Greg, the idea of coring, pulling out the plug, does work. I used a diamond coring bit, done in a matter of minutes. The bit has an OD of
1 1/4" and an ID of 1", using a drill press. The problem is centering the ball number to get a perfect cut around it.
Thanks to everyone for your thoughts! Keep them coming!
Pat
I could see where It would be. The centering issue came to my mind upon first thought for several reasons.
Common hole drills usually have a regular drill bit in the middle that helps center the coring part of the bit, and that helps stabilize it, but the center drill would damage the number you are trying to save. I have tried using those without the center drill before to get a solid plug, and in My case the centering didn't matter as much, because I wasn't trying to save a number like that, which was a good thing because they can walk around when first trying to start the hole. Not sure If your having that problem with your quality coring bit, if walking is not the problem, then I would look into a better clamping or aligning method. Trying to clamp a ball in a straight jaw machinist vice, would be difficult, but a special jig to hold spheres may be an option. That would depend on if It was something you would want to invest the time or money into.
If neither one of those things are a issue, then lining them up By eye may be proving difficult. One quick thing that comes to mind would be to find a washer or make a ring with your 1" ID, center it By hand where it looks centered on the number, and trace It out, then try to use that circle to better align your coring bit. of coarse all of that would be made easier if using a vice that can travel in both directions.
I have a drill press that I never use anymore, but when I had no other choice I can remember using it for things that did not seem like they would work, but with enough effort, and sometimes wasted material I got It to do what I needed. I remember making ring billet on It one time. I just had a regular clamp, although It did have travel. I did not have indexing, but at the time one of My old wood lathes did, so I used the wood lathe to mark where the slots would go, and lined each one up by hand when I transferred over to the drill press. That was a long time ago, being somewhat spoiled when It comes to making those now, I don't think I would have the patience to make them that way again.
I eventually got a bench mill, and It pretty much handles everything the drill press did and then some, so the drill press has been gathering dust for years.