The first part of Operation 40 will be to mill the cylinders down to the same length since parting operation on the lathe left material of different lengths. All cylinders should be of length 1.200" +/- .005"

The vise should be setup with a single 1" tall parallel against the master jaw to support the cylinders at the same height. The V-Block will be used on the moveable jaw side of the setup and will be used to clamp each cylinder for cutting.

A facemill should be used for this operation. Keep the maximum depth of cut for the facemill at .100" or less while cutting the cylinder lengths.

The use of the v-block on the clamping side of the setup will keep the cylinder from pivoting and supplies adequate clamping force from the moveable jaw.

Note: Make sure to clamp the vise, the picture shows the vise open so you can see just how the v-block is positioned inside the vise for display only.

The next setup for operation 40 will require the cylinder to be milled into a semi circle, or semi-cylinder. The picture to the left shows before milling (left part) and post milling (right part).

It is important to only clamp one piece at a time as two cylinders with unequal length will cause the vise to twist rather than clamp straight and you will sacrifice your milling rigidity.

The transparency of the vise in the picture lets you see the cylinder sitting on the 1.25" tall parallels.

Here is another view of the second milling setup for a different perspective.

Notice the parallels supporting the cylinder. 1.25" tall parallels will provide enough height above the vise jaws to mill the cylinder down to their required heights.

In this setup, the clamping force from the vise is applied to the flat cylinder ends. There will be adequate clamping force to keep the cylinder rigid during milling.

See the setup sheets linked below for additional instructions.