I know what you mean about the hoists being so cheap you can't beat just the cost of the steel. I have thought about buying used lifts to make an English wheel at one point. I see them come up with engine stands for 60-70 dollars fairly often.
I will see if I can find some aeroseal as you suggested too. I hate rtv and only get a good seal with in 1 out of every three uses. I have pulled an oil pan a year after application and the stuff was still wet in the middle.
back on topic I got a little work done
had to grind out the end cap of the old motors housing. there were some "embossed" sections in the casting that looked like they were intended to be removed for air circulation. I ground those out and cut out the center section of the cast section that mounts to the bs body. No going back now for better or worse. there wasn't clearance by just a small amount but now the mill motor without the fan fits in the old motors housing.
I also knocked out the center section coils from the old motor. they took some convincing with my engineers hammer and largest punch.
here is part of the motor mount, which still needs some work. it will get a another section of angle and have all 4 sections tied together. I am trying the original mounting location based off of the old motors bolt holes. if the alignment is not right I will slot the holes on one section of the plate and adjust as necessary.
i had to stop "welding" as I found what I assumed was steel rg45 was really some kind of copper coated brazing rod which melted like a messy crayon on to the angle.
the housing loosely sitting over the motor mount

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