How to mill the end of a large kaleidoscope blank?

[randyrls]

I need to mill the end of a kaleidoscope blank. It is about 1-3/4" and the hole in the middle is 13/16" so it is too large to fit even a 3/4" pen mill.

I have a Shopsmith and 12" sanding disk so I am thinking of putting a pen mandrel and sleeve in the tailstock and using the sanding disc to flatten the ends of the blank. This thought gives me unpleasant qualms about getting my pinkies that close to the sanding disk.

I normally have a sanding jig to square blank ends, but this is much too large to fit in the jig.

How does everyone else do this??? Any suggestions appreciated.

 

[southernclay]

Can you hold in a scroll chuck and bring live center up to hold steady while you mill it? Assuming you have a scroll chuck. I just did my first mills and held it between centers to square all but the center but that got hollowed out

 

[ed4copies]

When you make kaleidoscopes and peppermills, you are usually using the hole to center it and turn between centers.

Square the end by cutting it off with a parting tool.

 

[Edgar]

I don't mill the ends of my kaleidoscope blanks.
I cut the ends off square with a miter saw to the exact 2-1/4" length needed for the kits then use a 13/16" forstner bit to drill the hole with a drill press, making sure the table is properly aligned to the drill bit.

 

[KenV]

Randy - If I cannot use Edgar's approach, I make sure the blank is as perfectly square as possible (I use a jet drum sander - but there are other ways). now it will fit in scroll chuck jaws across the corners. You can turn the end square -- only need a small flat where the bushing sit, if you are using bushing and a mandrel.



Mark the corners you uses with the jaws if you need to reverse the blank for the other end.

 

[randyrls]

Ken and Edgar; Unfortunately, it is not cut square. When I put it on the lathe it was VERY noticeable.

Thanks to everyone for the suggestions.

Some time ago I got a modular faceplate setup from Craft Supplies. I took one of the plates and attached it to a piece of 5+" plywood and then stuck on a self stick sanding sheet. I put an adjustable mandrel in the tail stock with a sleeve on it. My lathe is variable speed and goes down to about 125 RPM. It worked perfectly. The smaller size and lower speed increased my comfort level. Now to finish that kaleidoscope.