Our Reconditioning Process

    Machine tool reconditioning is the systematic restoration of a used or worn machine to its original factory accuracy and performance. Unlike a simple repair — which addresses a specific fault — reconditioning treats the machine as a whole, returning every critical surface, alignment, and motion system to specification. It is the difference between fixing a symptom and curing the patient.

    At VTT-WB, our reconditioning process for vertical lathes and boring machines follows a defined sequence honed over decades of experience. Every step is documented, every measurement is recorded, and every adjustment is verified. This rigour is what allows us to warrant our reconditioned machines — and what gives our customers confidence in the results.

    1. Full Machine Inspection

    Before any work begins, we conduct a comprehensive geometric inspection. Using precision levels, dial indicators, and laser alignment tools, we measure table flatness, ram alignment, cross-rail parallelism, column perpendicularity, and spindle concentricity. This establishes a baseline — what is worn, by how much, and what needs attention. The inspection report forms the basis of the reconditioning plan and the cost quotation.

    We also assess the machine’s history: how long it has been in service, what applications it has been used for, what repairs have been carried out previously, and what issues the operator has noticed. This contextual information helps us identify the root causes of wear, not just the symptoms.

    2. Strip-Down & Assessment

    The machine is systematically stripped down to its major components. Each part is inspected for wear, damage, and fatigue. Bearings are checked for play and surface condition. Gears are inspected for tooth wear and pitting. Slideways are measured for parallelism and straightness. Seals are examined for leakage and deterioration. Nothing is assumed — everything is verified.

    Each component is categorised: reuse as-is, refurbish, or replace. This assessment is documented and forms part of the reconditioning record. For regulated industries, this documentation supports traceability and quality management requirements.

    3. Hand-Scraping of Slideways

    This is where the craft of machine tool reconditioning truly lies. Worn slideways are hand-scraped to restore geometric accuracy. Our engineers use precision scraping tools, blueing compound, and master straight-edges to restore sliding surfaces to within microns of specification. This is slow, skilled work — but it is the foundation of a machine’s accuracy.

    Hand-scraping is not a lost art at VTT-WB. Our engineers have been trained in traditional scraping techniques and have years of experience applying them to vertical turning machines of all types and sizes. Each slideway is scraped to achieve the correct bearing area, oil retention, and geometric accuracy — ensuring smooth, stick-free motion and precise positioning.

    4. Bearing & Component Replacement

    Table bearings — typically the most heavily loaded components — are replaced or re-metalled as required. Thrust bearings, radial bearings, and sleeve bearings are renewed. Worn gears, clutches, and drive components are replaced with new or refurbished parts. Seals are renewed throughout to prevent leakage and contamination. Every replacement component is verified for fit and function before installation.

    For Webster & Bennett machines, we maintain an extensive stock of original and pattern parts. For other makes, we can manufacture replacement components to original specifications where original parts are no longer available.

    5. Reassembly & Alignment

    The machine is reassembled with careful attention to alignment at every stage. Table levelling, ram perpendicularity, cross-rail alignment — each geometric relationship is set and verified before moving to the next assembly step. The process is incremental: each component builds on the accuracy of the one before it, so errors cannot accumulate.

    6. Testing & Certification

    The completed machine undergoes a full geometric test programme, with results recorded in a certification document. Test cuts verify machining accuracy under load — because a machine that measures correctly when idle but cannot hold tolerance under cutting forces is not truly reconditioned. Only when the machine meets our quality standards is it signed off for return to production.

    Reconditioning vs Retrofit vs New

    If you have an ageing vertical lathe, you have three options: recondition it, retrofit it, or replace it with a new machine. Understanding the differences helps you make the right decision for your operation and budget.

    Reconditioning

    Reconditioning restores the mechanical accuracy of the machine. If your machine is structurally sound but has worn slideways, tired bearings, and accumulated geometric errors, reconditioning brings it back to factory spec. This is the right choice when the existing control system is still functional and you are primarily concerned about accuracy and mechanical reliability. Reconditioning is typically the lowest-cost option and can extend machine life by many years.

    Retrofit

    A CNC retrofit replaces the control system and drives whilst leaving the mechanical structure largely intact. This is the right choice when your machine is mechanically sound but the controls are obsolete, unreliable, or limiting your capabilities. A retrofit can be combined with reconditioning for a complete machine overhaul — addressing both mechanical wear and outdated controls in a single project.

    New Machine

    Buying new makes sense when your existing machine is structurally compromised, when you need a different capacity or configuration, or when the combined cost of reconditioning and retrofit would exceed the value of a new machine. If you are considering a new machine, talk to Iain first. He can help you compare it honestly against a rebuild or retrofit.

    In many cases, reconditioning offers the best return on investment. A well-built vertical lathe from a quality manufacturer has decades of structural life — the cast iron frame does not degrade in the way that bearings and controls do. Reconditioning unlocks that remaining life at a fraction of the cost of new. And if you later decide to retrofit the controls, the reconditioned mechanical structure provides an excellent foundation for the new systems.

    Restoring Accuracy: Hand Scraping

    Hand scraping is the defining skill of machine tool reconditioning. It is the process of removing very small amounts of cast iron from a sliding surface using a hand-held scraping tool, in order to restore that surface’s flatness, parallelism, and oil-retaining properties. It is a technique that has remained essentially unchanged for over a century — because no automated process can match its precision and adaptability.

    Why is hand scraping so important? Because every slideway on a vertical lathe — the table guideways, the cross-rail ways, the ram ways — determines the machine’s geometric accuracy. When these surfaces wear, the machine loses its ability to hold tolerances. No amount of electronic compensation can fully substitute for accurately machined and scraped sliding surfaces. The slideways are the reference — everything else is measured from them.

    Our reconditioning team includes skilled scrapers with decades of combined experience. Using traditional techniques — blueing, spotting, and incremental scraping — we restore slideways to within microns of their original specification. This is not fast work, but it is the difference between a machine that merely moves and a machine that machines accurately.

    The scraping process also restores the oil retention characteristics of slideway surfaces. A properly scraped surface holds a micro-film of lubricating oil that prevents stick-slip and ensures smooth, consistent motion. This is why reconditioned machines often feel better than machines that have been ground but not scraped — the surface texture matters for both accuracy and operator experience.

    Hand scraping also allows us to correct specific geometric errors that would be difficult or impossible to address by grinding alone. If a column has shifted slightly over decades of use, or if a cross-rail has worn unevenly, the scraper can compensate — removing material selectively to bring the geometry back into alignment. This flexibility is why scraping remains the gold standard for machine tool reconditioning.

    Sectors Served

    Our reconditioning services are called upon across a range of demanding industries where machine accuracy and reliability are not just desirable but critical:

    • Defence: Reconditioning machines used in the manufacture and maintenance of military vehicles, ordnance, and defence systems where accuracy and reliability are critical and supply chain security is a priority
    • Nuclear: Restoration of machines used in nuclear component manufacturing, with full traceability, documentation, and quality management to meet nuclear industry requirements
    • Oil and gas: Reconditioning large-capacity vertical borers used for machining flanges, valve bodies, wellhead components, and pressure vessel parts to the tolerances the sector demands
    • Aero engine: Precision reconditioning of machines used in the manufacture and repair of turbine components, casings, and engine assemblies where tolerances are measured in microns
    • Aerospace: Restoring machines used for structural and component machining to the tight tolerances and high reliability the sector requires

    Each sector has its own requirements for documentation, traceability, and quality management. We work to our customers’ quality systems and provide the documentation they need to satisfy their internal and regulatory requirements. Our reconditioning records — from initial inspection through to final certification — provide a complete picture of the work carried out and the results achieved.

    Request an Assessment

    If you have a vertical lathe or boring machine that is showing its age — whether through declining accuracy, increasing downtime, or rising maintenance costs — a professional reconditioning assessment is the first step.

    We will inspect your machine, report on its condition, and provide clear recommendations with costs. There is no obligation — just honest, expert advice from engineers who have spent their careers working with vertical turning machines. We will tell you whether reconditioning is worthwhile, whether a CNC retrofit should be considered at the same time, or whether the machine has reached the end of its economic life.

    Even if your machine is currently performing adequately, a baseline inspection can be valuable. Establishing the current condition of your machine — before problems arise — provides a reference point for future monitoring and helps with maintenance planning and budgeting.

    Call Iain Exeter on 07808 789597 or Petr Gabrhelik on 07808 789598 to arrange an assessment, or visit our contact page.

    You may also be interested in our CNC retrofit services, our Webster & Bennett support, and our range of vertical boring machines and used vertical lathes.

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