Re: latest measurements
Dave Paine
I have also experienced issues when a bearing is not parallel to the shaft.
The inner races fit tight on the shaft as observed when we pressed them out. I cannot imagine the inner race having this issue.
It is possible for the outer race, but if this happened I think it is due to the machining of the inside of the housing based on measurements I just took.
As best I can measure with my limited equipment, the front machined area is 1.377 in dia (34.98mm). The back is 1.375 - 1.376 in dia (34.93mm - 34.95mm).
The bearings are 35mm outer diameter and 15mm inside.
I decided to try and improve measurements by mounting the housing on the metal lathe and use a dial indicator.

I measured at the start and end of each machined section. A lot of variability and more runout than I expected.
With the dial indicator I can only measure runout at a given point. I am not able to determine difference in diameter at these locations with this indicator.
Runout measurements.
Front as in right in the picture machined area
Start 0 - 5 thou (min - max)
End 1.7 - 7.5 thou (min - max)
Rear as in left in the picture, bottom machined area
Start 0.8 - 5.6 thou (min - max)
End 2.75 - 7 thou (min - max).
I then measured runout on the MT2 extension I used to mount in the chuck. Using a new dead centre, closest to true I have for an MT2 taper. I got about 1.5 thou max runout.

Next I mounted a router pin in the chuck, the closest I have to a test bar. This gave me about 0.5 thou max runout which is what I had when I recently trued up this chuck.

I measured the shaft as best I could on the metal lathe, seems to be consistent and minimal runout. I did not take a picture at that time.
I am concluding the issue is the machining of the housing.
After I get new bearings I will do a test fit and then decide how to get a better fit of the bearings in the housing - use a cylinder hone or to bore the machined areas.