Acknowledgement

The set of drawings has been verified by the construction of a grinder from them. Any
mistakes or omissions being corrected when found. This grinder is illustrated below and I
would like to thank Laurie Clarke ( Melbourne Australia ) who made it and kept me
informed. The drawings should be reliable but I take full responsibility if this proves not
to be the case.
Don Willis

Bonelle TCG Drawing Revisions

20/2/04
21/02/04
23/02/04
24/02/04
25/02/04
26/02/04
28/02/04
01/03/04
06/03/04
06/03/04
06/03/04
30/03/04
31/03/04
22/05/04
00/00/00
00/00/00
00/00/00
00/00/00

G4 rev 1 dim 2 was 2 3/8, G3 rev 2 notch added

L1 minor changes principally to clarify where used
C7 Sketch added to show positioning of components.
L2/2 13/13 was 7/8 Rearranged to show slots more clearly.
Cross references to keys & clamps ( Drgs L1 & L2) corrected on drawings :B2, B4, D1, G1, G2, G10, H1, H3, K4.
B2 Shape corrected to correspond with B3
C10/2 scale added
C2/4 added
G11 dim 4 7/16" was 4 5/16"
H2 missing dims added
G5 dim1 5/8" was 1 11/16"
H1 assembly clarified
H7 & H8 added
D1 dim 2 1/2" added

Bonelle TCG
Drawings
A. General Arrangement
B. Base
C. Wheel head
D. Wheel Guard
E. Dust Containment
F. Spindle
G.Workhead
H.Toolholder
J. Front Bar
K.Tooth Rest
L.Miscellaneous
Conventions used.
The drawings are arranged so that detail drawings follow
immediately after the assembly on which they are used and bear the
same drawing prefix letter A,B, etc. Details are usually easily
identifiable on the assembly by their appearance. Specific reference
by detail number is only made when this is not the case.
The drawings do not show tolerances and mating parts have the same
dimensions. The necessary clearances must be considered and
provided during manufacture.

Conventions used continued

Reference to a detail .........
F12
3

= Drawing showing that detail.

= Detail number on that drawing.

Detail Numbers.................
Det 3
(2)
S
B
CI
S
SS
L

Example:- Det3 (2) S.

= Detail number
= Quantity required
= Material.
= Brass
= Cast Iron (Continuously Cast Bar)
= Bright Mild Steel
= Silver Steel
= Leather

Fixings............................

J.B.D.Willis

Example:- F12/3

The nature of the fixing is shown by the

drawing (cheese head screw, cap head
screw etc) only the size is specified eg.
2BA X 3/8".

Bonelle TCG

30

30
20

20
10

10

Half Size
column height not to scale
C

J.B.D.Willis.

Revision
0

Date
22/10/00

General Arrangement (Front Elevation)

Drg No A1

Bonelle TCG

column height not to scale

Half Size
C

J.B.D.Willis.

Revision

Date

24/10/00

General Arrangement (Side Elevation)

Drg No A2

Bonelle TCG

Section A - A
40

30
20

10
0
10
20
30
40

J.B.D.Willis.

Revision
2

Date
17/03/03

Base Assembly

Drg No B1

Bonelle TCG
B4/5

secure with Loctite

Ensure that B6/1 & B6/2 are in the

same plane then secure B6/2 with Loctite.
B6/2

1/16
B6/3
12"
B4/6

secure with Loctite

( see note on C7
regarding levelling
screws)

B6/1

J.B.D.Willis.

Revision
2

Date
26/02/04

Base Sub Assembly

Drg No B2

Bonelle TCG

11 "
2 1/4 "

3 1/2 "

1 3/8

1 3/8

1 1/8 "

3 1/2 "

1 1/2

F
2in

15/16

1 7/8 "

1 1/2 "

C
1 1/2

60

1"

1
1 5/8 "

1 3/16

1 7/16

1 3/8 in

15/16 in

3 1/4 in

1 1/2

1 1/2

CL

1/2 in

3/8 in

1 1/4 in

1/4 "

3/8

1 3/8 in

1 7/16

40mm see note on C4 (cleans up to 1.54" typically)

Tap M4 10mm deep on 1 1/2 " pcd

see note on C4

1 1/4 in

1 3/16

Tap M8 3/4 " deep

2 BA

B
E

9/16 1 1/8

1 1/4 "

retain offcut
to make K2/1

4BA X 3/8

Tap M4 10mm deep

on 1 1/2 " pcd

120

Det 1 (1) CI
C

J.B.D.Willis.

1 1/4

1 7/8

3 1/2"

Revision

Date

20/03/03

41/64"

5/8"

8 mm

Det 2 (1) CI
Notes
1. Lightly machine faces check that they
at 90deg to each other.
2. Bolt together using holes C.
3. Bore holes A to give close slide fit to bar
4. Holes B to be .003" larger than A
5. Hole D to be a push fit on vertical bar
6. Holes E (on underside ) 2BA X 3/8"
7. Holes F 9/32" C'Bore 1/2" X 1/2"

Base Details (A)

Drg No B3

Bonelle TCG

1 1/2"
1/4"

1 1/8"

1/4"

1/2"

1/4" *
1/2"

1/2"
1/4"

1/2"

3/16"

1/4" knurl

Det 2 (1) S
A"
1/4" knurl

7/8"

3/8"

1"

5/8"

5/8"
2 BA"

5/8"

Det 3 (1) S

J.B.D.Willis.

Revision
1

1 1/4"

1"

Det 4 (1) S

Date
17/03/03

1/2"

9/32" dia

* adjust these dimensions to suite actual sizes of B3/1 & B3/2

C

3/8"

2 BA"

Det 1 (1) S

Base Details (B)

Det 5 (2) S A = 1 3/4"

Det 6 (1) S A = 2"*
If levelling screws are to be
incorporated as shown in
Z2 or Z3 then det 5 and 6
to be modified accordingly.

Drg No B4

12 7/8""

3/8"

Bonelle TCG

3 Holes

5/8" knurl
Tap 2 BA 3/8" deep
Det 1 (1) S

1"

3/16"
1/4"

5/8"

5/8"
1"

5/8"

11 3/4""

1/4"

13 3/4""
13 1/4""

1 3/16 "

3/8"

Det 2 (1) S

3/8"

1 1/2"

1/8"

3/8"

3/16" dia
3 3/8"
1 1/2"

1/16"

11/16" "

1/8"
1/2"

1/2"
5/8"
C

J.B.D.Willis.

Revision
1

Date
16/12/03

Det 3 (1) S
3/16" dia

Base Details (C)

3/4"

2 BA
Det 4 (1) S

Drg No B5

3 1/4"

3/8"

3/8"

1/2"

1"

15 3/4" "

Bonelle TCG
Det 1 (1) S

!/32" chamfer

1"

Det 2 (1) S

1 1/4"

Det 3 (1) S

15 5/8" "

13 /1/2" "
C

J.B.D.Willis.

Revision
0

Date
29/10/00

Bar Details

Drg No B6

Bonelle TCG

J.B.D.Willis.

Revision
1

Date
28/02/04

Wheelhead Assembly

Drg No C1

5 7/8

Bonelle TCG

3/8" holes fitted with

bushes tapped 1/4 BSF

1.96 see note

3/16

5/16
1/8

5 1/2

7/16

1/4

C
L

2 3/4

4 3/8

CL

1 3/8

7/32

4.5 mm

Det 2 (1) S 1/16" thick

8.5 mm

3/8

1/2

5/16

4 BA c'sk
1 3/4

3 1/8

M5
1/4 " c'sk (for Parvalux SD13 Motor)

Det 3 (1) S

3/16

NOTE
The (UK) continuously cast
iron bar is metric ie 50 mm
and, when cleaned up
results typically in a separation
between arms of 1.96"

1/32

2 3/8

3/8
1/2

1/4
1 3/8

csk for M5 screws

Det 4 (1) S

Det 1 (1) S
C

J.B.D.Willis.

Revision
3

Date
14/03/04

Motor Mounting Plate

Drg No C2

Bonelle TCG

1 1/4"
Bore to suit spindle
1 3/8"
3/8"

if used with
spindle F1
13/32"

1 3/16 " 1"

2"

1 9/16"
if used with
spindle F1a

CL
11/16"

3 11/16"

1 3/8"

1"

9/32" "

1 3/8"
Det 1 (1) S

J.B.D.Willis.

2 7/16 "

Revision
Date
2
12/2/04

All tapped holes M5

All clearance holes 5.1mm

1 3/8"

9/16"

Det 2 (1) S

Wheelhead Arms

Drg No C3

4"
3/4"

1/8"

Bonelle TCG

2" 1 3/8"

1 3/8"
4BA 1/4" deep

M5 3/8" deep both sides

2 3/4"

1 1/8"

1 3/8"

1/4 BSF
1/2"
2" 1 1/2"
9/32"dia

9/32""
C

J.B.D.Willis.

Revision
1

Date
09/03/03

Wheelhead Details

Drg No C4

Bonelle TCG

2 3/4 "

1/2 "

1 "

R1/16 "
12 mm
5/16 "

5/16 "
2 BA
2 3/4 "
2 BA

15/16 "

3/16 "

Det 1 (2) S

3/32" key way

1/4 "
1/2 "

7/8 "

5/16 "

1/2 "
3/8 "

1/4 "
k

BSF

2 7/16 "
5/16 "

J.B.D.Willis.

Revision
0

Date
29/10/00

1/4" BSF

1/4 "

3/32 "
Det 3 (2) S

3/16 "
C

1/4 "

Det 2 (1) S

5/8 "

1/4 "

3/8 "

1/2 "
Det 4 (2) S

Wheelhead Details

Drg No C5

13/16 in

Bonelle TCG

R1 5/8 in

Form and connect by

strip riveted accros joint.
3 1/16 in

1/16 in

6 3/4 in

1 3/8 in

2 7/16 in
Solder or
Araldite

5/16 in
4.8 mm dia
R1 1/8 in

3/8 in

15/16 in
Section on centreline
C

J.B.D.Willis.

Revision

Date

24/10/00

Pulley Cover Assembly

Drg No C6

C11/2

C8/2

Fit det 1 so that

scribed lines will
aligne with
those on C10/2

CL

Oilite
Bushes

Using a surface plate assemble

3/32" C8/1 & C8/2 to C11/2 using Loctite
1/4" so that they are positoned and
supported as shown.
Ideally bar B6/3 should be used in this
proceedure. The flat bed of a lathe
may serve instead of a surface plate.

Det 1 (2) S
C

J.B.D.Willis.

Revision
1

Date
23/02/04

Wheelhead Guide Assembly

3/8"

Scribe Line

1/8"

3/16"

otherwise as L2/1

7/8"

C8/1

Bonelle TCG

Drg No C7

Bonelle TCG

2" "
9/16" "
7/16" "
1/2" "

9/16" "

7/16" "

9/16" "
R3/8" "

1/8" "

3 3/8" "

2" "

1 11/16" "

C
L

3/16" "

2" "

tap 2BA

3/16" "

5/8" "

1 1/4" "

R1/4" "

1/4" "
1 5/8" "

3/4" "
1 1/4" "

7/32 "dia
Det 1 (1) S

J.B.D.Willis.

Revision
0

Date
18/04/03

Wheelhead Guide Details

Det 2 (1) S

Drg No C8

Bonelle TCG

Holes
3/16 " locate on spigot
from det C8/2
3 "

Rivet det2 to det 3 using 1/16" rivets

1 13/16 "
3 "

1 1/4 "

1 1/4 "
1/4 "

40
30
20
10
0
10
20

5/8 "

30
40

1/4
90

1 5/8 "

1 7/8 "
1/4 "

90

2 3/16 "

1/2"
5/32"
engrave
line
Det 1 (1) B 1/8" thick
C

J.B.D.Willis.

Revision
0

Date
29/10/00

1/4"

5/8 "

2"R
1 1/

Det 2 (1) S 1/8" thick

Wheelhead Guide Details

Det 3 (1) S 1/16" thick

Drg No C9

1 1/4"

1/8"
5/16 " "
1/8"

1/8"

knurl

Bonelle TCG
0

20

10

1/2"

40

scale

1/2"

1 1/8"

5/16 " "

3/4"

R1/2"
7/16 " "

1 3/4"

3/8"

7/16"

7/8"

1/8"

1/4"

3/8 " BSF

recess 1/16 " deep

3/16"
Det 1 (1) S
Revision
1

1/16"

1/8"

Det 4 (1) S
Date
28/02/04

R1/4"

1/8"

Det 2 (1) S
1/8"
1 1/4"

7/16 " "

J.B.D.Willis.

1/8"
1 1/8"

10 1/4 " "

30

Jack Screw Details

Det 3 (1) S
1 1/4"

3/8"

1/8"
Det5 (1) B

Drg No C10

Bonelle TCG
1 1/2 "

3/4 "

7/16 "
9/16 "
1/2 "

13/16 "
5/16 "

10"

1"

15/16 "

8"

8"

9 7/8"

1/8 "
5/16 "
13/32"
1/2 "
7/16 "
tap 3/8 BSF

4 BA
1/2 "

5/32 "

18g

1 1/2 " 1 "

13/16 "
3/8 "

5.1mm

J.B.D.Willis.

Revision
0

1/2 "

Det 2 (1) S

Det 1 (1) CI
C

7/16 "

Date
29/10/00

Wheelhead Guide Details

1 9/16 "
Det 3 (1) S

Drg No C11

Bonelle TCG
2BA X 1 1/4" brass earthing stud
fixed into tapped hole in motor frame.

Box fixed to Det C11/1

by two 2BA c'sk screws

Det C11/4

Det C11/3
Det C12/2

Det C11/1 fixed to motor frame by

stud and 2BA screw (tap frame)

J.B.D.Willis.

Revision
0

Date
24/10/00

Switchbox Assembly

Drg No C12

Bonelle TCG
adapter plate

13/16 "

3/4 "
R1 "
1 1/8 "

CL

40mm

7/32 "
3/8 "

1/2 "
1/16 "

to match adapter plate

Hole for mains inlet

chassis Euro Plug
Det 3 (1) S

7/8 "
2 1/2 "

7/32 "

CL

1 1/2 "

1 7/8 "
1/2 "
1 5/16 "
1/2 "

1/2 "

3 1/4 "

1 7/8 " 2 1/2 "

3 1/4 "

c'sink on underside
for 2BA screw.

Det 1 (1) S

J.B.D.Willis.

Revision
0

Date

2 1/2 "

to form soldering tag

Box ;- SAREL PB256
Earthing plate :- 0.015th brass
Det 2 (1)

29/10/00

1 1/2 "

corner bent

7/32 "

1/8" thick adapter plate BMS or Tufnal.

1 1/2 "

Switch Box Details

Det 4 (1) B

Drg No C13

Bonelle TCG

L1/1
1/16"
R2 1/8"

1 3/4"

L1/7
2 1/2"

3/32"

R1 5/16"

D2
welds

2 1/8"
3/16" csk for 2BA scr
Det1(1)S

J.B.D.Willis.

Revision
2

Date
22/05/04

Wheel Guard

Drg No D1

Bonelle TCG
15/16 "

2"
13/16"

1/2"
1/4"

13/16"

7/32 "dia

1/4"

13/16"
1 3/4"

tap 2BA

2"
13/16 "

45

tap 2BA

1/8"

5/16"

all sawcuts 1/16 " wide

J.B.D.Willis.

Revision
1

Date
30/01/04

Wheel Guard Boss

Drg No D2

Bonelle TCG
2 3/16 "

15/16"
1/2"
1/4"

13/16"

7/32 "dia

1/4"

13/16"
1 3/4"

tap 2BA

2"
13/16"
tap 2BA

1/8"
1 9/16"

13/16"

all sawcuts 1/16 " wide

J.B.D.Willis.

Revision
0

Date
11/2/04

Wheel Guard Boss

Drg NoD2a

Bonelle TCG
15/16"

2"
13/16"

1/2"
1/4"

1 1/16"

7/32 "dia
13/16"

1/4"

2"

tap 2BA

45

13/16 "
tap 2BA

1/8"

1 1/2"

1 3/4"
all sawcuts 1/16 " wide

J.B.D.Willis.

Revision
0

Date
11/2/04

Wheel Guard Boss

Drg No D2b

BonelleTCG

E2/3

E2/1

E2/2

J.B.D.Willis.

Revision
1

Date
30/01/04

Dust Containment Mask

Drg No E1

7"
1/4"
CL

1 3/4"
1/2"

2"
5"

2 1/4"

1/8"

4 3/4"

/16
5
11

3/4"
Det 1

"

2"
4 3/4"

1 15/16 " "

1 1/4"

1"
1/16"

Det 2

Det 3
Material :- 4mm polycarbonate sheet

J.B.D.Willis.

Revision
1

Date
30/01/04

Dust Containment Details

Drg No E2

1/2"

5/16"

Millennium TCG

3/16" square X 1 13/16"

fix by two 1/16" rivets
boss as drg D1

1"
1/8"
1/4" dia

1 5/8"

4 3/4"
1 1/4"

1 3/4"

1"

3/16"
1 5/8"
3/4"

2 1/2 " "

Welds

3/16 csk for 2BA scr "

C

J.B.D.Willis.

Revision
0

Date
30/01/04

2 1/4"
Section on CL

Dust Containment Casing

Drg No E3

Bonelle TCG

1.5 X F/S
BEARINGS :- BSI series BML EN metric series (EN13)
C

J.B.D.Willis.

Revision
Date
1
12/2/04

Spindle Assembly

Drg No F1

Bonelle TCG

1/8"

30

1/16"

3/8"

3/16"

1 13/16"

13mm"A" B"

3/16"

1 3/8"

1" 1 1/4"

b" a"

1 1/16 "

1/4"

A = a + 0.005 "
B = b - 0.005 "
Det 3 (1) S

five grooves in bore

a =3/4 "
1/32 " wide 1/32 " deep
b=1"
Det 2 (1) S

9/16"

Det 1 (1) S
1/4"

5 3/32 "
1/16"

15/32"

13/32"

1"
11/16 " across flats

40
5/16"

J.B.D.Willis.

13mm"

3/16"

All threads 32 TPI

Det 4 (1) S
C

9/16"

C" = 5/8 "

1/16"
5/16"

B" A"

1/2"

A = a + 0.005 "
B = b - 0.005 "

Revision
Date
0
29/10/00

Det 5 (1) S

Spindle Details

Drg No F2

Bonelle TCG

3 3/4"
1 3/16 "

7/16"

3/16"

3/16"
15/32"

1 3/8" 1 1/4"

30mm"

5/8"

7/8"

30mm"

1/16"

13mm "

c = C - 0.005 "
( see F2/2 )

1/16"
2 7/16 "
Det 1 (1) S

Det 2 (1) S
2 25/32"

5/8"
1.179 " "

1 7/8"

1/32"

1"
13/64 ""

c"

29/32"

3/4"
19/32 "

5/8"

13mm "

15/32"
Det 4 (1) S

Det 3 (1) S
C

J.B.D.Willis.

Revision
1

Date
02/03/03

Spindle Details

Drg No F3

Bonelle TCG

3/16"
1 1/8"

3 3/16 "

L"

D"
5/16"

Det 1 (1) S

40

3/8"
5/8"

5/8"

5/16"

3/16"

1/4"

1 1/4"

knurl

3/8"

tap 2BA 1/2" deep

each end

Det 2 (3) S L = 7/16" D = 1/2"

Det 3 (1) S L = 5 1/2" D = 1/2" omit tapped hole
Det 4 (1) S L= 2 3/4" D = 3/8" omit tapped hole

3/16"

h" 1 1/2"

Det 5 (3) S h = 1/2" Det 6 (3) S h = 3/16"

C

J.B.D.Willis.

Revision
1

Date
30/01/04

Spindle Details

Drg No F4

Bonelle TCG

1 9/16 "

BEARING :- ISO 7202 15mm bore X 35mm outside dia X 11mm wide
C

J.B.D.Willis.

Revision
0

Date
7/2/04

Spindle Assembly (ISO)

Drg No F1a

Bonelle TCG

5"
13/32 "
3/8"

13/32"

7/32"

3/16"

40
5/16"

19/32"
32 TPI

23/32"

a"

9/16"

Det 1(S)1

Det 2(S)1

1/4"

19/32"

5/8"

see F3/3

Loctite together
23/32"

b"

1/16"

1"
11/16"

2 7/16 "

15/32"

thread to mate with Det 1

Det 3(S)1
C

J.B.D.Willis.

Revision
Date
0
12/2/04

Det 4(S)1

Spindle Details

Det 5 (S)1

Drg No F2a

Bonelle TCG

3 3/4"
1 3/8"

2 1/4"

1/16"

5/8"
1/16"

25/32 "

1 9/16"

1 1/8"

35mm "

35mm"

1/4"

5/16"
Det 3(1)S
C

J.B.D.Willis.

Revision
0

3/16"

23/32 + 0.005"

a"

A " B"

a = A - 0.005" b = B + 0.005"

A = 1 1/8" B = 7/8"

Spindle Details

Det 2(1)S

5 grooves in bore
1/32" X 1/32"

1 7/16 "
1 9/16 "
approx

3/16"

Date
8/2/04

7/32"

3/16"

19/32"

b"

1/32"

23/32 "
3/8"

30deg

1 13/16"

35mm"

1/4"
5/8"

Det 1(1)S

5/8"

15/32"

1/16"
Det 4(2)S

Drg No F3a

BonelleTCG

30

30
20

10

20
0

10

J.B.D.Willis.

Revision
1

Date
24/02/04

Workhead Assy ( Front Elevation )

Drg No G1

Bonelle TCG

L1/3

L1/4

L2/5
Section A - A
A

L1/6
Loctite stud
into arm G8/2
L2/1

L1/1

A
C

J.B.D.Willis.

Revision
1

Date
24/02/04

Workhead Assy ( Side Elevation ) Drg No G2

R1/2"

5/16"

1/16"
R1/2"
3mm"

5/16"

Bonelle TCG

5/16"
3/8"

3 1/8"
5mm"
R1 7/8"

CL

2 9/16 "
1 3/8"

3/4"
5/16"

CL

5/16"

R1/4"
R1 3/8"

1/2"

3/4"

2 1/2"

32
slots 3/16" wide

32

Det 1 (1) S
1/4"

Det 2 (1) S
3/32"

5/16 BSF "

7/8"

1"

5/16"
20
1/16" dia pin

Det 3 (1) S
C

J.B.D.Willis.

Revision
2

Date
20/02/04

Front and Back Plates

Drg No G3

Drill two 1/8" dia holes eachend

then c/bore & mill recess in back face.
0.6" PCD"

Bonelle TCG

4 9/16 "
3 1/4"
2 1/2"

5/16"
1 1/8"

Front
1 3/4"
3/8"

41/64 "
3/8 ""

1 5/16""
each end.
3/16"

5/32"

32 TPI

1/2"

C/Bore 1/8" deep

40mm"

CL

3/16"

2 1/2"

3/8"

3/16"

M5

Rear
40mm"

1 1/2"

Section on
C

J.B.D.Willis.

Revision
1

CL

1"
Date
20/2/04

1/2"

CL 3/4"

5/8 "

Sliding Base

Drg No G4

Bonelle TCG

3/8""
5/16""

1/4"
1/8"

1/8""

5/16""

5/8""

31/32"

90

2 3/4"

2 1/2"

2 3/8""

2 1/4"

3"

5/8""

7/8""

1/16""

1/2"

1 5/8"

7/16""

1/8""

1/16""
1/4"

Det 1 (1) S

Det 2 (1) S

Ream 1/4" dia

Det 3 (1) S
Det 4 (1) S
Make det 3 initially oversize then finish overall on mandrel to ensure concetricity of hole and to mate with G9
Assemble dets 1,2 & 3 using Loctite then lightly machine top face of det 1with assembly on mandrel
Assemble det 4
C

J.B.D.Willis.

Revision
2

Date
06/03/04

Rotating Base

Drg No G5

Bonelle TCG
45

90

10

slot

5mm

2 0

( omit scale )

15/16" "

7/8""
90

3 0

4 0

90deg "

scale marking

4 0

3 0

90

2 0

10

scale repeated in
3 quadrants only

slot 3/8" W X 3/8"L

J.B.D.Willis.

Revision
0

Date
29/10/00

Rotating Base Details

Drg No G6

1 1/4 "

Bonelle TCG

3/16 "

5/8 "

1/8 "
5/16 "

11/32 "
1"

38

3/4 "

7/16 "

R1 1/2 "
3/16 "

15/16 "

5/8" dia bore to be

parallel with base

1 1/4 "

3/16 "
1/2 "

tap 2BA
Det 1 (1) S

Det 2 (1) S
3/16 "
3/8 "

3 1/2"

5/8 "

3/8 "

1/2 "

3/4 "
k

5/8 "

2 BA
3/8 "

Det 3 (1 ) S
C

CL

J.B.D.Willis.

Revision
0

Det 4 (2) S
Date
29/10/00

Rotating Base Details

1/8 "
3/8 "
Det 5 (2) S

Drg No G7

R1 31/32 " "

1/8" "

Bonelle TCG
7/8" "

R1/2" "

R7/32 " "

3 1/16 " "

2 1/2" "

2 1/4" "

5/16" "
30

1 3/8" "
1 7/8" "

30
20

27/32" "

20

10

10

5/16" "

tap 2 BA

R7/32 " "

R9/32 " "

1/2" "

1/8" "

Det 1 (1) B
3/16" "

R3/16 " "

Csk on back
1/8" "

Det2 (1) S
scribe line

3/16" "
1/8" "
Det 3 (1) S
C

J.B.D.Willis.

Revision
0

Date
18/03/03

Workhead Details

Drg No G8

90

1/4"
5/16""

3/16""

Bonelle TCG

3/8"

1/8"dia

3/16""

1/2""

1 1/8" "
1/2""

3/16" "
5/16""
1/2""

25/64" "

9/16""

5/8"

7/8""

1/2""

1 1/8"

5/8""

3/8""
1/2" ream"

5/8""

3/8""
1"

R1
1/2
"

1 1/4""

3/8""

1/8""

1/8""
1"

Tap M5 3/8" deep

1/8"dia
Assemble to det 1 locating
on a 1/8" dia pin using
Loctite

2 11/16""
Det 2 (1) S

Det 1 (1) CI
C

J.B.D.Willis.

Revision
2

Date
28/02/04

Tilting Bracket

Drg No G9

Bonelle TCG
L1/1

J.B.D.Willis.

Revision
2

Date
10/03/04

Rocking Arm Assembly

Drg No G10

Bonelle TCG
1 3/8"
1"

6 3/16 "
4 7/16 "
1 3/8"

5/16"
5/8"

3/4"

11/16 "

1/2"

7/32"

1 3/8"

1 1/4"

2"
4.5 deg
5/16"
1/4" BSF

9/32"

J.B.D.Willis.

1 1/2"

drill after assembly.

3/32"

3/16"

3/8"
Revision
2

Date
06/03/04

Rocking Arm Detail

1/2"

9/32"

Drg No G11

3/4"

3/4"

1/8"

1/4"

Bonelle TCG

7/32 "

1/2" 30 TPI

3/16"

5/16"
CL

3/4"

1 1/8"

1 1/4"
R1/8"
4 BA

1/2"
3/8"

Det 3 (1) B

30 TPI
Det 2 (1) S

1 1/2"

1/4"
1/4"

1/2"
knurl

5/16"

4 BA"
1/2" long

1"

3/4"
2 7/8 " "
1/2"
3/16"

40 graduations 9deg apart

8 longer lines 45 deg apart

Det 1 (1) S
C

J.B.D.Willis.

Revision
0

Date
17/03/03

3/16"
Det 4 (1) S

Harden
end

1 7/16 "

Det 5 (1) SS

Det6 (1) S

Rocking Arm Details

Drg No G12

Bonelle TCG
10 pairs

2 3/4"

6BA X 1/4"

1 1/8"

Det 1 (40) L1/32" thick

Apply a 1/8" wide band of impact adhesive to each edge
that is to be joined. Join then stich together 1/16" from
the edge. Join initially in pairs at the centre then at the periphery.

J.B.D.Willis.

Revision
0

Date
11/03/03

Bellows

Drg NoG13

3/8"

Bonelle TCG

3/32"
a
b

1 3/4" 1 5/8" 1 1/2"

1 11/16"

1 3/8" 1 1/16 "

Holes
a - tap 6BA 90deg apart
b - 3mm csk 6BA "
c - 4mm 180deg apart
Threads
24 TPI

b
1/8"

3/16"

Det 2 (4) S
Det 1 (2) S

1/16"
1/16"

3/8"

3/16"
c

2 1/4"

2 1/8" 1 11/16"

1 3/8" 1 15/16"

2"

1 1/2" 2 1/8"

Det 4 (2) S

Det 5 (2) S

1/16"
Det 3 (2) S
C

J.B.D.Willis.

Revision
0

Date
31/03/03

Dust Seal Details

Drg No G14

Bonelle TCG
Assemble H6/2 & H6/3 using
Loctite with H6/3 vertical

L2/3

L2/1

J.B.D.Willis.

Revision
2

Date
30/03/04

Toolholder Assembly

Drg No H1

41/64" "

2"

Bonelle TCG

2.3mm dia

1 15/16"
3/8"

3/4""
1 1/2" "

"
1

1 3/8"

3/4"
1 1/16 "

3 5/16""

2"

5/16""
9/16"

5/32""
29/64" "
13/16"
5/8"
9/16"

1 1/8"

1 1/2" "

3/4""

3/16"
drill 2.3mm dia
c'bore 7/32" dia X 1/8"
1 15/16""
Prepare 50mm x 50mm x 3 5/16"
blank then bore all the principal
holes before cutting profile.
C

J.B.D.Willis.

Revision
2

Date
06/03/04

5/8"

Toolholder ( Initial Stage )

Drg No H2

7/16"

Bonelle TCG

1/4"

1 1/4"
7/16"

1/8"
a

R1 1/2"

5/16"
3/8"
5/16"

3/8"
Holes marked a
refer to drawing L2.
assemble clamp and transfer hole
position onto clamp using 2.3mm drill.
Remove clamp and tap hole 6BA.

J.B.D.Willis.

Revision
2

Date
25/02/04

1 1/8"

Toolholder ( Final Stage )

For remaining dimesions

see drawing H2

Drg No H3

Bonelle TCG
5/8"

R1/4"

30

3/8"

2 5/8"

2 1/8"

1 3/16 " "

40

3"

1 1/2"

1/16 ""

3 1/4 PCD "

Use S2 centre drill,

10

20

30

40

40

30

20

10

Scale ( repeated in each quadrant )

J.B.D.Willis.

Revision
Date
1
17/03/03

Toolholder Index Plate

Drg No H4

Bonelle TCG
15/16 "

1"

R1/4"

3/8"

2 1/8 " PCD "

20 TPI

1 3/16"

1/16 "

1 1/2"

40

30

1 3/16"
20 TPI
1 3/4"

1/16"
1/4"
Slots extend over threads to give thickness of 1/16 "
Det 1 (1) S

J.B.D.Willis.

Revision
0

Date
31/03/03

Det 2 (1) S

Toolholder Collet

Drg No H5

1/4"

5/32 "

3/16 "

1/4"

Bonelle TCG

1/8"

2 1/4"

1 1/4"

3/4"
1/4"
60

Knurl 9/16"
1/2"

5/16"
1/8"
1/8"
1/2" dia

1 1/16 "

Det 1 (1) S
3"
5/16"
5/16"

3/4"

Det 2 (1) S

1/2"
1/4"

1/8"
Det 3 (1) B
engrave line

J.B.D.Willis.

Revision
0

Date
31/03/03

Toolholder Details

Drg No H6

Bonelle TCG
1/4" X 1" dia key with 1/8" handle

Loctite

press fit

J.B.D.Willis.

Revision
1

Date
19/04/04

Headstock Linkage Assembly

Loctite

Loctite

Drg No H7

Bonelle TCG

1 1/2"
1 1/8"

1/4"

1"

5/8"

5/8"
1"

3/16"

3/8"
1/8"

1/2"
3/8"

5/16"
Det 4 (1)S

R3/4"
2"

1/4"
3/16"

5/16"

5/16"

1 1/2"
7/8"

1/4"
5/16"

7/16"

1 1/32 " 3/16"

5/8 "

R1/2"
Det 2 (1)S 1/4" thick

J.B.D.Willis.

Det 5 (1)B
1 3/4"

5/8"
3/16"

1/8"

1/4"

Det 3 (1)S
3/8"

1/16"

4.7mm for interferance

fit of det 7

3/16"

Det 1 (1)S 1/4" thick

Revision
1

Date
19/04/04

6BA X 3/8"

Det 7 (1)SS

Det 6 (1)S

Swinging Headstock Linkage

Drg No H8

Bonelle TCG

J.B.D.Willis.

Revision
0

Date
24/10/00

Front Bar Assembly

Drg No J1

1 3/4 "

1/4 "

Bonelle TCG

1 3/8 "
1/2 "
5/16 "

3/16 "

3/4 "

1/4 "

1/4 "

5/16 "

3/4 "

1"

7/16 "

3/16 "
3/8 "

5/16 "
1/2 "

1/16 "

1/2 "

1/16 "
Det 3

Det1
1/2 "

Det 2
1"

15/16 "

1 1/2 " knurl

1/8 "

1/8 "

1 3/8 "

1/4 "
3/4 "

24 TPI
3/16 "
1/4 "

5/16 "

Revision
0

1/2 "

1/4 "

Det 4
J.B.D.Willis.

3/8 "

5/32 "

2BA 1/2 "deep

1 3/16 "

Det 5
Date
29/10/00

Micrometer Details

Drg No J2

3/8 " BSF

Bonelle TCG

1"

7/32

3/16 "

1 15/32 "

5/8 "

3/16 "

3/4 "

1 3/16 "

1 1/16 " 1 3/4 "

2 BA

R9/16 "
13/16 "

1/2 "

5/32 "

Det 1 (1) S
1 3/4 "

Det 2 (1) S

5/32 "

1 3/16 "

5/8 "

0
1/2 "

3/8 "

1 5/16 "

1 1/4 "

1 1/16 "

1/8 "

1 1/4 "

10

20

30

40

60 1 3/16 "
Thimble Scale

1/2 "
1 1/2 "

Det 4

Det 3 (1) S
C

J.B.D.Willis.

Revision
0

Date
29/10/00

Micrometer Details

Drg No J3

Bonelle TCG

Loctite J2/4 to column

2 7/16 "

J.B.D.Willis.

Revision
0

Date
24/10/00

Tooth Rest Column Assembly

Drg No K1

9/16"

2 11/16"
1/2"

1 1/8"

Bonelle TCG

1/2"

1"

9/16"

3/16"
3/8"

3/8"

7/16"

3/8"
1 5/16 "

1/4"

7/16"
1"

5/16"

1 15/16"

3/4"
7/8"

25 TPI
1/2"

1 "

1/4"
Det 4 (1) S

1/2"

9 1/2 " "

Det 3 (1) S

3/32"

3/8 dia X 1 13/16 deep

3/16 dia X 1/16 deep

2 BA

3/4"
0
Det 1 (1) CI ( offcut from A3 )
C

J.B.D.Willis.

Revision
0

Date
31/03/03

Det 2 (1) S

10 20 30
Thimble Scale
Det 5

Tooth Rest Column Details

Drg No K2

Bonelle TCG

Knurl
5/8 "

5/16 "
1/2 "

3/16 "

1/4 "
7/8 "

3/4 "

3/8 "
2 BA

Det 1 (1) S

1/16 "

Det 2 (1) S

3/4 "
Det 3 (1) S

3/8 "

2BA

Knurl
Det 4 (1) S

1/2 "

Det 5 (1) S

1/8 "

1/4 "

1/8 "

3/8 "

1 11/16 "

3/4 "

3/4 "

13/16 "

1"

1/2 "

6 BA

3/16 "

1/8 "

1/16 "

3/8 "

5/16 "

1 3/8 "

1/2 "

3/4 "

9/16 "

1 3/8 " 9/16 "

5/16 "
1/16 "

1/8 "

5/16 "
Det 6 (1) S
C

J.B.D.Willis.

Revision
0

Date
29/10/00

Det 8 (1) S
Det 7 (1) S

Tooth Rest Column Details 2

1/8 "

Drg No K3

Bonelle TCG
L1/3 modified as shown
13/16"

J.B.D.Willis.

Revision
2

Date
25/02/04

Tooth Rest Assembly

Drg No K4

Bonelle TCG

3/8"

3/4"

5/8"

9/16"
3/8"

1 15/16 "

3/16"

3/4"
1/2"

3/4"

3/8 "
Det1 (1) S

3/8"

1/16"
2BA"

5/16"

1/4"

knurl

tapped holes
2BA

3/8"

1/2"

1/2"

Det 2 (1) S

2 3/4"

3/8"
1/2"

2BA X 3/8"
Det 3 (1) S
C

J.B.D.Willis.

Revision
1

Date
23/02/04

Tooth Rest Details

Drg No K5

1 1/8"

1"

Bonelle TCG

1/4 BSF "

1/2"
2 1/4"

1/4BSF "

1 1/2"

3/8"
3/8"

3/16"

5/8"

3/16"
Det 1(6)S used on B1, C7, D1, E1, G2, G10.
1 1/2"
1/4 BSF "
1 1/8"
3/8"

Det 2(1)S used on C1

1 1/2"
2 1/4"
1/2"

1/2"

3/16"

3/16"

Det 3(2)S used on G2 & K4

3/8"

2BA X 1/2" "

3/8"

7/8"

5/8"
3/8"
Det 5 (1) S used on B1
C

J.B.D.Willis.

Revision
2

Date
21/02/04

Det 4(1)S used on G2

1 3/4" "

3/16"
2BA X 3/8"
Det 6(1) S used on G2

1/2"

5/16"

Det 7(12) S

3/16"

All holes 3/16" dia. To be drilled

after trial assembly to determine
correct angular position of det 7

Key & Handle Details

Drg No L1

L"

7/8"
1/16"
c

5/8"

1/64"
a

1/32"

R1/2"

View on A - A

1/2"
41/64" "

Bonelle TCG

Slots c

L"

3/4"
Refer to drawings H1 & H2.
Assemble clamps then transfer
positions of the 2.3 mm holes on to them.
Remove clamps and enlarge holes to 3/32".
Elongate each hole to a depth of 1/16" as
shown.
Finally tap holes in H2 for 6 BA screws.

Det 3 (1)
Det 1 (1) S L = 11/16"
Det 2 (1) S L = 13/16"( remaining dims as det 1 )
11/16"

a = 1/4" BSF
b = 9/32"dia
d = 3.2"dia X 1/8"deep
11/16"
spring seatings

11/16"

11/16 "
1/16"

1/16"
d
b

29/64" "

9/16"

J.B.D.Willis.

Revision
2

R5/16 "
Det 4 (1) S

Date
24/02/04

25/64" "

9/16"

R1/4"

Det 5 (1) S used on G2

Bar Clamp Details

Drg No L2

Bonelle TCG

6 4 2 0

10

20

Scale around thimble

J.B.D.Willis.

Revision
0

Date
29/10/00

Micrometer Assy

Drg No L3

Bonelle TCG

30

30
20
10

20
0

10

J.B.D.Willis.

Revision
0

Date
10/03/03

Composite GA of Workhead

Drg No Z1

Bonelle TCG

1 1/2"

7/16 "

Loctite sleeve in existing base

OR tap CI base

3/4"

+ & - 1/4"
adjustment
2 1/2"

1 7/8"

1 1/4" dia knurled adjusting

wheel loctite to support.
C

J.B.D.Willis.

Revision
Date
0
29/03/03

Make in one piece if not

adapting an existing base

B3/1 front foot

B3/2 centre foot

B3/1 rear foot

Incorporation of levelling screws

Drg No Z2

tap 2 BA

2 BA screw

Bonelle TCG

3/8"

adjustment

1 1/8"
3/4"
1/4"

3/4"

2 1/2"

1/2"

1 1/4" dia knurled adjusting

wheel loctite to support.
B3/1 front foot
C

J.B.D.Willis.

Revision
Date
0
3/12/03

B3/2 centre foot

B3/1 rear foot

Incorporation of levelling screws

Drg No Z3