On 23 May 2014 02:20, Gene Heskett <[email protected]> wrote:

> The screw, measured from bottom of ball groove to the ball groove half a
> turn away from it, is about 8.12mm.  That .12mm is probably the angle that
> the caliper is sitting at

1.25mm half-pitch. Pythagoras suggests sqrt(8^2 + 1.25^2) = 8.097mm.
But as you are measuring rangent to the circular grooves I can believe
8.12.

> I'll literally sand it off with a large dremel diamond wheel, which will
> do it without any heat to speak of at 2500 revs, a job I can start & check
> on the progress of tomorrow. :)

I have always avoided losing the balls from ballnuts, but as far as I
can see it isn't horribly difficult to re-ball them (depending on the
design).
Perhaps you could face-off the flats in a 4-jaw chuck on the lathe
using a carbide or CBN tool?

-- 
atp
If you can't fix it, you don't own it.
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