Neil,

Looks like it's coming along!

I've had a shake up here as well, lots of my toys are still in boxes. Was laid off, found a job, moved from California to Michigan (~2300 miles!), bought a house... phew, that makes me tired all over again thinking about it!

Here are some pics of my copycat spindle design, I think I'm in the same spot of the build as you are Neil.

Click image for larger version.  Name: 8mm Spindle Assembly - Outrunner Version - IMG 1.JPG  Views: 2230  Size: 80.9 KB  ID: 6032Click image for larger version.  Name: 8mm Spindle Assembly - Outrunner Version - IMG 2.JPG  Views: 2422  Size: 104.8 KB  ID: 6033Click image for larger version.  Name: 8mm Spindle Assembly - Outrunner Version - IMG 3.JPG  Views: 3475  Size: 127.9 KB  ID: 6034Click image for larger version.  Name: 8mm Spindle Assembly - Outrunner Version - IMG 4.JPG  Views: 4669  Size: 118.6 KB  ID: 6035
Click image for larger version.  Name: Z-Axis Assembly - Tight - IMG 1.JPG  Views: 3458  Size: 104.4 KB  ID: 6036

I'm using a Turnigy G110 motor, two 8x22x7 angular contact bearings, 4 belleville washers, and an er11 collet with 8mm shank. I'm mostly going to use this spindle for light work: plastics, engraving, PCB cutting, etc.

I'm a little concerned the bearings will heat up, any thoughts on this?

Also, did you re-install the e-clip ring onto the new shaft?