127mm f/9.4 OTA Construction - Focuser (jig to hold focuser housing)

 

The focuser housing sitting in a jig that will be used to grind away the outer flange... (Click for enlarged view)

 

To remove the unwanted material from the outside of the focuser housing's flange, a jig was setup on my drill press as shown in the photo above. This setup will allow me to reduce the diameter of the flange so it can fit the main tube. All it consisted of was a scrap piece of 3/4" plywood, two small blocks of Teflon, two drywall screws to secure them, and two small "C" clamps to lock the apparatus to the drill press table. A sand disk is chucked in place and will remove the outer surface of the flange as it is rotates. The jig was gradually moved in toward the sanding disk as aluminum material was ground away from the flange.  Very simple process, but let's see how effectively it worked.