YATES AMERICAN J40
Mortising Machine Rehab
July 6, 2002







I had wanted a mortising machine for quite some time. It was about the time that Joe Johns went bragging about his mortising machine buy that really got me started doing some hunting around for one. Scott Graf helped me out tremendously in the search. Though he did find a J40 for me, it wasn't the one I bought. I called Dan at Davis and Wells and he told me he had one dire need of disassembly and a rebuild. Price? $300! There was a catch he said, the head casting had broken when the machine fell over. He sent me pictures of the machine and I knew it was very repairable. Besides woodworking, my other hobby is metalworking. Some of you know I recently added to my shop a small machine shop.
Anyway, enough here are the pictures of the progress. All told I probably have about 80 hours into the project and as of today its not quite finished.

CLICK ON PICTURES TO ENLARGE


I chose to use aircraft stripper.
 


This casting was REALLY rough, typical of old castings. There was a skim coat of body filler on the machine. On the right, you will not that I have already laid down on coat of body filler and sanded it. Folks, don't do this if you don't have to. Its A LOT of work! I had litte choice as much of the machine was scratch deeply down to the metal. I had done this before on my Bridgeport Mill....sigh, I wasn't looking forward to the experience again. On a positive note, tis smaller than a Bridgeport?
 
 
 

Parts is parts. All parts as came out of the $219 Harbor Freight Sand Blast cabinet....
 


Above to photos show the main casting with its final coat of body filler, then sprayed with dark gray primer surfacer. This paint is thick and heavy, once sanded it helps hide sanding marks and other imperfections. The splotchyness is from the spot/glazing putty. Touching up deeper gouges and scratches.


Main Casting after it was painted.


Partial Assembly....


Machine assembled except for the head.


A nice shot showing the table etc. Really cool, runs left right on rack (X axis motion), in and out on a screw (Y axis motion), of course the table lowers and raises (Z axis motion) and another benefit is that the table will tilt left/right to 45 degrees. You can't see it in this picture but the lower arc casting is graduated in 5 degree increments.

ON TO THE HEAD AND ITS REPAIR....
 


Picture of the head casting. Note the lower right corner where the damage to the casting is.
 


Milling out the damage on the Bridgeport mill. This squares everthing up.


I chose a "cold repair" there wouldn't be much stress in this area as there are 2 other pads on this side of the head. What I did is machine a block of steel to fint this area, Drilled and tapped for 4 counter sunk 10/32 cap screws.


Metal bolted in place


Milling the face flush with the main casting and taking a cleanup cut on the casting.


Completed repair.


Another shot of the completed repair.
 
 


Shot of nearly completed machine. I had a 1hp Rockwell motor that I fitted to the head. I had to modify the impeller blower and bush the motor side to match the motor's 5/8" shaft as well as accept a 3/4" shanked 1/2" drill chuck that I ordered. Should be here in the next couple days. I also need to bush the 1-1/8" opening for the chisels. I'll make the bushings on my lathe. One will be for 3/4" shanked Chisels and the other for 5/8" Chisels.


Shot of the repaired area of the head.

Shot showing the Drill chuck. I machined a new adapter, mates the 5/8" motor shaft to a 5/8" straight dril chuck arbor. You can also see the bushing that I machined to adapt the 5/8" chisel shank to the head. I also machined a 3/4" adapter while I was at it.

Machine Completed! 9/29/2002





Questions or comments? Email me! escarcega@cox.net