chapmanruss wrote
Mike,
The chip out of the brass bushing is interesting. Wonder how that could have happened. The drive shaft must have slipped in the flywheel at some point. The spot welds seem to take care of that nicely and does not appear to interfere with the yoke. Something for others to remember if they have the same problem.
If you have any woodworking stores in your area they should have scroll saw blades.
Yes, I have Rockler near me but completely forgot about them.
I did consider grinding the welds down a bit, but they didn't seem to be interfering with the yoke or operation, so I left well enough alone (for now :D ). I didn't consider the bushing damage could have been from the flywheel when it came apart. I thought maybe from driving in replacement bushings, but your idea does make more sense. The bushing does not appear to have a thrust component to it and it is actually recessed a bit. I don't think the brass washer next to the flywheel even contacts it. If it does, it didn't leave any marks on the washer. There was also no signs of wear on the drive shaft, so again, I left it alone.
One thing I don't like is the clicking sound from the coupler when using the spring return upper chuck. Maybe I need a new coupler, or tighter fit? When the spring return part of the stroke kicks in it clicks, then clicks again when the drive part of the stroke starts. I only have one coupler right now and I really don't want to break it. This clicking does not happen in bottom chuck "saber saw" mode only.
Thanks, Mike