This viewis from the back of the saw.
Top of BT
The next step was drilling the vertical holes in the BT. I new I did not want the bearing out side the BT on the back side. so I made the center of the hole in from the front 5/16”. The first step was to drill for the 5/16” tap, in aluminum I go to sizes down or 1/32” smaller than the tap size. After setting up the fence and stop block I began to drill the holes, drilling all the way threw the 2” of BT height. I then flipped the piece end for end keeping the face of the BT against the fence. I then repeated this process for the remaining 9
Next was drilling the 5/16” hole from the top to the cutout at the half way point. At this point I removed the stop block and drilled the first hole, slid the block over and drilled the second hole. And again continued and did the same for 9 more BT’s. The last step for these hole was to now drill a 1/2” hole to recess the head of the bolt, continuing for all of them.
Next step was drilling for the 4 face bearing holes.
For drilling the next holes I used a piece of the steel angle that was to be the guide rail. With a bearing on both sides of the angle I measured with my calipers from outside of center hole to the inside of the center hole opposite it. That measurement was the center to center measurement I needed. I set up the drill press again with the fence and a stop block. First the fence to set me at proper distance from edge to center of the hole, and then from the stop block set back far enough to not interfere with the edge guide bearings.
Next I started drilling hole for a 5/16” tapped hole (1/32” undersize for the threads) first hole against fence and stop block, flip hole end for end and drill again. Then roll the BT and drill 1st hole on the other side, flip BT end for end and drill the last hole.
By the way I was using aluminum stock from the scrap yard that explanes the extra holes in some of the trucks.
Next was threading all 6 holes in BT. I used a 5/16” spiral hand tap set up in my cordless impact driver.
That with a little oil on tap in between holes and it cut great.
Next step was to bolt on all the bearings:
I’ll add more as soon as I have a chance
Thanks , Todd
-- Todd Swartwood (Todd Swart-Woodworks)