Sherline 5000 Mill Assembly Instructions

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Getting answers to your questions about machining
Over the years we have found that the majority of our
customers are both highly intelligent and skilled craftsmen.
Often they are also new to machining. The instructions we
have included in this book, while far more extensive than
anything included with other machine tools, even ones
costing thousands of dollars, still only scratch the surface
when it comes to machining. We have tried to anticipate
the most common problems and questions asked by a new
machinist. What we have provided in this book and with
each accessory, when combined with a liberal amount of
common sense, is more than enough to get you started. If
you apply what you learn here, you will be well on your
way to making good parts. No doubt you will also have
many questions specific to your project that simply can’t
be addressed in a booklet of this type.
Answers to questions beyond the scope of this booklet will
have to come from your own research. Bookstores and
libraries are full of excellent books on machining, and the
Internet is forming some great user groups that can put
you in direct contact with others who share your specific
interests. Our own Worldwide Web site is a great source
of information as well. We have published there all the
instructions for all our tools and accessories for you to
read and print out for free. There are also links to many
other fascinating sites. For the past thirty-five years I have
found Machinery’s Handbook to be the source I turn to
for answers to my own questions.
I recently wrote a book called Tabletop Machining that is
specifically directed to the owners of Sherline tools and to
anyone who wants to learn to make small, metal parts.
The instructions you are reading that come with your
machine are quite complete; however, if you want to get
into more detail or want to see color photos of setups and
projects made by some of the best craftsmen around, I am
sure you will find more than your money’s worth in
Tabletop Machining. May your journey toward becoming
a skilled machinist be an enjoyable one.
What new machinists like most and least
If you are new to machining, you may find it to be either
one of the most rewarding skills one can learn or the most
frustrating thing you have ever attempted. What makes
machining fun for some is the complexity and challenge.
The same thing will drive others up the wall. One customer
may be overjoyed because he can now make parts that
were not available for purchase. Another may wonder why
AN INTRODUCTION TO THE WORLD OF MINIATURE MACHINING
he just spent all day making a part that is similar to one he
could have purchased for two dollars. The difference is
that it is not the same as the two-dollar part—it is exactly
the part needed.
There are no shortcuts
Machining is a slow process because parts are made one
at a time. The interesting thing is, a skilled machinist may
take almost as long to make the same part as a novice.
Shortcuts usually end in failure. Unlike some other trades,
mistakes cannot be covered up. There are no erasers, white-
out or “putting-on tools” for machinists; you simply start
over. To expand a little on an old rule: “Think three times,
measure twice and cut once!”
The craftsman’s strength–anticipating a tool’s limitations
The skill in machining isn’t just “moving the dials.” It is a
combination of engineering and craftsmanship. A file is
just as useful a tool to a good machinist as a multi-thousand-
dollar machine tool. Tools “deflect” or bend under load,
and anticipating this bend is what it is all about. Sharp
tools deflect less than dull tools, but with each pass the
tool gets a little duller and the deflection becomes greater.
If you try to machine a long shaft with a small diameter,
the center will always have a larger diameter than the ends,
because the part deflects away from the tool where it has
less support. You can go crazy trying to machine it straight,
or you can simply pick up a good, flat mill file and file it
straight in a few moments. Machine tools will never replace
the “craftsman’s touch,” and machining is a combination
of both good tools and good technique.
You don’t become a machinist by buying a machine
You should strive from the beginning to make better and
more accurate parts than you think you need. Work to closer
tolerances than the job demands. Be on the lookout for
ways to make a job easier or better. Having a selection of
appropriate materials on hand and a good cutoff saw to
get them to rough size is a good start. Take some time and
read through this instruction book before you try machining
anything. We want you to enjoy the process of creating
accurate parts from raw metal. Buying a machine didn’t
make you a machinist, but using it along with the skill and
knowledge you acquire along the way eventually will. With
the purchase of Sherline equipment, you have taken your
first step toward many years of machining satisfaction.
We thank you for letting us be a part of that.
—Joe Martin, President and owner
Sherline Products Inc.
GENERAL PRECAUTIONS
• DO NOT attempt to operate the lathe or mill without
first mounting them to a secure base. (See page 10.)
• DO NOT turn on the motor with a 3-jaw chuck mounted
if the jaws are not tightened on themselves or on a part.
The acceleration of the spindle can cause the scroll to open
the chuck jaws if not tightened.
• DO NOT lift or carry the machine by the motor. The
motor mount was not designed to support the entire weight
of the machine. Carry the machine by lifting under the
base or by the mounting board. It is also advisable to
remove the headstock/motor/speed control unit when
transporting the machine. The inertia of a sudden shock
can also overstress the motor mount.