You don't mention the temp gradient, is rubber lined pipe out of the question? They can apply the lining to just about anything with proper prep.
http://www.fullerindustrial.com/rubberlining.asp
http://www.fullerindustrial.com/rubberlining.asp
We used to make similar parts and rigged a sheet stretcher on the mill so the sheet was flat and held off the platen, we used simple knurled cams to lock the sheet in place and tighten.
All operations took place before the final cutout, once completed they went through a rolling machine to...
Why not pin it, if done properly it is as good as welding as long as there is enough material around the crack to take the procedure.
http://www.enginebuildermag.com/Article/1968/pinning_down_the_cold_repair_process.aspx
Teflon packings do not conduct heat like a graphite packing does so overheat of the shaft is common when switching over, usually some leakage is required to use a teflon packing which is typically objectionable in the common service fire pumps are required to work under (no leakage while idle...
You will get the best results using a rigid drill press for alignment and a spiral bottoming tap such as used in CNC equipment. I have always used Rapid Tap lubricant for the best results.
Make sure the work is clamped and you only go a quarter of a turn at a time and back off to break the...
You use two flute end cutting cutters for keyseats, not four flutes. You should plunge into the work and then make the seat, if you need to come out you start at the end of the keyseat and work out with the two flute.
Four flute cutters will cut oversize because of vibration.
Have you considered upgrading to a air lift style station, the catch basin is one way valved and an air compressor is utilized to pressurize the basin when the basin lift floats indicate high water.
Very simple to operate and maintain and only regular screen cleaning and yearly air compressor...
We regularly used off the shelf "wood" routers with carbide tooling for chamfering AL plates of all sizes, it is noisy with lots of chips flying but it works like a charm. Use small diameter tooling as they wear more slowly at the high rpms of the typical router.
Make sure you are climb milling...
I second the Lignum Vitae wood bearing for this usage, you will not find a longer lasting bearing for a submerged application like yours with as high a load rating.
We use them on hydro turbine shaft bearings with very high loads and they can last 50 years or more, stainless steel shafts are...
Try shimming your carbide cutters out 0.001" and one of them down 0.001", this places one cutting edge out of the horizontal chip load zone but down into the face cut load zone to do the finishing. I'm assuming your using a square insert carbide face mill for this. If your using a triangle...
