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  • Yeah, clamped to the table with a couple of g-clamps as per the top photo, then used a good quality, two handed hacksaw (with a bit of WD-40 on the blade) and just took it easy and kept checking it was straight.
    Then I neatened up the angle and copied the chamfers from the original quill end onto my new end using a wide, flat file. As far as I could figure out, the most important thing is to get exactly the right (correct) angle for the wedge-nut to butt up against, otherwise the stresses will end up being in the wrong places and you'll be risking a failure.

    Let us know how you get on!

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