Wouldn't matter what he did, somebody would complain about it. It's hard to fight one problem without causing others. IMO, triple seems like a lot, especially given the quality of some of the material.
FWIW, I work as a contractor/consultant. I follow a fundamental rule in that anything I recommend isn't influenced by how it affects me personally. If they can save money by showing me the door, I'll be the first to justify it! Truth in business is as hard to come by as anyplace else.
IMO, as long as you have no authority to set the priorities and no significant budget for tooling and equipment, you're stuck. If the people above don't have any understanding of what it takes to do a job, you're stuck. OTOH, if you/they are talking, there's some hope, but they have to trust you...
I don't know beans about anodize dye but I sure don't like parts that turn purple in sunlight. The stuff has to be stable over time and environmental factors, or you'll get complaints.
I've done 3-jaw jaws on the SG with great success and it's my preferred method. You can even arrange a bit of toe-in if desired. Not sure I'd try it with jaws that don't fit the body well. The calculation for how much to take off is trivial but I still mess it up so there's a program at the...
Solidworks often has a deal on their Maker version of the software. Just be aware that it's been designed to have near zero compatibility with their commercial version. You can't work on a file at work and then bring it home to the Maker version or vice versa.
I was fortunate enough to pick up a lightly used Atco Punchmate #1. I wouldn't dream of hitting it with anything; why would you? It's a great problem solver for grinding, light machining and inspection. There are all sorts of things I wouldn't have been able to do without it. I don't know...
I've never operated a shaper so this is armchair speculation. I've tried to do some simple grooves by cranking a piece past a fixed tool on a Bridgeport and discovered that chatter is almost insurmountable. My guess is a shaper works as well as it does because of the mass. It's probably hard to...
The phrasing makes me wonder what you're doing, "near the end of the hub." Is this the bore of the pulley that it attaches or runs on? I've always found messing with bores after the pully is made is a recipe for trouble. Best to machine the pulley and drill/ream the hole without removing it from...
Specifying a machining process is a no-no, but the work I do is so fussy that sometimes I have to. Being a sneaky you-know-what, I do it in a surface finish callout, where it's perfectly legal.
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