What a CNC Retrofit Includes

    A CNC retrofit is the process of replacing the outdated control system, drives, and electrical infrastructure of a machine tool with modern, programmable CNC technology — whilst retaining the machine’s existing mechanical structure. For vertical lathes and boring machines, this transformation can add decades of productive life to a machine that would otherwise become increasingly difficult to maintain and operate.

    The principle is simple but powerful: the cast iron frame, slideways, table, and ram of a quality vertical lathe do not wear out in the way that electronic components do. A machine built in the 1960s or 70s may have decades of structural life remaining, but its control system — based on relay logic, DC drives, and mechanical feed boxes — is now obsolete, unreliable, and increasingly difficult to support. A retrofit replaces the ageing nervous system of the machine with modern technology, unlocking the value of the mechanical structure.

    A typical CNC retrofit from VTT-WB includes:

    • New CNC control system: Modern industry-standard controller with conversational programming, graphics, and diagnostic capabilities
    • Servo and spindle drives: Replacement of old DC or early AC drives with current-generation digital servo systems
    • Feedback systems: High-resolution encoders and linear scales for precise positioning
    • Electrical panel rebuild: Completely new control panel, wiring, and safety circuits built to current standards
    • Safety systems: PUWER-compliant safety relays, e-stops, interlocks, and guarding
    • Hydraulic and lubrication upgrades: Modern pump controls, pressure monitoring, and automatic lubrication systems
    • Software: Post-processor configuration, part programming support, and backup of machine parameters
    • Operator interface: Modern HMI with graphical programming, tool path visualisation, and diagnostic displays

    Every retrofit is tailored to the specific machine and customer requirements. We assess the existing machine, discuss your production needs, and design a retrofit package that delivers exactly what you need — no more, no less.

    CNC Lathe Retrofit Cost

    One of the most common questions we receive is: how much does a CNC lathe retrofit cost? The honest answer is that it depends on several factors, but it is almost always significantly less than the cost of a new machine of equivalent capacity. Understanding the cost drivers helps you evaluate whether a retrofit is the right investment for your operation.

    Factors that influence retrofit cost include:

    • Machine size and complexity: A two-axis vertical borer is simpler than a multi-station turning centre with additional axes
    • Number of controlled axes: Each additional axis requires its own servo drive, motor, and feedback system
    • Control system specification: Entry-level conversational controls cost less than full DNC/networked systems with advanced features
    • Mechanical condition: If slideways, bearings, or gears need reconditioning alongside the retrofit, this adds to the project scope
    • Safety requirements: Sector-specific requirements (nuclear, defence, oil and gas) may demand additional safety systems and documentation
    • Auxiliary systems: Tool changers, coolant systems, and chip conveyors that may need integration or upgrade
    • Foundation and installation: Most retrofits use the existing foundation, but modifications may be needed

    As a rough guide, a CNC retrofit typically costs between 30% and 60% of the price of a comparable new machine — and often less when you factor in installation, training, and foundation work that a new machine would require. The existing machine is already installed, levelled, and connected to services; a retrofit works within that existing footprint, avoiding the disruption and cost of a new installation.

    It is worth noting that the cost of a retrofit is not just the price of the engineering work. There is also the value of the machine you retain — a machine that may have been fully depreciated on the books but still has substantial intrinsic value as a production asset. A retrofit converts that latent value into productive capability.

    We provide detailed, itemised quotations after inspecting your machine. There are no hidden costs — you will know exactly what is included and what is optional before any work begins. We can also phase the work if budget constraints require, starting with the control system and adding safety systems or auxiliary functions in subsequent phases.

    The ManuPlus Programme

    The ManuPlus programme is VTT-WB’s structured approach to CNC retrofits for vertical turning machines. Developed through years of experience modernising Webster & Bennett, Bullard, and other vertical borers, ManuPlus provides a defined process with clear stages, deliverables, and quality milestones.

    What sets ManuPlus apart is the combination of engineering rigour and practical machine tool experience. We do not just swap components — we understand the machines we work on, the applications they serve, and the production environments they operate in. This means our retrofits are designed for real-world reliability, not just theoretical specification.

    Stage 1: Machine Assessment

    We inspect your machine on-site, assessing mechanical condition, existing control systems, and your production requirements. This includes checking slideway condition, table drive health, ram wear, and electrical system status. We discuss your current operations, the parts you machine, the tolerances you hold, and any limitations you experience with the current setup. You receive a detailed report with recommendations and a fixed-price quotation.

    Stage 2: Design & Engineering

    Our engineering team designs the new control system, specifies components, and produces detailed electrical schematics. Mechanical modifications — if required — are planned at this stage. All designs are reviewed and approved before any work begins on the machine. We select components from established suppliers, ensuring long-term availability of spares and support.

    Stage 3: Retrofit Execution

    The machine is taken out of service (or work is completed during scheduled downtime). Old control systems are removed, new panels are built, servo motors and drives are installed, and the complete electrical system is rewired. Mechanical reconditioning — if specified — is completed in parallel to minimise total downtime. Our engineers work methodically, documenting each connection and adjustment.

    Stage 4: Commissioning & Testing

    The machine is powered up, axes are tuned, geometric accuracy is verified, and test cuts are made to confirm performance. We work with your operators to ensure they are comfortable with the new control system before signing off the project. Any issues identified during commissioning are resolved before handover.

    Stage 5: Handover & Support

    Full documentation is provided, including electrical drawings, operating manuals, and maintenance schedules. Operator training is delivered on-site, covering programming, operation, and basic maintenance. Ongoing support is available through our maintenance programme, with telephone support, scheduled service visits, and access to spares.

    PUWER & Safety Compliance

    Many older vertical lathes in service today predate current health and safety legislation. The Provision and Use of Work Equipment Regulations 1998 (PUWER) require that machinery is safe to operate, maintained in good order, and provided with appropriate guards and safety devices. A CNC retrofit through the ManuPlus programme brings machines fully up to PUWER compliance.

    Our retrofits include:

    • Emergency stop circuits: Category-rated e-stop circuits across all operator stations, meeting the performance levels required by current standards
    • Interlocking systems: Safety interlocks on access doors, guards, and covers to prevent access to hazardous areas during operation
    • Safe stopping: Monitored brake systems for rapid, safe deceleration of the table and axes
    • Guarding: Design and installation of perimeter guarding where required, with safety-rated monitoring
    • Documentation: Technical files demonstrating compliance with essential health and safety requirements, including risk assessments and safety circuit diagrams
    • Training: Operator training that covers safe operation, emergency procedures, and maintenance safety

    For machines operating in regulated environments such as nuclear, defence, or oil and gas, we can design safety systems to meet sector-specific standards and documentation requirements. This includes compliance with standards such as EN ISO 13849 for safety-related parts of control systems, and sector-specific quality and documentation requirements.

    PUWER compliance is not optional — it is a legal requirement. If your machine has not been assessed for compliance, a retrofit through the ManuPlus programme provides a cost-effective path to meeting your obligations whilst simultaneously improving machine capability.

    Case Studies & Lead Times

    Every CNC retrofit we complete becomes a reference for future projects. Here are some examples of the work we have delivered:

    Webster & Bennett 48 — Defence Contractor

    A W&B 48 in a defence manufacturing facility was running on 1960s electrical controls with increasing reliability issues. Spare parts for the original control system were no longer available, and each failure resulted in extended downtime whilst parts were sourced or fabricated. The ManuPlus retrofit delivered a modern two-axis CNC control system, new servo drives on X and Z axes, a PUWER-compliant safety system, and conversational programming capability. The machine returned to service with improved accuracy, reduced setup times, and full safety compliance. The project was completed within a planned maintenance shutdown, minimising production impact.

    Bullard Vertical Borer — Oil and Gas Sector

    An oil and gas valve manufacturer required a Bullard vertical borer modernised to handle CNC-programmed facing operations on large flanges. The existing machine was mechanically sound but required manual positioning of the tool head, resulting in inconsistent results and long setup times. The retrofit included a new control system, spindle drive upgrade, and custom macros for recurring part families. The result was a 40% reduction in cycle time for batch production work, with improved consistency and reduced operator fatigue.

    Webster & Bennett 36 — General Engineering

    A subcontract engineering workshop operating a W&B 36 faced increasing downtime due to electrical failures and difficulty finding replacement contactors and relays. The ManuPlus retrofit replaced the entire electrical system with a modern CNC control, new spindle drive, and servo-driven axis feeds. The machine now runs reliably with programmable speeds and feeds, and the workshop has gained the ability to store and recall part programmes for repeat work.

    Typical lead times for a ManuPlus retrofit range from 8 to 16 weeks depending on scope, with machine downtime typically 4–8 weeks. We work closely with your production planning to minimise disruption, and can schedule the execution phase around planned shutdowns or quiet periods.

    To discuss your CNC retrofit requirements, call Iain Exeter on 07808 789597 or Petr Gabrhelik on 07808 789598. You can also reach us via our contact page.

    Learn more about our related services: machine tool reconditioning, Webster & Bennett support, and our range of CNC vertical turning lathes.

    More reading: browse all VTT-WB guides, including rebuild or replace? how to decide.