Since this is an independent rear suspension, I'm leaving plenty of material here so I can bolt up a bearing hub to support the inner u joint on the axle shaft. Start big & whittle it down to fit...eyeball engineering...
More procedure. My solution to not having a rotary table.
Washer keeps the aluminum work piece slightly off the vice. Nuts are in the vice. Everything is solid & plumb.
Accounted for the thickness of the washer with a piece of .092...used a piece of .062 & set the depth stop loosely to it. This will give me a 1/16"...1/2" @ 1:1... base for this side of the side cover where it bolts to the center section.
Centered the lay out mark in the vice opening & with the bit centered on that mark it will run with the axis up the ramp to the center of the piece.
I'm employing trippple quadruple redundancy in this set up...I've got an entire sunday invested in the side covers at this point...got to get this right, the first time!!!
Building side covers for the rear end. Here's my procedure. Having neither mill or lathe, I'm forced to be innovative & think outside the box to achieve my desired results.
Rough in on the band saw.
Button head on bolt is the dia I want for the outside end. Big washer is correct for where it bolts to the center section. I'll work to these as my size templates. Jam nut keeps everything tight in the spinning drill press.
Jigged a coarse rasp in the vice to hold it steady as the spinning aluminum plug is lowered on to it. Slow going.
But I'm getting the result I want. On to the next step.