Gene;

We really need to break your DC motor fixation. If you think PCW's 5i25 is neat 
just wait until you start using a VFD controlled spindle.

Odds are that a better replacement motor and VFD will cost near the same of 
what your planning to build to support that marginal OEM DC motor.

I have several great treadmill motors and some motor controllers for them, but 
trying to keep fine tune of RPM vrs load is a hemroid and using those controls 
for reversing just isn't practical. Then there was the heating issue of running 
the motor at lower RPMs.

I would get a 1.5 or 2hp motor with a lower 60Hz rpm spec then over speed it as 
needed so you have plenty of low rpm power.

On a side note you would still have the Pico drive available for your old mill 
so little things like engraving could still be done on it.

That 240V is just waiting to be used...

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