email: tony@lathes.co.uk
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Dore Westbury Vertical Miller

Dore Westbury Mk.1 continued here on page 2 (of 2)

Dore Westbury Mk. 2    Dore Westbury Kit of Parts

A set of build instructions and engineering  drawings
are available for the Dore Westbury

Introduced in the Model Engineer Magazine in April, 1964, and named after its designer, Edgar T. Westbury, a well-known model engineer and author. The first version of this popular "home-build" machine was known simply as the "Westbury" (pictures at the bottom of this page) with, initially, sets of casting and drawings made available for the enthusiastic amateur to machine - unfortunately, some proving so large that they were beyond the scope of all but the most generously equipped workshop. In 1967 Arnold Throp C.Eng., F.I.Mech.E. (who lived in the suburb of Dore, Sheffield, South Yorkshire), assisted the designer with a complete rethink - and this resulted in a machine of both greater capacity and improved versatility. Re-named the "Dore-Westbury" the miller went on to become one of the most popular in the model engineering world - for nothing else on sale at the time could offer the enthusiast such a remarkable combination of value, adaptability, speed range and compact dimensions. The marketing of the machine was also revised and the kit of parts soon included all the larger castings with the bigger machining operating already completed. Everything else could be finished on a Myford ML7, or a similar-sized lathe, and a bench drill. Final development of the machine was undertaken by Ivan law, Arnold Throp and Peter Southworth.
In 1971 production relocated to "
Model Engineering Services" in Chesterfield, this Company being run by Ivan Law, an ex-Rolls Royce engineer. The result was the revised and even more successful Mk. 2 Model,  that offered several important refinements including a larger table of 16" x 5.5" with 11" of lengthwise movement and 5" crosswise (Mk. 1 tables seem to vary in size and travel). To make the most of the table, no fewer than fourteen T-slots, designed to take standard 3/8" bolts and which needed no machining, were cast into the periphery of the table and enormous (almost jig-borer size) micrometer dials could be fitted in place of the tiny ones offered on the Mk. 1.  Instead of a simple coil spring to pull the spindle back up a proper "clock" spring was held in a housing on the left-hand side of the column and the spindle clamping arrangement improved by greatly increasing the size of the boss that drew together the split down the front of the casting. Both the Mk. 1 and early Mk. 2 used epicyclic gearing built into the head to provide low speeds. The Mk. 1 had three direct-drive belt-driven speeds and three through the gears whilst the Mk. 2 was given a considerably improved range of ten speeds - six by belt and four through the gears - it being inadvisable (but possible) to use the two highest speeds through the reduction gearing. On all but late models of the Mk. 2, the epicyclic gearbox used inexpensive, off-the-shelf Myford changewheels and was rather clattery in action. The final machines were re-engineered to incorporate a much-improved set-up with helical gears running in an oil bath, a modification that resulted in a much quieter, smoother and more reliable drive. The range of speeds - approximately 32, 59, 106, 157, 200, 364, 660, 947, 1287 and 1880 r.p.m. - was certainly impressive and added considerably to the miller's versatility. To engage the gears on the epicyclic models one - and sometimes two - small pins have to be pulled out from under the pulley housing. They will be retained either by the friction of an "O" ring or tiny, hard-to-find grub screws. The pins should have been made so that one of them can be passed through the side of the drum into a hole bored in the side of the head casing - so locking the outer ring of the gear unit and allowing the planet wheels to turn and produce a low-ratio drive.
Continued below:



A standard Dore Westbury Mk. 1

The improved Dore Westbury Mk 2

Continued:
While the Dore Westbury is not a rigid machine it is extremely versatile - a consideration that trumps, for the amateur, the ability to remove large amounts of material in one pass. While a Deckel Universal-type FP1, FP2 a Bridgeport Series 1Centec 2A/B or Schaublin 13, etc, are just as versatile and capable of much heavier work, they are large, heavy and difficult-to move machines - and might break through the floor of your garden shed workshop. If a job cannot be accommodated, a machine is useless - and the writer would be pushed to think of a model engineering job, or one involving the restoration of an old car or motorcycle, that a Dore Westbury could not tackle. Need to fit in a tall job? No problem, the whole head can be elevated by a screwed ring to give an enormous clearance beneath the cutter. The head can also be pushed in and out, rotated about its vertical axis and tilted sideways. Both a rack-and-pinion-driven rapid drill-feed and a worm-gear-driven fine-feed are fitted to the quill and the spindle was provided with a 2 Morse taper internally together with a ubiquitous Myford 7 Series (1.125" x 12 t.p.i.) spindle thread externally. When combined, a tilting head and quill feed along the same axis is a tremendous feature allowing all sorts of tasks to be undertaken; a head that tilts but has no quill feed is really a waste of time--and an enormous frustration. As an option, it's believed that either a No. 3 Morse or R8 (Bridgeport-type) taper could be provided - though on the thirty or so examples known to the writer over the years not one was so equipped. On Mk. 1 machines the quill travel was 21/8" but on the Mk 2 increased to a much more useful 41/2". The column was milled with a coarse-pitch thread and, running through a large circular fixed "nut" provided with Tommy-bar holes, could be lifted and lowered by passing up and down through the base casting. Of course, to accommodate the full range of movement a large hole had to be bored in the workbench - and use of the first drawer lost as the column descended into it. Besides the standard length, a column 12" taller was available as an option - though even the standard machine could accommodate massive jobs on the table when the head was elevated to its highest position. A table power-feed unit, supplied as a complete kit for home-construction, became available at around the time of the Mk. 2's introduction but is, sadly, seldom found.
As one would expect, the quality of finished machines varied enormously and, while many were paragons of engineering virtue and worked superbly, some were rather less well built and consequently less certain and accurate in operation.
Although the Dore Westbury could not take heavy cuts, its wonderful versatility and adaptability more than compensated and so offered the impecunious model engineer (and they all tend to be a bit tight with money) the chance to undertake machining operations that would otherwise have meant buying several other machine tools - and that was the key to its great success. A tip: to aid rigidity, when using the machine casually, keep the head as far in as possible and raised to the minimum height needed for clearance
Production petered out in the late 1990s - it was surprising that it lasted so long as the import of inexpensive, ready-to-run Taiwanese and Korean mill-drills such as the Nareok, Alpine, Sealey and NuTools, etc., had begun in the early 1970s. Although of relatively crude construction and dubious quality, these machines are surprisingly effective - though they all lack the enormous versatility of the Dore-Westbury..





A very early version of the Dore Westbury with a number of home-engineered modifications

Capstan handle for rapid drill feed of the quill - and the very simple arrangement of the return spring

Worm-and-wheel gearing for the quill fine feed



Home-engineered head-elevation mechanism

Keyway to ensure that, when unlocked and elevated or lowered, the head retained its alignment

Modified epicyclic reduction gearing


Dore Westbury Mk.1 continued here on page 2 (of 2)

Dore Westbury Mk. 2    Dore Westbury Kit of Parts

A set of build instructions and engineering  drawings
are available for the Dore Westbury


Dore Westbury Vertical Miller
email: tony@lathes.co.uk
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