How do you cut a 40 mm hole in the front lower bones?
Answer..Very carefully
http://i129.photobucket.com/albums/p212/muddypaws4x4/locost107.jpg

Took me all day to make the plates
and god knows how many cutting discs.

finaly got them done
http://i129.photobucket.com/albums/p212/muddypaws4x4/locost111.jpg

Only last night to find out I could have bought them for about £8 from 3GE
bu***r

David

Ah but the pleasure of knowing you made them rather than just buying them

I chain drilled mine and filed them by hand

For what it's worth I have a copy of the Boxford manual and it recommends drilling large items (that are too long to fit in your chuck) the other way round. i.e. with the drill bit or cutter in the chuck and they supplied a fixture that fitted into the tailstock that you could clamp the work to, but i dare say that you could make up a suitable fixture if required

laser cut them

chain drill.... easy.

Wait a minute, holy crap, how thick is that metal plate? 10mm? Only needs to be 3-5mm!

Or is it an optical illusion?

I reckon they're tack welded together

^^^^

Yep thats how I did mine. Two bits of 5mm plate tacked together as one .

Hard work but a matching pair

Yup spot on, tack welded together.

Mind you should have seen the lathe wobble when I first started it up.
Full speed

had to do it at about 100rpm
Still frightning though.

I usually use a hole saw for things like that, a good HSS one will do lots of holes but the cheapo ones might only last for one .
Paul.

Took mine to me local precision engineers (or anz fabricators ought to do). I now have hole saws. Easy