DIGITAL HEIGHT GAUGE

This height gauge is made from parts salvaged from a digital caliper and an analog height gauge.  A vertical  post is employed to support the scale and minimize any tendency of the scale to warp.  The dimensions of the base have been tailored to fit my hand.  The maximum range of measurement is 145 mm.



1. Unnecessary parts cut away.  Use care NOT to OVERHEAT  during cutting.

2. Drilling two 2 mm holes on end of scale, VERY hard stainless steel.  Carbide bits  eventually completed the task,  but only after damaging three bits.

3. Rough-cutting base from a block of cast iron.

4. Fly cutting edge of base.  

The fly cutter uses a triangular carbide insert as shown in Article Number 36.

The material is a block of the cast iron.

5. Counterboring hole in base.


6. Grooving  base for finger grip, followed by rounding all corners  with a reverse round end-mill. 

Base is held in vise, with additional support of  jack screw.

7. Surfaces finished on belt sander after machining. 




8. Support shaft threaded.  The diameter is 12 mm and the material is hard steel, sometimes called  "silver steel" or "drill rod."













8a.  Support shaft attached to base with nut.



9. Knurling  fine-adjust nut;  brass, 16 mm diameter.  

The following procedure  was used -
Provide a generous supply of oil.
Clean knurled area  after each pass. 
Wear eye protection.
Inspect quality with 10 X magnification paying particular attention to the form of the crests.

10. Reaming slide hole in slide base.  

The right-hand piece  contains an error, and is used only to aid work-holding.

11.  Machining slide base.

12. Fly cutting fine adjusting block.

13. The two fixed supports of the scale are rounded on the belt sander with the aid of a dedicated tool; a hardened collar on each side of the fixed supports is used as a guide.


14.  The angle bar for foot has been rough cut.  Material is mild steel.
15. Drilling two mounting holes.
They are countersunk for the screw heads.

16.  The slide base was reshaped to a more pleasing profile.  (Photo #11 shows the original profile.) 

17. Attaching scale to top bracket with 2 mm screws.

18. Fine adjustment mechanism.
19. Foot attached to the lower end of the angle bar with box bracket.