Tony@lathes.co.uk
Home      Machine Tool Archive     Machine Tools For Sale & Wanted
Machine Tool Manuals   Machine Tool Catalogues   Belts

Colchester Student & Master
Mk. 1 & Mk. 2 Lathes

& Colchester Dominion Lathes

Clausing 12" and 13" Models 6564, 6565, 6524, 6525, 6566,
6567, 6526, 6527, 8010, 8011, 8012, 8013

A Handbook & Parts List, new changewheels & backplates are available for these models
Headstock & Gearbox Pages  Carriage Pages
***************************************
COLCHESTER HOME   Bantams Original
   Bantams 800, 1600 & 2000 Modern   
Chipmaster   Student 1800   Mascot 1600    Student/Master Mk. 1 & Mk. 2   
Student 3100   Master Original 1930s/40s  Master 2500  Triumph Mk. 1 & Mk. 2   
Triumph 2000   Mascot - 1950s  Mastiff 1400   Magnum   Serial Numbers   
Outline of Colchester Range as Text Only   Factory  Testing
Catalogue Covers   Early Drive System   Colchester 1909/14   Colchester 1919

Founded in 1908 - when they made a Drummond-like 3.5-inch lathe - by the early 1950s Colchester products were beginning to look distinctly old-fashioned, indeed, hardly any different from their pre-WW2 counterparts. To remedy the situation the Company began the introduction, one by one, of new versions of their long-established 6.5-inch Master and 7.5-inch Triumph models (and an improved but still awkward-looking 8-inch Mascot) together with one additional and important newcomer (and the first in the series), the 6-inch Student. Backed by redesigned and part-colour advertising literature, the new lathes were all styled to closely resemble each other and employed a common and easily used control system that allowed apprentices and regular operators to move quickly and safely from one model to another. Following contemporary practice they were mounted on neat, self-contained cabinet stands with a built-in electrical system, storage drawers (with a lock that also isolated the motor) and provision for an internally mounted coolant tank and pump. Although the model names may have been old these new machines represented a quantum advance for the firm and were assembled in what was to become Europe's largest plant devoted to the manufacture of lathes. Two 300-foot long moving-floors were used, together with a system of "flow-line" production based on automotive practice that aimed to achieve a consistently high standard of quality to "American toolroom limits of accuracy". However, like all production processes, and despite the new factory and much fresh equipment, hidden factors contrived to make some lathes more accurate than others, a fact that the Company turned to advantage by choosing the best machines from each production batch and offering them (with black micrometer dials) as machines to improved "toolroom" standards of accuracy. 
Although the new models shared many design clues with earlier versions, and had very similar-looking geared headstocks and apron controls, there were few interchangeable parts (or accessories), showing that each had been newly and individually designed for a particular class of work. The success of this engineering and marketing strategy was particularly evident in the case of the Student and Master for the two models were, over the next 20 years, to prove enormously popular in both training establishments and small professional workshops and to became by far the most popular and common mid-sized lathes on the British used market.
Ignoring the pre and just post-WW-2 versions (on their open distinctive and old-fashioned looking cast-iron legs) the three most common versions of the Student and Master likely to be encountered today are the early "round headstock" Mk. 1, the "flat-top headstock" Mk. 2 and the more modern "1800/2000/2500" series; these notes concern only the Mk.1 and Mk. 2. The Triumph was produced in only a single form during the 1950s and early 1960s (though the apron was changed for a single-lever safety type) before becoming the very different (and highly successful) Triumph 2000. Although the basic design of the Triumph and its controls closely mirrored those of the smaller machines (and much of what follows is also applicable to that model) a separate section has been devoted to this machine to outline differences in screwcutting and other capabilities.
The names "Student" and "Master" (of both the Mk. 1 and Mk. 2 designations) refer, in effect, to the centre height and bed length - the Student being 6" x 24" and the Master 6.5" x 36" - for, in all other respects, the lathes were identical (
in reality, most Student lathes appear to have been built with a 6.5-inch centre height - so beware if buying a replacement tailstock). Although the specification laid down in the sales literature was quite unambiguous, the factory would build a batch of machines with any modifications (or mixture of features) that the customer desired and the author has seen, over the years, examples that combine almost as many changes and adaptations to the previous differences as could be imagined. The factory even offered "special single or two-tone colour finishes" and the option of chromium-plated control levers and handwheels. However, one unvarying feature was that, on gap-bed lathes, the carriage-traverse handwheel was positioned on the right-hand side of the apron and on straight-bed machines it was always to the left.
Beds
The bed on all models was braced by heavy elliptical cross-ribbing, the ways were ground finished and, at extra cost, could be induction hardened (in which case the machine carried a small sticker at the tailstock end proclaiming the fact). Both straight and gap beds were listed and, although a very useful feature, the latter can suffer one or two problems: if the gap is removed for a large-diameter turning job and not immediately replaced for ordinary turning, the bed (especially on unhardened models) will suffer excessive wear as the saddle is unsupported when the turning tool reaches the chuck-end of the workpiece. When replaced, the gap can cause inaccuracies as the saddle runs over it; the cause is usually dirt between the mating surfaces or uneven tightening. Before refitting make sure that the whole of the gap section is scrupulously clean, insert the screws, bring the saddle over the piece to roughly align it then lightly tighten the screws a little at a time. Final alignment can be made with a few blows in the right direction from a hide-faced mallet before tightening the four Allen screws fully and evenly. One tip is to strike the lathe bed near the gap (rather than the gap piece itself) to help bed things in. When removed, always store the gap piece in the lathe cabinet - or it will certainly be lost.
Continued below:

Colchester Student & Master Mk. 1 (see below for Mk. 2)

Continued:
Drive System and Spindle Speeds
Although the option of fitting the Master (but not Student) to old-fashioned cast-iron plinths (and rigged for drive to overhead line shafts) remained until as late as 1960, the vast majority were mounted on the same type of full cabinet stand employed as standard for the Student. Both models used a 1425 r.p.m 3 h.p. 3-phase motor mounted on a large adjustable plate inside the headstock end of the stand, with drive to the headstock pulley by either a wide flat belt or double V-belts. Although efficient, the twin V-belt drive can cause problems and, should the geared headstock on any V-belt drive Colchester make a knocking, rattling or rumbling sound, the cause may not be worn gears or bearings but unequal-length drive belts "fighting" each other. To check, try running on one belt to see if the headstock runs more smoothly; if it does, fit a second belt, run a chalk line across the two, start the machine for a few seconds and check that the belts are still in line; it's almost certain that they will not. Should it prove impossible to buy a pair of genuine "matched" belts, either buy a dozen standard ones (and find the two closest in length) or, even better, use a modern T-link belts. A further point on V-belt drives (and relevant to all applications) is the effect of belts with sections worn thin: as the worn sections fall into the pulleys and the thicker sections ride up them this effectively varies the gear ratio and causes the drive to speed up and slow down. The end result is vibration, with detrimental effects on the longevity of the machine and often a poor surface finish on workpieces. Fitting new V-belts can often make a significant different to how smoothly a machine tool runs.
The range of spindle speeds differed slightly according to the year of manufacture. Machines produced immediately prior to the 1950s Student and Master usually had a rather slow range, from 20 to 550 r.p.m., with the new models much faster at 52 to 1000 r.p.m. and later further improved to 54 -1200 r.p.m., both with eight speeds. Two-speed motors were a costly and hence infrequently fitted option, but gave sixteen speeds from 34 to 1500 rpm or even, on some very rare, special-order models, 17 to 750 rpm.
Another (rarely-encountered drive configuration) drive used a two-speed Brook Compton motor and an electrically-actuated disc brake. On this model the normal "plug-in" electrical control panel on the front of the stand was replaced by a line of four switches and a stop button immediately beneath the front edge of the chip tray. This version also had a "third-shaft" control rod fitted below the powershaft and operated by a lever attached to the right-hand end of the apron - an arrangement not unlike that employed on a Mk. 1 Bantam. At the right-hand end of the rod was a box, containing a cam that operated the special
Klockner Moeller reversing switchgear. On some of the Klockner-equipped lathes an unusual (and presumably heavier-duty) main spindle arrangement has been found where, instead of the components being located by a single key a much heavier fully splined shaft was used with the sliding components engaged by dog clutches. If you have one of these models the writer would be interested to hear about it.
As standard, both Student and Master were fitted with a spindle brake, operated by a horizontal lever (on the headstock's front face) that also acted as a motor switch. To start the lathe the lever had first to be pulled out against a safety spring (designed to prevent accidental engagement then lifted up (this mechanism was later more fully developed with a proper external gate and called "Safti-lok" by the makers). The lathe was stopped by returning the lever to its central position and then pressed down further to operate what was, when the lathe was new, a powerful drum brake built into the headstock input pulley - though Colchester's assertion that this stopped the spindle "instantaneously" revealed that the handbook writer had either not used the lathe - or a dictionary. However, the brake was very useful, especially to those being paid on "piece-work" who would otherwise have had to watch the seconds tick away as 120 lbs of cast iron came slowly to rest from top speed. It's worth knowing that, after many years of neglect, the headstock brake first becomes ineffective and then (usually following ham-fisted attempts to improve it) may start to interfere with the free running of the spindle. If your Colchester shows signs of slowing down or even "seizing up" after a few minutes running, the brake assembly is the first place to look. If shoe linings are badly worn most industrial areas have a friction-materials specialist who can bond on new material. Unfortunately, unlike the competitor English Harrison lathes, a combined clutch and brake was not fitted as standard but a multi-plate clutch manufactured by "Matrix" used instead. This was a very well designed, easily adjusted and reliable device - and one that should still be working perfectly when any lathe fitted with it is otherwise worn out. Although a 3-phase motor is very robust, and will put up with a good deal of abuse, its 1-phase cousin is a relatively delicate thing and best run near its rated capacity all the time (i.e. worked nearly flat out); if such a motor is switched on and off frequently against "no load" the windings will be damaged and, if run through a cycle where it is started, worked briefly, stopped and started again, the capacitor will fail prematurely.  To prevent this happening on 1-phase (and DC) equipped lathes Colchester fitted a Matrix clutch as standard - even though it meant sacrificing the benefits of a brake. On clutch-equipped lathes the stop/start handle was adapted to open and close the plates with a separate electrical switch on the front control panel. In normal use, once started, the motor was left running for as long as possible, the spindle being controlled by the clutch. If you come across one it is worth knowing that on early clutch-equipped lathes the safety-spring loading on the start handle was not fitted - and accidentally brushing against it can start the lathe running. If needed, a clutch can be retrofitted to a used machine - but make sure you acquire all the operating linkages as well. An electrical reversing switch was (at first) an optional extra and, if chosen, was neatly built onto the hub of the stop/start lever and worked concentrically with it.
Headstock
The 1.5" bore No. 3 Morse-taper headstock spindle (bushed down to No. 3 Morse from something close to, but not actually, a No. 5 Morse) carried an American Type L (long-taper) nose - this, for the benefit of readers unfamiliar with the world's first widely-adopted safety spindle fitting, consists of a large screwed ring (held captive on the spindle's tapered and keyed nose), with a matching thread taper in the chuck backplate. Unfortunately, the various sizes of this fitting are easily confused by the inexperienced; the Student and Master both used the L0 (L-zero) size, while larger models used an L1 or L2, (etc.) - and smaller machines the L00. If you have a sample with which to make ca omparison, all is well, but it is very easy to believe that the fitting either side of the one you need is correct. If you look carefully the size is (usually) stamped somewhere on the backplate; failing this - do your homework, and use a ruler. The 8-inch 3-jaw chucks commonly fitted to these lathes when new were high-quality ones, with an integral backplate, made by in the UK by Burnerd. Today these special chucks are no longer available, but new standard ones can be fitted to a separate backplate - however, don't be tempted to use a cheap, unbranded import; the stresses encountered on top speed when holding large job are considerable. Instead, you are welcome to email for details of quality replacements that we can recommend.
The forged, high-tensile steel 1.5-inch (38 mm) bore spindle ran in Gamet "One-micron Precision" bearings - Gamet being a separate company within the controlling 600 Group who also supplied many other machine-tool makers. A small pre-load was applied to the bearings by spring pressure - that immediately behind the spindle nose being a double-row type with a single-row at the rear. Gamet claimed that the "
unique design ... ensures minimum temperature rise and accurate running of the spindle throughout the speed range"
All the gears were hardened and honed with the 8 spindle speeds changed by two levers on top of the headstock and one, for high and low speed ranges, on the front. Unfortunately the gears of the Mk. 1 were never entirely silent, even when new (though individual examples did vary widely with some even being relatively "quiet"), and a "noisy" headstock can almost be expected on these machines. The Mk. 2, with gears cut on newly-installed German machinery, were much better but even so, prolonged use inevitably leads to a noisy headstock - the worst offender usually being that speed immediately below the highest. In an attempt to quieten the headstock some owners have mistakenly resorted to using a thick oil instead of the thin hydraulic lubricant that should be used; the heavier oil will defeat the spiral oil-return grove (built into the bearing cover plate on the left-hand end of the spindle) and appear to be almost 'sucked out' as the machine runs. Small oil leaks from the headstock are almost a feature of these lathes and, providing the oil is kept topped up, should result in no harm; the time to worry is when the oil stops coming out - the reservoir will be empty. If the rest of the machine is serviceable, but the headstock gears are in very poor or damaged condition, it might be worth removing the headstock cover and arranging a V-belt drive direct to the middle or end of the spindle from a variable-speed, inverter-controlled 3-phase motor; although a crude solution this has been known to extract another decade's life from some machines. On Student and Master lathes the headstock pivots on a dowel, fitted to the back corner nearer the tailstock and can, as a consequence, be adjusted. At the left-hand end of the headstock, sitting between the bedways is a block with pointed-end Allen screws that can be used, by slackening one and tightening the other, to swing the headstock slightly. Before doing this the holding down bolts, which have a little clearance round their holes, should be slackened but not loosened completely. An accurate test bar will needed (it fits directly into the headstock spindle), together with a high-quality DTI used to assess the alignment. Alternatively, test cuts can be taken between minute amounts of adjustment with the holding-down bolts fully tightened, of course.
Continued here:

Colchester Student & Master/Clausing Mk.  2

A "Mark-one-and-a-half" Colchester Triumph/Clausing 15-inch (the Student, Master and Clausing 13-inch were laid out in an identical fashion) with the same rounded headstock but fitted with the improved design of "Safety" apron shared with the Student and Master models.


Tony@lathes.co.uk
Home      Machine Tool Archive     Machine Tools For Sale & Wanted
Machine Tool Manuals   Machine Tool Catalogues

Colchester Student & Master Mk.1 & Mk.2 Lathes
& Colchester Dominion Lathes

Clausing 12" and 13" Models 6564, 6565, 6524, 6525, 6566, 6567, 6526, 6527, 8010, 8011, 8012, 8013
A Handbook & Parts List, and new changewheels are available for these models
Headstock & Gearbox Pages  Carriage Pages
***************************************
Bantams Original
   Bantams 800, 1600 & 2000 Modern   Chipmaster   Student 1800   Mascot 1600
Student/Master Mk.1 & Mk.2   Student 3100   Master Original 1930s/40s  Master 2500
   Triumph Mk.1 & Mk.2   Triumph 2000   Mascot - 1950s  Mastiff 1400   COLCHESTER HOME
           Magnum   Serial Numbers   Outline of Colchester Range as Text Only   Factory  Testing