Henry Milnes DF4 Lathe Guards

[Darren ReidParticipant @darrenreid51999]

Hi all I have recently joined. I own a Henry Milnes DF4 lathe (Denham Junior), I bought the lathe almost 30 years ago when I started college. It belonged to the workshop technicians father who had recently passed away, he estimated that it was probably dated from late 1940s. It has served me well over the years. My problem is that change wheel guards are missing. (Part 4/ 596 and 4/597) It has been like this since I bought it, but now I would like to replace them and give the lathe a overhaul and a new coat of paint. Would anyone with the same lathe be able to draw around the profile of the guards and provide some measurements so I could manufacture them? I did post this on Facebook group machinist museum but unfortunately no response. Thanks Darren

II have parts manual but I can't workout how to attach relevant page

[Darren ReidParticipant @darrenreid51999]

[David George 1Participant @davidgeorge1]

Hi Darren welcome to the forum. Have you looked on here. http://www.lathes.co.uk/denham/ as it may give you some ideas.

David

[Michael GilliganParticipant @michaelgilligan61133]

Posted by Darren Reid on 12/11/2022 22:26:10:

Hi all I have recently joined. I own a Henry Milnes DF4 lathe (Denham Junior),

[…]

II have parts manual but I can't workout how to attach relevant page

.

Welcome, Darren

It would be interesting to see that … so may I encourage you to read this: **LINK**

https://www.model-engineer.co.uk/forums/postings.asp?th=103028&p=1

… or at least skim through it until you get the general idea

If you are still struggling, just ask

MichaelG.

[Darren ReidParticipant @darrenreid51999]

Hi David and Michael

Thank you for the welcome and the swift replies Yes David I have been on the "lathes" site which is an excellent resource. Michael hopefully now with your advice I will be able to post photos.

[Darren ReidParticipant @darrenreid51999]

Belt guard.

[Ady1Participant @ady1]

I think it depends on the lathe

Got a couple of piccies here with a full length job

 

Edited By Ady1 on 13/11/2022 09:56:24

[Darren ReidParticipant @darrenreid51999]

Hi Ady, thank you for that it dose look similar to my lathe but the headstock is different. I do not know if the guards would be the same ? I have attached a image I found on Google of the guard I need.

Edited By Darren Reid on 13/11/2022 10:06:25

[Ady1Participant @ady1]

Your picture looks by far the best one for having a go at fabrication, plus you have your fixed points at the securing screws

Make up your inside plate first and then use it as a template for your outside effort would be my route

Edited By Ady1 on 13/11/2022 10:29:21

[Darren ReidParticipant @darrenreid51999]

I may have to go down that route if I don't get any further responses to my post. It will be a case of CAD "cardboard aided design" Ady

[HopperParticipant @hopper]

Make a cardboard and tape mock-up based on the pic above and then check it has clearance for the gears and banjo when the largest and smallest gears are fitted throughout.

[SillyOldDufferModerator @sillyoldduffer]

Posted by Darren Reid on 13/11/2022 10:05:50:

Hi Ady, thank you for that it dose look similar to my lathe but the headstock is different. I do not know if the guards would be the same ? I have attached a image I found on Google of the guard I need.

…

Welcome to the forum Darren.

In the event the measurements aren't forthcoming, perhaps no-one has the same lathe as you, it may be necessary to reverse-engineer a guard from the lathe and photo.

It can be done by cutting cardboard sheet to the approximate shape and size, offering it up to the lathe, and progressively trimming to exact size. It would start by identifying the fixing points on the lathe. May take a few goes to get right, but you end up with a cardboard replica that can be dismantled and laid out flat as a template to cut the sheet metal shapes needed to make a real one.

As the cardboard replica has to hold together, thinking about it's joints will inform the real build.

Sheet metal isn't my thing, but the original guard looks to have been stamped, rolled and maybe crimped from cheap mild steel sheet with pricey equipment you don't have. Several alternatives depending on what you have and depth of pocket. Do you have tools for cutting and forming sheet metal? Do-able with basic tools, but as always the job is easier when the right tools are available.

For an exact replica, wooden formers may be necessary. Brass is easy to work and can be soft-soldered but is pricey. Aluminium is cheap, but difficult to solder, so pop-rivets or nuts and bolts. Steel is nicely in the middle, especially if welding is available. If safety is the only concern and looks don't matter, keep it simple – a boxy plate and wire-mesh construct quickly bodged to fit would do.

However you do it, it's an interesting challenge. Can you post updates please – be good to see how you get on. It's a learning experience!

Dave

[DC31kParticipant @dc31k]

Posted by Hopper on 13/11/2022 10:42:02:

Make a cardboard and tape mock-up

Extending your idea, make some cardboard circles 1" greater in diameter than the biggest change gear used in a particular place. Stick them to the gears with the gears mounted on their shafts and then stick the individual circles together so they maintain their relationship when removed. Lay on the bench and join with tangential lines (or reverse curves – draw around a bucket). Can do the same with the mounting screws.

[Darren ReidParticipant @darrenreid51999]

Hi folks thank you for all the very useful information and suggestions. In response to Dave I just had a quick search on forum and there are a few members with the same lathe. It was also called a Denham Junior, Chris Blight has restored one recently. I have access to sheet metal tools so my plan was to cut out the outer profile with plasma cutter. Then roll the sides to required profile and tack and weld together. I can turn locating sleeves on lathe. I have used mount card in the past to create templates, it is about 1mm thick but holds it shape well and can be hot glue guned together.

[DC31kParticipant @dc31k]

At the risk of flogging a dead horse, you might be able to improve on the original guard.

If it is necessary to use a 127t gear on the leadscrew for metric screwcutting (maybe not something that was thought of when the machine was mde), you could make the guard suit that gear.

[Darren ReidParticipant @darrenreid51999]

Hi DC31K another great suggestion, I just checked the change gear table and it was originally designed with metric included with the 127t gear as you stated.

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