Hello John,
Glad to hear that you are making progress.
I wonder if your machine has had it’s bed reground at some point, making the shears thinner than standard. That would be a possible explanation for you having to reduce the width of the insert – I had no probems with mine, which is an ex-school machine that has not been reground.
To align the apron, slacken the screws holding the apron to the saddle. Position the carriage as close as possible to the tailstock end of the bed and, with the apron screws adjusted to be just lightly in contact, engage the halfnuts to centre the apron with the leadscrew. Tighten the screws. Aligning the apron with the screw at a position close to the end bearing (where it is well supported) will prevent excess loading on the leadscrew in operation.
The rack can be adjusted too – if it is too tight in mesh with the pinion, loosen the screws & move the rack within the cleanace of the mounting holes.
It may be worth checking the width of the front & rear shearsat several places along their length – your comment about “tightening towards the tailstock end” suggests that, most probably, the front shear is worn. This will probably affect the tailstock alignment at different positions along the bed – the effect could be alieviated by pushing the tailstock towards the rear shear while applying the clamp.As the inside edge of the front shear was previously used by both the saddle and the tailstock, this is the face I would expect to be most worn – the inside edge of the rear shear less so, so it should still provide a reasonably accurate location for the tailstock.
Regards,
Nigel B.