Here is a picture of the broken portion of the dovetails, rear half of the saddle.





So I get to play like a machinery repair tech...




After milling out the broken portions, I moved the saddle back to the lathe to free up the Bridgeport for the next steps.  In the picture below, the milled out pockets are visible.  I had to leave some of the broken portion on the right-hand dovetail due to proximity to the capscrew holding the wing to the saddle visible just to the lower right- milling it clean would have brought the cut very close to the capscrew head & shank.. 

The repaired cross-slide is also shown, after soldering with ~2% silver bearing solder.  I'll do a final cleaning and fill voids with JB weld before painting.

The next step is to prep some new dovetail pieces and screw them down in the milled out pockets.  I'm still debating using silver-bearing solder vs silver brazing to permanently fix the new dovetails.  While I think about it, I'm going to install the motor, controls and VFD and get the lathe rolling... :)






Next step was to fit some 1018 stock into the pockets and screw them down, then the excess is trimmed.  I'll cut the dovetails last.





I milled off the excess material all around, then started milling the dovetails.  Naturally the first dovetail cutter was too small, the second was too large, but the third was Just Right.





The test fits are good, so I deburred and moved the saddle off the Bridgeport.  Next step is to take the dovetail sections off, clean & prep for soft soldering.  If I had an oxy/acetylene rig I'd braze.  OTOH the new  sections only support the taper slide, so they don't need maximum strength.

;;; eof