4.5" Tesla Turbine Hot Rotor Kit

Detailed Assembly Instructions

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5. Locate the (1/2-inch) countersink bit. Again using very low speed and lots of coolant/oil, bore countersink holes in all 9 hole locations in the outer end disk #452 (3/16-inch thick disk with exhaust port slots). 

Be careful to bore the countersink holes only deep enough to allow the head of the 10-24 machine screw to recess approximately 1/64-inch under the disk surface.

6. With all four disks bored/tapped, it is time to grind and polish the disks. If any of the disks already have one polished surface, that surface only requires finish sanding and buffing. 

1. With all other rougher surfaces, begin by knocking down all of the high spots (drill holes, etc.) with a fine, sharp, flat file. 
2. After all of the high spots are cut down it is time to begin the finishing process. Although hand sanding blocks may be used, a good palm/orbital sander makes the job much quicker and easier.
3. Start with a 120 grit sandpaper, followed by 220, 320, and finishing with 400-600 wet/dry paper. Keep it in mind that you want these surfaces to be a close to a mirror finish as you can reasonably get. When you get to the final paper (400-600 grit) use water/oil to help cut and polish the surface.
4. For those of you who want a fanatically perfect finish, use a buffing wheel and rouge stick for the final polish. In all cases, very smooth is good enough.
5. Complete this section by filing or sanding the high spots on the three star washers.

Finish sanding is easier with a palm sander

... Or you can use a sanding block

Buffing wheel provides final polish