Bollocks - Y bracket cockup - machine heal thyself!

The Y axis bracket looks as if it should fit on / together OK. Here's what it looks like at first glance. Doesn't look too bad....

...until you try to bolt it to the knee. At which point it becomes clear that the motor is about 3mm too close to the knee casting. Clashes with the knee casting:

Holding the motor body perpendicular to the bracketshows how much it needs to move:

I can just about get a 3mm drill into that gap

Not much danger of modifying the bracket or the motor to overcome the problem. No. Instead, the pragmatic solution seems to be hacking away at the casting to make room. Or technically "machining" a shallow indentation using a router. 

I planned on moving the Y axis DRO scale back a bit anyway - I need about 15mm:

There is the required space at the other end. I'll need to drill and tap a couple of new M6 holes.

Before whipping this lot off to machine the knee, for the record, here's the position of the fixing screws relative to the adjustment slots:

So, back to the machining. I have 4 angle brackets, so I've managed to cobble together a contraption that will hold my small Bosch router at the correct orientation and be able to move it in and out in the X and Y directions using the table controls. And the Z axis by loosening a couple of bolts and shifting the tool periodically. The router is bolted to the loominum angle plate using the original M4 holes in its base. I've checked that the table can provide the required range of movement without fouling anything. It's not going to be pretty (or quiet) but there we are.

After a bit of last minute adjustment to give the required range of movement, we are ready to go:

It makes a lot of sparks.

Part way through. I won't get any marks for style. The vertical adjustment is by loosening the bolts and raising or dropping the whole chebanc manually, so pretty hit and miss. The right / left adjustment is by eye, so also pretty scrappy.

It packed in part way through. Turns out one of the brush retainers had unscewed. Luckily it had landed in the chip tray and I was able to find it easily.

I made a couple of passes with 2mm axial DOC and full width , which was possibly a bit aggressive. The cutter didn't last very well but I had a spare and at £6 a pop it hardly broke the bank. You can see it got pretty hot but there again it was probably rubbing rather than cutting by this stage.

Here's the final result. Not pretty, as expected. But the motor fits nicely and nobody died. 

Now I need to remove the scaffolding, clean up and reassemble the DRO scale, motor bracket etc etc and resume the assembly / fitting process....