This happened today...

[Skizzity]

Reading back through this thread, I believe that this is a Shopsmith built PowerPro installation (not a DIY) built into a recycled headstock casting. Is that correct?

Correct, Dusty. I purchased my Mark 7 at a Lowe's in March of 2015 through Mike Young.

[ChrisNeilan]

Wow, hard to believe! I'm sure they will make it right. They can get you a new casting, but can they replace your time? Good luck.

[Skizzity]

Talked to customer service on the phone. They hadn't read my email yet but we're able to find it. Jibber Jabber. CS is going to pass it along to the engineers at their afternoon meeting. Don't expect a call back until tomorrow some time. ::grumble::

[charlese]

I know 2000 is too fast for the bandsaw. I use the built-in speed chart which for softwood says "1100". Hardwood says 1000 and the sticker says 900. Which is right? I used 2050 rpm to sand my pen.

I just got an email fired off to SS.

Sorry, Skizz! I stupidly mis-read your 2050 RPM pen turning speed to refer to the bandsaw.

Back to the countersinks;
Countersinks are not only too deep, but they also appear to be drilled at angles. My guess is - somehow this screwed up headstock case got thrown into the wrong bin and got used to build a PowerPro.

When getting a DIY kit, - it comes with a metal countersink jig, also a new countersink bit. It is really hard to screw up the 'drill and sink' when the jig is used. Don't know if Shopsmith uses this jig. But I suppose it is possible to apply Murphy's law to it's use.

Anyway the holes probably would have held if the headstock didn't jump and bang with the bandsaw.

[dusty]

I know 2000 is too fast for the bandsaw. I use the built-in speed chart which for softwood says "1100". Hardwood says 1000 and the sticker says 900. Which is right? I used 2050 rpm to sand my pen.

I just got an email fired off to SS.

Sorry, Skizz! I stupidly mis-read your 2050 RPM pen turning speed to refer to the bandsaw.

Back to the countersinks;
Countersinks are not only too deep, but they also appear to be drilled at angles. My guess is - somehow this screwed up headstock case got thrown into the wrong bin and got used to build a PowerPro.

When getting a DIY kit, - it comes with a metal countersink jig, also a new countersink bit. It is really hard to screw up the 'drill and sink' when the jig is used. Don't know if Shopsmith uses this jig. But I suppose it is possible to apply Murphy's law to it's use.

Anyway the holes probably would have held if the headstock didn't jump and bang with the bandsaw.

The holes do not have countersinks until they are drilled on the way to becoming a PowerPro. No matter how it happened, a good quality check would have prevented this fiasco.

[Skizzity]

If the power supply assembly got replaced wouldn't you think this sticker would be replaced if the headstock is still under warranty? I would think so. I opened the inspection hole to find it curled up like that.

I tried to take close ups of each countersink in the casting. None of the countersinks is neat. Should I post them? One of the screws is also splayed out in the hex hole like the "tool box" was inserted in the screw and pryed in all six directions.

I guess I'm being super duper anal at this point but when I drop 4 grand on a machine I expect a lot out of it.

[algale]

Yes post the countersink photos. As for the belt wear, this is speculation, but I suspect there was enough movement due to the busted countersinks and drooping that things got out of alignment and put a lot of wear on the belt in a very short period of time.

[Skizzity]

[dusty]

This is NOT what Shopsmith stands for. But while it is anomalous, it is totally unacceptable. However, I am extremely confident that Shopsmith will make this right. Regretfully, they did not do that the first time.

I am equally confident that Jim did not see any of this. I do not believe he personally would have allowed it to leave the factory.

[JPG]

Yes the counter sinking is atrocious.

What bothers me more is the black areas that appear to be voids in the casting.

P.S. I think SS owes you a replacement and use yours as an example for 'instructive' purposes to those who create the 'new' holes in the headstock castings.