 (1) S
3/16
NOTE
The (UK) continuously cast
iron bar is metric ie 50 mm
and, when cleaned up
results typically in a separation
between arms of 1.96"
1/32
2
2 3/8
3/8
1/2
1/4
1 3/8
csk for M5 screws
Det 4 (1) S
Det 1 (1) S
C
J.B.D.Willis.
Revision
3
Date
14/03/04
Motor Mounting Plate
Drg No C2
Bonelle TCG
1 1/4"
Bore to suit spindle
Ø1 3/8"
3/8"
if used with
spindle F1
13/32"
1 3/16 " 1"
2"
Ø1 9/16"
if used with
spindle F1a
CL
11/16"
3 11/16"
1 3/8"
1"
9/32" "
1 3/8"
Det 1 (1) S
C
J.B.D.Willis.
2 7/16 "
Revision
Date
2
12/2/04
All tapped holes M5
All clearance holes 5.1mm
1 3/8"
9/16"
Det 2 (1) S
Wheelhead Arms
Drg No C3
4"
3/4"
1/8"
Bonelle TCG
2" 1 3/8"
1 3/8"
4BA 1/4" deep
M5 3/8" deep both sides
2 3/4"
1 1/8"
1 3/8"
1/4 BSF
Ø1/2"
2" 1 1/2"
9/32"dia
9/32""
C
J.B.D.Willis.
Revision
1
Date
09/03/03
Wheelhead Details
Drg No C4
Bonelle TCG
Ø2 3/4 "
1/2 "
Ø1 "
R1/16 "
12 mm
5/16 "
5/16 "
2 BA
2 3/4 "
2 BA
15/16 "
3/16 "
Det 1 (2) S
3/32" key way
Ø1/4 "
1/2 "
7/8 "
5/16 "
1/2 "
3/8 "
1/4 "
k
BSF
2 7/16 "
5/16 "
J.B.D.Willis.
n
Revision
0
Date
29/10/00
1/4" BSF
1/4 "
3/32 "
Det 3 (2) S
3/16 "
C
1/4 "
Det 2 (1) S
5/8 "
1/4 "
3/8 "
1/2 "
Det 4 (2) S
Wheelhead Details
Drg No C5
13/16 in
Bonelle TCG
R1 5/8 in
Form and connect by
strip riveted accros joint.
3 1/16 in
1/16 in
6 3/4 in
1 3/8 in
2 7/16 in
Solder or
Araldite
Ø5/16 in
4.8 mm dia
R1 1/8 in
Ø3/8 in
15/16 in
Section on centreline
C
J.B.D.Willis.
Revision
Date
0
24/10/00
Pulley Cover Assembly
Drg No C6
C11/2
C8/2
Fit det 1 so that
scribed lines will
aligne with
those on C10/2
CL
Oilite
Bushes
Using a surface plate assemble
3/32" C8/1 & C8/2 to C11/2 using Loctite
1/4" so that they are positoned and
supported as shown.
Ideally bar B6/3 should be used in this
proceedure. The flat bed of a lathe
may serve instead of a surface plate.
Det 1 (2) S
C
J.B.D.Willis.
Revision
1
Date
23/02/04
Wheelhead Guide Assembly
3/8"
Scribe Line
1/8"
3/16"
otherwise as L2/1
7/8"
C8/1
Bonelle TCG
Drg No C7
Bonelle TCG
2" "
9/16" "
Ø7/16" "
Ø1/2" "
9/16" "
Ø7/16" "
9/16" "
R3/8" "
Ø1/8" "
3 3/8" "
2" "
1 11/16" "
C
L
3/16" "
2" "
tap 2BA
Ø3/16" "
5/8" "
Ø1 1/4" "
R1/4" "
1/4" "
1 5/8" "
3/4" "
Ø1 1/4" "
7/32 "dia
Det 1 (1) S
C
J.B.D.Willis.
Revision
0
Date
18/04/03
Wheelhead Guide Details
Det 2 (1) S
Drg No C8
Bonelle TCG
Holes
Ø3/16 " locate on spigot
from det C8/2
Ø3 "
Rivet det2 to det 3 using 1/16" rivets
1 13/16 "
Ø3 "
Ø1 1/4 "
Ø1 1/4 "
1/4 "
40
30
20
10
0
10
20
5/8 "
30
40
1/4
90
1 5/8 "
1 7/8 "
1/4 "
90
2 3/16 "
1/2"
5/32"
engrave
line
Det 1 (1) B 1/8" thick
C
J.B.D.Willis.
Revision
0
Date
29/10/00
1/4"
5/8 "
2"R
1 1/
Det 2 (1) S 1/8" thick
Wheelhead Guide Details
Det 3 (1) S 1/16" thick
Drg No C9
1 1/4"
1/8"
5/16 " "
1/8"
1/8"
knurl
Bonelle TCG
0
20
10
1/2"
40
0
scale
1/2"
1 1/8"
5/16 " "
3/4"
R1/2"
7/16 " "
1 3/4"
3/8"
7/16"
7/8"
1/8"
1/4"
3/8 " BSF
recess 1/16 " deep
3/16"
Det 1 (1) S
Revision
1
1/16"
1/8"
Det 4 (1) S
Date
28/02/04
R1/4"
Ø1/8"
Det 2 (1) S
1/8"
1 1/4"
7/16 " "
J.B.D.Willis.
1/8"
1 1/8"
10 1/4 " "
C
30
Jack Screw Details
Det 3 (1) S
1 1/4"
3/8"
Ø1/8"
Det5 (1) B
Drg No C10
Bonelle TCG
1 1/2 "
3/4 "
7/16 "
9/16 "
1/2 "
13/16 "
5/16 "
10"
1"
15/16 "
8"
8"
9 7/8"
1/8 "
5/16 "
13/32"
1/2 "
7/16 "
tap 3/8 BSF
4 BA
1/2 "
Ø5/32 "
18g
1 1/2 " 1 "
13/16 "
3/8 "
5.1mm
J.B.D.Willis.
Revision
0
1/2 "
Det 2 (1) S
Det 1 (1) CI
C
Ø7/16 "
Date
29/10/00
Wheelhead Guide Details
1 9/16 "
Det 3 (1) S
Drg No C11
Bonelle TCG
2BA X 1 1/4" brass earthing stud
fixed into tapped hole in motor frame.
Box fixed to Det C11/1
by two 2BA c'sk screws
L
Det C11/4
N
Det C11/3
Det C12/2
Det C11/1 fixed to motor frame by
stud and 2BA screw (tap frame)
C
J.B.D.Willis.
Revision
0
Date
24/10/00
Switchbox Assembly
Drg No C12
Bonelle TCG
adapter plate
/
13/16 "
3/4 "
R1 "
1 1/8 "
CL
40mm
3
Ø7/32 "
Ø3/8 "
Ø1/2 "
1/16 "
to match adapter plate
Hole for mains inlet
chassis Euro Plug
Det 3 (1) S
7/8 "
2 1/2 "
Ø7/32 "
CL
1 1/2 "
1 7/8 "
1/2 "
1 5/16 "
1/2 "
Ø1/2 "
3 1/4 "
1 7/8 " 2 1/2 "
3 1/4 "
c'sink on underside
for 2BA screw.
Det 1 (1) S
J.B.D.Willis.
Revision
0
Date
2 1/2 "
to form soldering tag
Box ;- SAREL PB256
Earthing plate :- 0.015th brass
Det 2 (1)
29/10/00
1 1/2 "
corner bent
Ø7/32 "
1/8" thick adapter plate BMS or Tufnal.
C
1 1/2 "
Switch Box Details
Det 4 (1) B
Drg No C13
Bonelle TCG
L1/1
1/16"
R2 1/8"
Ø1 3/4"
L1/7
2 1/2"
3/32"
R1 5/16"
D2
welds
2 1/8"
3/16" csk for 2BA scr
Det1(1)S
C
J.B.D.Willis.
Revision
2
Date
22/05/04
Wheel Guard
Drg No D1
Bonelle TCG
15/16 "
2"
13/16"
1/2"
1/4"
13/16"
7/32 "dia
1/4"
13/16"
1 3/4"
tap 2BA
2"
13/16 "
45°
tap 2BA
1/8"
5/16"
all sawcuts 1/16 " wide
C
J.B.D.Willis.
Revision
1
Date
30/01/04
Wheel Guard Boss
Drg No D2
Bonelle TCG
2 3/16 "
15/16"
1/2"
1/4"
13/16"
7/32 "dia
1/4"
13/16"
1 3/4"
tap 2BA
2"
13/16"
tap 2BA
1/8"
Ø1 9/16"
13/16"
all sawcuts 1/16 " wide
C
J.B.D.Willis.
Revision
0
Date
11/2/04
Wheel Guard Boss
Drg NoD2a
Bonelle TCG
15/16"
2"
13/16"
1/2"
1/4"
1 1/16"
7/32 "dia
13/16"
1/4"
2"
tap 2BA
45°
13/16 "
tap 2BA
1/8"
Ø1 1/2"
1 3/4"
all sawcuts 1/16 " wide
C
J.B.D.Willis.
Revision
0
Date
11/2/04
Wheel Guard Boss
Drg No D2b
BonelleTCG
E2/3
E2/1
E2/2
C
J.B.D.Willis.
Revision
1
Date
30/01/04
Dust Containment Mask
Drg No E1
7"
1/4"
CL
1 3/4"
1/2"
2"
Ø5"
2 1/4"
1/8"
4 3/4"
/16
5
11
3/4"
Det 1
"
2"
4 3/4"
1 15/16 " "
1 1/4"
1"
1/16"
Det 2
Det 3
Material :- 4mm polycarbonate sheet
C
J.B.D.Willis.
Revision
1
Date
30/01/04
Dust Containment Details
Drg No E2
1/2"
5/16"
Millennium TCG
3/16" square X 1 13/16"
fix by two 1/16" rivets
boss as drg D1
1"
1/8"
1/4" dia
1 5/8"
4 3/4"
Ø1 1/4"
Ø1 3/4"
1"
3/16"
1 5/8"
3/4"
2 1/2 " "
Welds
Ø3/16 csk for 2BA scr "
C
J.B.D.Willis.
Revision
0
Date
30/01/04
2 1/4"
Section on CL
Dust Containment Casing
Drg No E3
Bonelle TCG
1.5 X F/S
BEARINGS :- BSI series BML EN metric series (EN13)
C
J.B.D.Willis.
Revision
Date
1
12/2/04
Spindle Assembly
Drg No F1
Bonelle TCG
1/8"
30
1/16"
3/8"
3/16"
1 13/16"
13mm"A" B"
3/16"
1 3/8"
1" 1 1/4"
b" a"
1 1/16 "
1/4"
A = a + 0.005 "
B = b - 0.005 "
Det 3 (1) S
five grooves in bore
a =3/4 "
1/32 " wide 1/32 " deep
b=1"
Det 2 (1) S
9/16"
Det 1 (1) S
1/4"
5 3/32 "
1/16"
15/32"
13/32"
1"
11/16 " across flats
40°
5/16"
J.B.D.Willis.
13mm"
3/16"
All threads 32 TPI
Det 4 (1) S
C
9/16"
C" = 5/8 "
1/16"
5/16"
B" A"
1/2"
A = a + 0.005 "
B = b - 0.005 "
Revision
Date
0
29/10/00
Det 5 (1) S
Spindle Details
Drg No F2
Bonelle TCG
3 3/4"
1 3/16 "
7/16"
3/16"
3/16"
15/32"
1 3/8" 1 1/4"
30mm"
5/8"
7/8"
30mm"
1/16"
13mm "
c = C - 0.005 "
( see F2/2 )
1/16"
2 7/16 "
Det 1 (1) S
Det 2 (1) S
2 25/32"
5/8"
1.179 " "
1 7/8"
1/32"
1"
13/64 ""
c"
29/32"
3/4"
19/32 "
Ø5/8"
13mm "
15/32"
Det 4 (1) S
Det 3 (1) S
C
J.B.D.Willis.
Revision
1
Date
02/03/03
Spindle Details
Drg No F3
Bonelle TCG
3/16"
1 1/8"
3 3/16 "
L"
D"
5/16"
Det 1 (1) S
40°
3/8"
5/8"
5/8"
5/16"
3/16"
1/4"
1 1/4"
knurl
3/8"
tap 2BA 1/2" deep
each end
Det 2 (3) S L = 7/16" D = 1/2"
Det 3 (1) S L = 5 1/2" D = 1/2" omit tapped hole
Det 4 (1) S L= 2 3/4" D = 3/8" omit tapped hole
3/16"
h" 1 1/2"
Det 5 (3) S h = 1/2" Det 6 (3) S h = 3/16"
C
J.B.D.Willis.
Revision
1
Date
30/01/04
Spindle Details
Drg No F4
Bonelle TCG
1 9/16 "
BEARING :- ISO 7202 15mm bore X 35mm outside dia X 11mm wide
C
J.B.D.Willis.
Revision
0
Date
7/2/04
Spindle Assembly (ISO)
Drg No F1a
Bonelle TCG
5"
13/32 "
3/8"
13/32"
7/32"
3/16"
40°
5/16"
19/32"
32 TPI
23/32"
a"
9/16"
Det 1(S)1
Det 2(S)1
1/4"
19/32"
5/8"
see F3/3
Loctite together
23/32"
b"
1/16"
1"
11/16"
2 7/16 "
15/32"
thread to mate with Det 1
Det 3(S)1
C
J.B.D.Willis.
Revision
Date
0
12/2/04
Det 4(S)1
Spindle Details
Det 5 (S)1
Drg No F2a
Bonelle TCG
3 3/4"
1 3/8"
2 1/4"
1/16"
5/8"
1/16"
25/32 "
1 9/16"
1 1/8"
35mm "
35mm"
1/4"
5/16"
Det 3(1)S
C
J.B.D.Willis.
Revision
0
3/16"
23/32 + 0.005"
a"
A " B"
a = A - 0.005" b = B + 0.005"
A = 1 1/8" B = 7/8"
Spindle Details
Det 2(1)S
5 grooves in bore
1/32" X 1/32"
1 7/16 "
1 9/16 "
approx
3/16"
Date
8/2/04
Ø7/32"
3/16"
19/32"
b"
1/32"
Ø23/32 "
3/8"
30deg
1 13/16"
35mm"
1/4"
5/8"
Det 1(1)S
Ø5/8"
15/32"
1/16"
Det 4(2)S
Drg No F3a
BonelleTCG
B
30
30
20
10
20
0
10
B
C
J.B.D.Willis.
Revision
1
Date
24/02/04
Workhead Assy ( Front Elevation )
Drg No G1
Bonelle TCG
L1/3
L1/4
L2/5
Section A - A
A
L1/6
Loctite stud
into arm G8/2
L2/1
L1/1
A
C
J.B.D.Willis.
Revision
1
Date
24/02/04
Workhead Assy ( Side Elevation ) Drg No G2
R1/2"
Ø5/16"
Ø1/16"
R1/2"
3mm"
Ø5/16"
Bonelle TCG
5/16"
3/8"
3 1/8"
Ø5mm"
R1 7/8"
CL
2 9/16 "
1 3/8"
3/4"
5/16"
CL
5/16"
R1/4"
R1 3/8"
1/2"
3/4"
2 1/2"
32°
slots 3/16" wide
32°
Det 1 (1) S
1/4"
Det 2 (1) S
3/32"
Ø5/16 BSF "
7/8"
1"
5/16"
20
1/16" dia pin
Det 3 (1) S
C
J.B.D.Willis.
Revision
2
Date
20/02/04
Front and Back Plates
Drg No G3
Drill two 1/8" dia holes eachend
then c/bore & mill recess in back face.
0.6" PCD"
Bonelle TCG
4 9/16 "
3 1/4"
2 1/2"
5/16"
1 1/8"
Front
1 3/4"
3/8"
41/64 "
3/8 ""
1 5/16""
each end.
3/16"
5/32"
32 TPI
1/2"
C/Bore 1/8" deep
40mm"
CL
3/16"
2 1/2"
3/8"
3/16"
M5
Rear
40mm"
1 1/2"
Section on
C
J.B.D.Willis.
Revision
1
CL
Ø1"
Date
20/2/04
1/2"
CL 3/4"
Ø5/8 "
Sliding Base
Drg No G4
Bonelle TCG
3/8""
5/16""
1/4"
1/8"
1/8""
5/16""
5/8""
31/32"
90°
2 3/4"
2 1/2"
2 3/8""
2 1/4"
3"
5/8""
7/8""
1/16""
1/2"
1 5/8"
7/16""
1/8""
1/16""
1/4"
Det 1 (1) S
Det 2 (1) S
Ream 1/4" dia
Det 3 (1) S
Det 4 (1) S
Make det 3 initially oversize then finish overall on mandrel to ensure concetricity of hole and to mate with G9
Assemble dets 1,2 & 3 using Loctite then lightly machine top face of det 1with assembly on mandrel
Assemble det 4
C
J.B.D.Willis.
Revision
2
Date
06/03/04
Rotating Base
Drg No G5
Bonelle TCG
45°
0
0
90°
10
slot
5mm
2 0
( omit scale )
0
15/16" "
7/8""
90°
3 0
4 0
90deg "
scale marking
4 0
3 0
0
90°
2 0
0
10
scale repeated in
3 quadrants only
0
slot 3/8" W X 3/8"L
C
J.B.D.Willis.
Revision
0
Date
29/10/00
Rotating Base Details
Drg No G6
1 1/4 "
Bonelle TCG
3/16 "
5/8 "
1/8 "
5/16 "
11/32 "
1"
38
3/4 "
7/16 "
R1 1/2 "
3/16 "
15/16 "
5/8" dia bore to be
parallel with base
1 1/4 "
Ø3/16 "
1/2 "
tap 2BA
Det 1 (1) S
Det 2 (1) S
3/16 "
3/8 "
3 1/2"
5/8 "
3/8 "
1/2 "
3/4 "
k
5/8 "
2 BA
3/8 "
Det 3 (1 ) S
C
CL
J.B.D.Willis.
Revision
0
Det 4 (2) S
Date
29/10/00
Rotating Base Details
1/8 "
3/8 "
Det 5 (2) S
Drg No G7
R1 31/32 " "
1/8" "
Bonelle TCG
7/8" "
R1/2" "
R7/32 " "
3 1/16 " "
2 1/2" "
2 1/4" "
Ø5/16" "
30
1 3/8" "
1 7/8" "
30
20
27/32" "
20
10
0
10
5/16" "
tap 2 BA
R7/32 " "
R9/32 " "
1/2" "
Ø1/8" "
Det 1 (1) B
3/16" "
R3/16 " "
Csk on back
1/8" "
Det2 (1) S
scribe line
3/16" "
1/8" "
Det 3 (1) S
C
J.B.D.Willis.
Revision
0
Date
18/03/03
Workhead Details
Drg No G8
90°
1/4"
5/16""
3/16""
Bonelle TCG
3/8"
1/8"dia
3/16""
1/2""
1 1/8" "
1/2""
3/16" "
5/16""
1/2""
25/64" "
9/16""
5/8"
7/8""
1/2""
Ø1 1/8"
5/8""
3/8""
1/2" ream"
5/8""
3/8""
Ø1"
R1
1/2
"
1 1/4""
3/8""
1/8""
1/8""
1"
Tap M5 3/8" deep
1/8"dia
Assemble to det 1 locating
on a 1/8" dia pin using
Loctite
2 11/16""
Det 2 (1) S
Det 1 (1) CI
C
J.B.D.Willis.
Revision
2
Date
28/02/04
Tilting Bracket
Drg No G9
Bonelle TCG
L1/1
C
J.B.D.Willis.
Revision
2
Date
10/03/04
Rocking Arm Assembly
Drg No G10
Bonelle TCG
1 3/8"
1"
6 3/16 "
4 7/16 "
1 3/8"
5/16"
5/8"
3/4"
11/16 "
1/2"
7/32"
1 3/8"
1 1/4"
2"
4.5 deg
Ø5/16"
1/4" BSF
Ø9/32"
C
J.B.D.Willis.
Ø1 1/2"
drill after assembly.
3/32"
Ø3/16"
Ø3/8"
Revision
2
Date
06/03/04
Rocking Arm Detail
1/2"
Ø9/32"
Drg No G11
3/4"
3/4"
1/8"
1/4"
Bonelle TCG
7/32 "
1/2" 30 TPI
3/16"
5/16"
CL
3/4"
1 1/8"
1 1/4"
R1/8"
4 BA
1/2"
3/8"
Det 3 (1) B
30 TPI
Det 2 (1) S
1 1/2"
1/4"
Ø1/4"
1/2"
knurl
5/16"
4 BA"
1/2" long
1"
3/4"
2 7/8 " "
1/2"
3/16"
40 graduations 9deg apart
8 longer lines 45 deg apart
Det 1 (1) S
C
J.B.D.Willis.
Revision
0
Date
17/03/03
3/16"
Det 4 (1) S
Harden
end
1 7/16 "
Det 5 (1) SS
Det6 (1) S
Rocking Arm Details
Drg No G12
Bonelle TCG
10 pairs
2 3/4"
6BA X 1/4"
1 1/8"
Det 1 (40) L1/32" thick
Apply a 1/8" wide band of impact adhesive to each edge
that is to be joined. Join then stich together 1/16" from
the edge. Join initially in pairs at the centre then at the periphery.
C
J.B.D.Willis.
Revision
0
Date
11/03/03
Bellows
Drg NoG13
3/8"
Bonelle TCG
3/32"
a
b
1 3/4" 1 5/8" 1 1/2"
1 11/16"
1 3/8" 1 1/16 "
a
Holes
a - tap 6BA 90deg apart
b - 3mm csk 6BA "
c - 4mm 180deg apart
Threads
24 TPI
b
1/8"
3/16"
Det 2 (4) S
Det 1 (2) S
1/16"
1/16"
3/8"
3/16"
c
a
2 1/4"
2 1/8" 1 11/16"
1 3/8" 1 15/16"
2"
1 1/2" 2 1/8"
a
c
Det 4 (2) S
Det 5 (2) S
1/16"
Det 3 (2) S
C
J.B.D.Willis.
Revision
0
Date
31/03/03
Dust Seal Details
Drg No G14
Bonelle TCG
Assemble H6/2 & H6/3 using
Loctite with H6/3 vertical
L2/3
L2/1
C
J.B.D.Willis.
Revision
2
Date
30/03/04
Toolholder Assembly
Drg No H1
41/64" "
2"
Bonelle TCG
2.3mm dia
1 15/16"
3/8"
3/4""
1 1/2" "
"
Ø1
1 3/8"
3/4"
1 1/16 "
3 5/16""
2"
5/16""
9/16"
5/32""
29/64" "
13/16"
Ø5/8"
Ø9/16"
1 1/8"
1 1/2" "
3/4""
3/16"
drill 2.3mm dia
c'bore 7/32" dia X 1/8"
1 15/16""
Prepare 50mm x 50mm x 3 5/16"
blank then bore all the principal
holes before cutting profile.
C
J.B.D.Willis.
Revision
2
Date
06/03/04
Ø5/8"
Toolholder ( Initial Stage )
Drg No H2
7/16"
Bonelle TCG
1/4"
Ø1 1/4"
7/16"
a
a
1/8"
a
a
R1 1/2"
a
5/16"
3/8"
5/16"
a
3/8"
Holes marked a
refer to drawing L2.
assemble clamp and transfer hole
position onto clamp using 2.3mm drill.
Remove clamp and tap hole 6BA.
C
J.B.D.Willis.
Revision
2
Date
25/02/04
1 1/8"
Toolholder ( Final Stage )
For remaining dimesions
see drawing H2
Drg No H3
Bonelle TCG
5/8"
R1/4"
30
3/8"
0
2 5/8"
2 1/8"
1 3/16 " "
40°
3"
0
1 1/2"
1/16 ""
3 1/4 PCD "
0
Use S2 centre drill,
0
10
20
30
40
40
30
20
10
0
Scale ( repeated in each quadrant )
C
J.B.D.Willis.
Revision
Date
1
17/03/03
Toolholder Index Plate
Drg No H4
Bonelle TCG
15/16 "
Ø1"
R1/4"
3/8"
2 1/8 " PCD "
20 TPI
1 3/16"
1/16 "
1 1/2"
40°
30°
1 3/16"
20 TPI
1 3/4"
1/16"
1/4"
Slots extend over threads to give thickness of 1/16 "
Det 1 (1) S
C
J.B.D.Willis.
Revision
0
Date
31/03/03
Det 2 (1) S
Toolholder Collet
Drg No H5
1/4"
5/32 "
3/16 "
1/4"
Bonelle TCG
1/8"
2 1/4"
Ø1 1/4"
3/4"
1/4"
60
Knurl 9/16"
1/2"
5/16"
1/8"
1/8"
1/2" dia
1 1/16 "
Det 1 (1) S
Ø3"
5/16"
Ø5/16"
3/4"
Det 2 (1) S
1/2"
1/4"
1/8"
Det 3 (1) B
engrave line
C
J.B.D.Willis.
Revision
0
Date
31/03/03
Toolholder Details
Drg No H6
Bonelle TCG
1/4" X 1" dia key with 1/8" handle
Loctite
press fit
C
J.B.D.Willis.
Revision
1
Date
19/04/04
Headstock Linkage Assembly
Loctite
Loctite
Drg No H7
Bonelle TCG
1 1/2"
1 1/8"
Ø1/4"
1"
5/8"
5/8"
Ø1"
Ø3/16"
3/8"
1/8"
1/2"
3/8"
5/16"
Det 4 (1)S
R3/4"
2"
1/4"
3/16"
Ø5/16"
5/16"
1 1/2"
7/8"
1/4"
5/16"
7/16"
1 1/32 " 3/16"
Ø5/8 "
R1/2"
Det 2 (1)S 1/4" thick
J.B.D.Willis.
Det 5 (1)B
1 3/4"
5/8"
3/16"
1/8"
C
1/4"
Det 3 (1)S
3/8"
1/16"
4.7mm for interferance
fit of det 7
3/16"
Det 1 (1)S 1/4" thick
Revision
1
Date
19/04/04
6BA X 3/8"
Det 7 (1)SS
Det 6 (1)S
Swinging Headstock Linkage
Drg No H8
Bonelle TCG
C
J.B.D.Willis.
Revision
0
Date
24/10/00
Front Bar Assembly
Drg No J1
1 3/4 "
1/4 "
Bonelle TCG
1 3/8 "
1/2 "
5/16 "
3/16 "
3/4 "
1/4 "
1/4 "
5/16 "
3/4 "
1"
7/16 "
3/16 "
3/8 "
5/16 "
1/2 "
1/16 "
1/2 "
1/16 "
Det 3
Det1
1/2 "
Det 2
1"
15/16 "
1 1/2 " knurl
1/8 "
1/8 "
1 3/8 "
1/4 "
3/4 "
24 TPI
3/16 "
1/4 "
5/16 "
Revision
0
1/2 "
1/4 "
Det 4
J.B.D.Willis.
3/8 "
5/32 "
2BA 1/2 "deep
C
1 3/16 "
Det 5
Date
29/10/00
Micrometer Details
Drg No J2
3/8 " BSF
Bonelle TCG
1"
7/32
3/16 "
Ø1 15/32 "
5/8 "
3/16 "
Ø3/4 "
1 3/16 "
1 1/16 " 1 3/4 "
2 BA
R9/16 "
13/16 "
1/2 "
5/32 "
Det 1 (1) S
1 3/4 "
Det 2 (1) S
5/32 "
1 3/16 "
5/8 "
0
1/2 "
3/8 "
1 5/16 "
1 1/4 "
1 1/16 "
1/8 "
1 1/4 "
10
20
30
40
0
60 1 3/16 "
Thimble Scale
1/2 "
Ø1 1/2 "
Det 4
Det 3 (1) S
C
J.B.D.Willis.
Revision
0
Date
29/10/00
Micrometer Details
Drg No J3
Bonelle TCG
Loctite J2/4 to column
2 7/16 "
C
J.B.D.Willis.
Revision
0
Date
24/10/00
Tooth Rest Column Assembly
Drg No K1
9/16"
2 11/16"
1/2"
1 1/8"
Bonelle TCG
1/2"
1"
9/16"
3/16"
Ø3/8"
3/8"
7/16"
3/8"
1 5/16 "
1/4"
7/16"
1"
5/16"
1 15/16"
3/4"
7/8"
25 TPI
1/2"
Ø1 "
1/4"
Det 4 (1) S
1/2"
9 1/2 " "
Det 3 (1) S
3/32"
3/8 dia X 1 13/16 deep
3/16 dia X 1/16 deep
2 BA
3/4"
0
Det 1 (1) CI ( offcut from A3 )
C
J.B.D.Willis.
Revision
0
Date
31/03/03
Det 2 (1) S
10 20 30
Thimble Scale
Det 5
Tooth Rest Column Details
0
Drg No K2
Bonelle TCG
Knurl
5/8 "
5/16 "
Ø1/2 "
3/16 "
1/4 "
7/8 "
3/4 "
3/8 "
2 BA
Det 1 (1) S
1/16 "
Det 2 (1) S
3/4 "
Det 3 (1) S
3/8 "
2BA
Knurl
Det 4 (1) S
1/2 "
Det 5 (1) S
Ø1/8 "
1/4 "
Ø1/8 "
Ø3/8 "
8
3
1 11/16 "
3/4 "
3/4 "
13/16 "
1"
1/2 "
6
6 BA
3/16 "
1
1/8 "
1/16 "
3/8 "
/
5/16 "
/
1 3/8 "
Ø1/2 "
3/4 "
1
9/16 "
1 3/8 " 9/16 "
5/16 "
Ø1/16 "
Ø1/8 "
5/16 "
Det 6 (1) S
C
J.B.D.Willis.
Revision
0
Date
29/10/00
Det 8 (1) S
Det 7 (1) S
Tooth Rest Column Details 2
1/8 "
Drg No K3
Bonelle TCG
L1/3 modified as shown
13/16"
C
J.B.D.Willis.
Revision
2
Date
25/02/04
Tooth Rest Assembly
Drg No K4
Bonelle TCG
3/8"
3/4"
5/8"
9/16"
3/8"
1 15/16 "
3/16"
3/4"
Ø1/2"
3/4"
Ø3/8 "
Det1 (1) S
3/8"
1/16"
2BA"
5/16"
1/4"
knurl
tapped holes
2BA
3/8"
1/2"
1/2"
Det 2 (1) S
2 3/4"
3/8"
1/2"
2BA X 3/8"
Det 3 (1) S
C
J.B.D.Willis.
Revision
1
Date
23/02/04
Tooth Rest Details
Drg No K5
1 1/8"
1"
Bonelle TCG
1/4 BSF "
1/2"
2 1/4"
1/4BSF "
1 1/2"
3/8"
3/8"
3/16"
5/8"
3/16"
Det 1(6)S used on B1, C7, D1, E1, G2, G10.
1 1/2"
1/4 BSF "
1 1/8"
3/8"
Det 2(1)S used on C1
1 1/2"
2 1/4"
1/2"
1/2"
3/16"
3/16"
Det 3(2)S used on G2 & K4
3/8"
2BA X 1/2" "
3/8"
7/8"
5/8"
3/8"
Det 5 (1) S used on B1
C
J.B.D.Willis.
Revision
2
Date
21/02/04
Det 4(1)S used on G2
1 3/4" "
3/16"
2BA X 3/8"
Det 6(1) S used on G2
1/2"
5/16"
Det 7(12) S
3/16"
All holes 3/16" dia. To be drilled
after trial assembly to determine
correct angular position of det 7
Key & Handle Details
Drg No L1
L"
7/8"
1/16"
c
A
5/8"
c
1/64"
a
1/32"
d
b
c
A
R1/2"
View on A - A
1/2"
41/64" "
Bonelle TCG
Slots c
L"
c
c
3/4"
Refer to drawings H1 & H2.
Assemble clamps then transfer
positions of the 2.3 mm holes on to them.
Remove clamps and enlarge holes to 3/32".
Elongate each hole to a depth of 1/16" as
shown.
Finally tap holes in H2 for 6 BA screws.
Det 3 (1)
Det 1 (1) S L = 11/16"
Det 2 (1) S L = 13/16"( remaining dims as det 1 )
11/16"
a = 1/4" BSF
b = 9/32"dia
d = 3.2"dia X 1/8"deep
11/16"
spring seatings
11/16"
c
11/16 "
1/16"
1/16"
d
b
a
29/64" "
9/16"
c
J.B.D.Willis.
Revision
2
a
R5/16 "
Det 4 (1) S
C
c
Date
24/02/04
25/64" "
b
9/16"
R1/4"
Det 5 (1) S used on G2
Bar Clamp Details
Drg No L2
Bonelle TCG
6 4 2 0
0
10
20
0
Scale around thimble
C
J.B.D.Willis.
Revision
0
Date
29/10/00
Micrometer Assy
Drg No L3
Bonelle TCG
30
30
20
10
20
0
10
B
C
J.B.D.Willis.
Revision
0
Date
10/03/03
Composite GA of Workhead
Drg No Z1
Bonelle TCG
1 1/2"
7/16 "
Loctite sleeve in existing base
OR tap CI base
3/4"
+ & - 1/4"
adjustment
2 1/2"
1 7/8"
1 1/4" dia knurled adjusting
wheel loctite to support.
C
J.B.D.Willis.
Revision
Date
0
29/03/03
Make in one piece if not
adapting an existing base
B3/1 front foot
B3/2 centre foot
B3/1 rear foot
Incorporation of levelling screws
Drg No Z2
tap 2 BA
2 BA screw
Bonelle TCG
3/8"
adjustment
1 1/8"
3/4"
1/4"
3/4"
2 1/2"
1/2"
1 1/4" dia knurled adjusting
wheel loctite to support.
B3/1 front foot
C
J.B.D.Willis.
Revision
Date
0
3/12/03
B3/2 centre foot
B3/1 rear foot
Incorporation of levelling screws
Drg No Z3