This is a heavy duty holesaw mandrel.  The shank on this is 7/16 inch and requires a 1/2 inch drill chuck.  My drill has a 3/8 inch chuck. 

I had to make several dozen 3 inch holes in our soffets (also spelled 'soffit') for ventilation louvers.  I ground the shank flats down freehand so the mandrel would fit my drill.  It worked, but it wobbled terribly. 

(The image is from Amazon.com.)

Step 1: Build it back up

I decided to restore my mandrel, but sized for my drill chuck and on center so it does not wobble.  The first step was to build the shank up again by welding.  A wire feed welder makes this much easier than with a stick welder.  (I did not take photos while I was actually doing this project, so this is a recreated photo.)
Where there's a Phil there's a way. Nothing like the good old we don't have a lathe so grind it solution I always say! The further I went along in your Instructable the more it reminded me of this I did recently:<br> <br> <a href="http://img199.imageshack.us/img199/6379/lead2b.jpg">http://img199.imageshack.us/img199/6379/lead2b.jpg</a><br> <br> To really take material off I used an angle grinder then the file and stones to clean it up somewhat. Now I'm going to have to think if I was running it the right way or not as per some of the comments in your post here.<br>
&quot;<em>Where there's a Phil there's a way</em>&quot; True enough in Phil B's case, but can I steal that one pfred? My name's Phil too. My main motto is &quot;There's <em>always </em>a better way&quot;.
I do not understand how you were able to ensure that the newly ground flats would be aligned properly (at 120 degrees).
Notice the hex nut that is part of the hole saw mandrel. It is visible in step 7. I used it as a guide to rotate the shaft approximately 120 degrees. In step 9 you can see how the flats I ground correspond closely to the flats on the hex nut.
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Excellent solution to this problem.&nbsp; I have an arbor that actually twisted off from heavy use with a 4&quot; blade.&nbsp; My small lathe was not solid enough to turn the hard section of the sleeve I welded back on.&nbsp; This little jig is the answer, and using my radial arm saw will act as a surface grinder to return the shank back to center balance.&nbsp; Thanks a million for the ideas~!<br />
Thank you for commenting.&nbsp; I had hoped someone might be able to use some general principles from this Instructable.&nbsp; I never guessed someone would need to do the same job.&nbsp; I hope it works out well for you.&nbsp; <br />
What an inspirational instructable!&nbsp; Share &amp;&nbsp;learn, share &amp;&nbsp;learn...<br />
Thank you.&nbsp; I have known people who have many tools, but get very little use from them.&nbsp; I made it my aim to have a few tools and find ways to make them do things the user manuals never tell you can be done with them.<br />
Use of the radial arm saw as a milling machine....a great idea. I am glad I never sold mine. Thanks a lot for the great idea. I have always wanted a milling machine, and never realized I had one all along! come to think of it, you could do the same thing with a table saw. Thanks again.<br />
Thank you for your comment.&nbsp; I have published a number of special things you can do with a radial arm saw.&nbsp; Search Instructables for &quot;radial arm saw.&quot;&nbsp; I expect you could do this job with a table saw if you set it up carefully.&nbsp; I hope you continue to enjoy your radial arm saw.&nbsp; <br />
Phil, you've done it again!&nbsp; I can't tell you how helpful your ibles are.&nbsp; I think I'm going to print all of the tool related ones off and put them in a binder.&nbsp; I already know&nbsp;some of the the things you post, but I always seem to forget when I'm in the middle of a project.
Thank you, Barry.&nbsp; I can mail a CD&nbsp;to you with all of my Instructables on it.&nbsp;I am glad they are useful to you.
Thanks Phil!&nbsp; Do you still have my adress?
Dewey in Pangburn?&nbsp; I think I do.<br />
That's it.&nbsp; Thanks!
It'd be a good guide for when skunk junior's building up his own toolshed/stealing yours...<br />
I'm afraid that ship has sailed.&nbsp; I've even given up on the recovery mission.&nbsp; But we are building a shed for him, so at least my shop will be cleaner with all of his (AND&nbsp;MY!) things gone.&nbsp; He has more time to accomplish things than I do these days, so I guess it's only fair.....
Well now you can take up any ridiculously space wasting hobby you can think of. <br /> <br /> Put the shed on castors without him knowing, secretly move it around a little each day, just enough to notice, then one night roll it in to a hiding place and dig a hole where it was... Follow up with a speech about how your tools and stuff just disappeared out of the shop... <br />
Yep, I've got the space wasting business all planned out!&nbsp; My Corvette needs shelter from the elements.&nbsp; I'm also going this week to pick up my grandfathers '72 Ford F-250.&nbsp; Rarely do I consider trucks worthy of restoration (I reserve that for sports cars, muscle cars and classic cycles), but this one will be a labour of love.&nbsp; He ordered it ( with various custom parts) the year I was born ('71), and he (almost) always kept it garaged.<br /> <br /> That's a great idea about the shop, but as it's about 30' x 30' and set in concrete, it'll probably have to stay put.
It is this &quot;thinkin' outside th' envelope&quot;&nbsp; that separates th' &quot;machinists&quot; from th' &quot;machine tool operators&quot; !!
Thank you.&nbsp; I almost did not publish this because I thought it had too little to offer.&nbsp; I am glad you and others find it to your liking.<br />
Right before I retired from th' U S Navy I discovered an old shipmate workin' at th' base machine shop ( he was almost retired as well)&nbsp; When he discovered a job that had been awaiting attention fer almost a month he was told &quot;we havent got th' parts fer th' lathe to cut th' threads in that &quot; he promptly checked what th' tread patteren was and then went and ground a lathe bit to shape ,&nbsp; chucked up th' offending part and proceeded to cut th' threads that this bunch of &quot; if I caint CNC it I cant do it &quot; machine tool operators had given up on !<br /> <br /> Always good to find someone who looks to what he CAN do ,&nbsp; instead of complainin' of what he CAINT do !!!
Thank you for sharing a great story.<br />
Good on you for extoling the virtues of the radial arm saw.<br /> <br /> I grew up with one and had that blalde in every concievable orientation possible.&nbsp; I also taught wood shop for 7 years (I'm doing auto shop now (bleck - fix'n old junque instead of making cool new stuff!)) and loved the 'ol 12 inch we had.<br /> <br /> I've got aon old craftsman 10&quot; and was given a 240V Craftsman 12&quot; that needs a bit O love.<br /> <br /> Great job using the saw as a surface grinder!
Thanks.&nbsp; If you have not seen <a href="http://www.instructables.com/id/Sears_Radial_Arm_Saw_Egg_haped_Indexing_Holes/" rel="nofollow">this</a>, you will appreciate it for your Craftsman radial arm saws, should this problem develop for you.&nbsp; The indexing holes do not wear at the same rate, and this is an easy fix to restore accuracy.<br />
Yet another excellent technical-shop project, Phil!&nbsp; And you're still using that radial arm saw for anything you can think of, aren't you?&nbsp; :-)<br />
He's brilliant, isn't he?!!!!&nbsp; He should write a book!
Thank you, Barry.&nbsp; I am thankful to share things I found useful and pray they will be a blessing to others, too.<br />
Thank you, Kelsey.&nbsp; George Washington Carver found many, many uses for the peanut.&nbsp; I am no George Washington Carver; but it is good to show folks what a radial arm saw can do in these days when miter saws have all but replaced them, and to prod those who use them only as cut-off saws to explore the full range of what one of these great tools can do.&nbsp; <br />
Io non llega Italiano.&nbsp; Grazie.<br />
Thank you.&nbsp;
Does the drill spin the same direction as the grinder, or opposite?<br />
I find opposite works better for removing material.&nbsp; That is easy with a reversible drill.&nbsp; Thank you for your comment.<br />
Seconded...any time I&nbsp;grind something held in a drill chuck I turn the drill the opposite direction- helps to pull the material into the wheel rather than bouncing it off.<br />

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Bio: I miss the days when magazines like Popular Mechanics had all sorts of DIY projects for making and repairing just about everything. I am enjoying ... More »
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