Quill is really sticky.

[DLB]

Today while re-assembling my headstock I think the light bulb finally came on. I believe the Quill Lock works by locking the quill feed, but also by tightening the casting around the quill. It's similar to the method for tightening the eccentric on the Idler Shaft. I'm thinking that whenever this headstock was over-tightened enough to deform the domed washer that probably also slightly deformed the casting in this area, a permanent set somewhat tighter than normal. You mentioned that it was a demo model and has always had a quill issue, I would engage Shopsmith on the issue. Getting warranty support after 17 years might be problematic, but if it were me I would want input from their engineer on reforming the bore. Unless, of course, someone else here has a good idea...

The part of the casting I'm talking about is shown best on the JPG edit of your pic, because he cropped the rest out. When the Quill Lock is tightened the gap between the pinion and the casting, to the left of the pinion in the picture, closes slightly, tightening the bore. The gap changed about 1/64 inch on my machine.

- David

[JPG]

That makes a lot of sense.

I cannot get used to the idea of the casting 'bending', but it does.

I now think that demo might have fallen off the truck(or whatever) and landed on the end of the quill shaft. There is also that splayed spring housing slot.

[DLB]

Another option - I do see one used "C" headstock bare casting on ebay. $30 + $23.65 shipping to my zip, probably varies. A new one from mothership is $346.38, I didn't check shipping.

I'm not endorsing, but it appears to me that used bare "C" versions are not that common, there were no recent sales. Personally I'd like to think that SS will help with a resolution though they might not be obligated to. But I might hedge in this case. You'd have almost enough leftover parts for a spare AC Headstock.

- David

[JPG]

Question remains, who/what/when did it get damaged. I do not think we have a manufacturing defect.

If it was a 'demo' then was it purchased from SS?

[mindpilot]

Hey everyone thank you so much for all your input, feedback, and suggestions! So here the update on my PowerPro upgrade that turned into a bigger project.

I cleaned up the bore, and put about 1500 coats of wax on the quill and now it slides in and out with almost no resistance at all. Perfect! I found a short nap paint roller makes a great tool for cleaning the bore. I was going to post some pix, but I get an error when uploading.

I went ahead and ordered a new quill feed assembly. (This is not a project I'm looking to cut any corners on) So now as soon as that and the new washer arrives I'm ready to go back together. All my other drilling, filing and cleaning is done.

I'm about 98% certain the casting is OK. There is one longitudinal mark in the bore--a sort of discoloration that I can't polish out. I also can't feel it at all so I'm not sure if it is a place where the metal was stressed too much or what. If I get it back together and start having quill issues again, I'll know for sure its the casting.

This machine was a SS demo...says so right on my production date label. So here's how that happened back in '03.
Been thinking about wanting a Shopsmith for a while, and was taking woodworking at community college at the time. I went Lowe's late one afternoon, and there happened to be a Shopsmith demo going on. It was the last day of the demo series, and the guy was looking to be done. He offered me a nice discount and along with buying the demo, I didn't have to wait, I didn't have to assemble it, and with Lowe's credit offering 12 months no interest, the time was right. We put it in my van and that's how I came to have a demo model Shopsmith.

As how or when that washer got crushed, that's an open question.

The best part about this project is I now have a much better understanding of how my Shopsmith actually works.

[JPG]

Just as a curiosity, who was the demo'r.

[mindpilot]

Sorry, but I don't recall. I dug back into my old paperwork and found the original Lowe's receipt, but nothing with the name of the gentleman doing the demonstration.

[mindpilot]

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Update: Finally received the new quill feed assembly and washer!! After many hours of polishing the bore to a mirror finish, the quill now moves smoothly and with even resistance for its entire length of travel. It has good action and feel.

But the quality of Shopsmith parts leaves a little to be desired. The washer came in bag with a label stating that "both washers must be used", yet there was only one washer in the bag. Put a call into Shopsmith about a week ago. Haven't heard back so I went ahead and reassembled with the single washer...seems to work OK. I had to spend about an hour with a thread file cleaning up damaged / badly machined threads before the quill lock handle would thread onto the shaft. Then I discovered that the spring housing is now a press fit into the main housing. And it's a tight one, I had to do a considerable amount of sanding on both the housing and the casting bore to get it to go in at all. The old one slipped in with probably a 64th of clearance, no hammering required.

And speaking of hammering, I was surprised at how hard I had to pound on that roll pin to remove the way tube wedges locking handle. And even more difficult to reinstall. Even after clearing the hole with a 1/8th inch drill, the roll pin won't seat all the way. There's about a 1/6 still protruding that I will grind off.

Almost back together! If you haven't seen the new motor for the Pro upgrade the thing is a beast compared to the old motor.

side by side old motor and new

both motors.jpg (90.21 KiB) Viewed 9412 times

[DLB]

Glad to hear that you are back to making progress on your PowerPro upgrade. I can't imagine what 'second washer' they'd be referring to. I would check that the part number for the new domed (aka spherical) washer matches an older book (501317), if it does then I'd think all is okay. If the number is different that might imply some kind of 'upgrade' and if it was me I'd set up an appointment for a call back from engineering. In my experience that is a more satisfying experience than Customer Service. They do not charge for those engineering calls for warranty service, and I'd think difficulty you encounter installing the PP would qualify. I used this service on a double tilt problem I encountered and service was excellent.

- David

[mindpilot]

All done! And so far seems to be working better than it ever has. All the locks and the quill seems to have a much better "feel" than before. I am going to run through some tests today to make sure cuts are still coming out square and true.

There are definitely some places where the instructions could be improved.

But here she is all clean and shiny new! I even restored the original production date label.

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