My newly acquired HLV-H came with a broken tailstock clamp. I can easily make a new part but am not sure how much clearance to allow on the square portion that fits through the tailstock body.
The square portion of the clamp is .395" but the broached hole in the tailstock is about .440" square. It's not clear to my why so much clearance and it seems that amount of play may contribute to bending of the plunger and tendency to break. There's no evidence of damage to either part, male or female.
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My inclination is to make the new plunger with just a few thousandths clearance on the square portion. Can anyone think of a reason to have more clearance than that?
Thanks,
Jim
The square portion of the clamp is .395" but the broached hole in the tailstock is about .440" square. It's not clear to my why so much clearance and it seems that amount of play may contribute to bending of the plunger and tendency to break. There's no evidence of damage to either part, male or female.

My inclination is to make the new plunger with just a few thousandths clearance on the square portion. Can anyone think of a reason to have more clearance than that?
Thanks,
Jim