LATHE CLUTCH

Warco WMT300/2 (similar to the Clarke, Grizzly 4015 and Smithy 1220)

The 3in1 machine always clattered and rattled badly when under power. It had been doing that from the day I got it home.

The black plastic handle knob on the left hand end of the lathe spindle is pushed in to provide drive to the milling spindle and pulled out to provide drive to the lathe chuck.
When black plastic handle knob is pulled out, the two clutch dogs mate and drive is provided to the lathe chuck. The rattle was due to two clutch dogs being poorly machined and not mating properly.

After five years the rattle started to become unbearable as the dogs continued to wear. Rather than remake the two dogs I decided to do a quick temporary repair.

↓ The ROUND NUT was undone and removed together with the TAB WASHER.
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↓ The LEFT DOG is pulled off the shaft.
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↓ The KEY is removed from the shaft.
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↓ The four screws are removed.
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↓ The RIGHT DOG assembly can now be removed.
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↓ The LEFT DOG can now be temporarily repaired.
This picture shows the absurd amount of play between the two dogs.
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↓ Flux is applied to the LEFT DOG.
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↓ The LEFT DOG is heated up and coated with silver solder.
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↓ I built the surfaces up with silver solder. I squeezed the two dogs together. From the impressions left by the squeezing I filed the vertical surfaces to get the best fit I could.
In this picture the vertical surfaces have been built up with silver solder, and then touched up with a file.
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↓ Here is a close up of the build up.
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↓ I used the Lathe Spindle Hand Crank to hold the spindle steady while tightening the ROUND NUT with a C Spanner.
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↓ The clutch is back together again. The fit is still abysmal, but the play has been taken up for now.
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↓ CONCLUSION.
The build up of silver solder on the LEFT DOG worked and the rattle has gone away. I was hoping that the surface finish on turned parts would improve once the rattle was dealt with, but this is not the case.
When the silver solder wears away and the rattle starts again I will remake the two dogs and do the job properly.

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