The interference fit of bushings actually shrunk the delrin a couple thousandths, so I reamed them out again (0.501"). To speed up the 72 bushings to ream I just let the initial taper auto center then held the piece by hand. (First I checked adjustment of bridgeport head to be sure it was perpendicular to table, saw about 1.5 thousandths off over ~6 inches and was able to improve it a bit)



Turned 12 feet of cold finished 1/2" steel rod into lots of small rods (each leg needs 6 axle pieces)



Sticking the rod in a drill and then running it against the disc sander worked perfectly to get a nice chamfer quickly on all the pieces



Most of the axles pieces are fine at the rough cut (+/- 1/16") length, but I needed to make the crankshaft pieces a more precise length. Came up with a much better process than I used for mk1 pieces. First I turned one end of each piece on the lathe, then I used the bridgeport and a stop to use an endmill to cut the other end at a consistent precise length



I was actually suprised that the finish looked much better with the endmill than the power feed facing cut I did on the lathe. (Using the random cutting insert that has seen who knows what abuse probably didn’t help). Here are some examples after a quick chamfer in the lathe, half of them will be drilled and tapped later

