Bosch PBD 40 Bench drill

I noticed whilst looking at the rear of the drill that there was some marks on the cable at the cable clip. This is directly below the height adjustment and as the machine is operated the cable can rub on the bracket and when at rest and may or may not be an issue. I'm probably overthinking this but with a lot of use the cable may wear through and electricity and metal don't mix that well. A possible solution is a 10mm spacer to help keep it clear or a clip to bring the cable to the side, not very elegant but I'll give it a try as a temporary fix.

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The other problem is the cavities under the base plate- dropped a 1/16” drill bit down the centre hole when having a fiddle last night and it rolled to one side:(. Also the drilling swarf will gather under there.
The base pate only sits on the 4 corners, there is a very slight gap around the perimeter so I guess you could blow the swarf out but that’s messy. I’ve designed a swarf drawer that sits under the base plate - hope to have it done later in the week.

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Originally Posted by apple8

A possible solution is a 10mm spacer to help keep it clear or a clip to bring the cable to the side, not very elegant but I'll give it a try as a temporary fix.

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I made up a spacer 16mm thick for a more permanent fix.

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Just an update on the problem of swarf getting under the table when it’s bolted down.

Modified my stand so there is now a cavity under the drill table. I was going to make a drawer but it’s not needed.

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I could drill out the back and fit an extractor hose but I don’t think it’s necessary - maybe something for the future.

The table has now been raised to a more comfortable 97cm.

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Originally Posted by KahoyKutter

$23 from Hare & Forbes. Inside bore is 25mm and I believe the handwheel shaft on the drill is 19mm so I've ordered a 25mm aluminium pipe with 3mm wall thickness to use as a sleeve. It should bring it down to 19mm but this is all theoretical at this stage because I don't yet have the drill or the pipe. :D

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Hey mate, do you have a part number or a direct link to hafco? Having trouble finding it

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Originally Posted by micmcg

Hey mate, do you have a part number or a direct link to hafco? Having trouble finding it

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Here's the link. I think the part number is either DY999 or #16104001C.

And my plan to use an aluminium pipe as a sleeve to reduce the bore worked a treat with a bit of sanding. You will also have to tap a M8 hole for the retaining grub screw. The 3 spoke handle already has a 6mm hole that is the right size for the M8 grub screw but it's in the wrong location. it needs to be about 7.5mm from the base. Good luck.



Here's a photo of it mounted to the drill....


Attachment 461745

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Originally Posted by KahoyKutter

Here's the link. I think the part number is either DY999 or #16104001C.

And my plan to use an aluminium pipe as a sleeve to reduce the bore worked a treat with a bit of sanding. You will also have to tap a M8 hole for the retaining grub screw. The 3 spoke handle already has a 6mm hole that is the right size for the M8 grub screw but it's in the wrong location. it needs to be about 7.5mm from the base. Good luck.



Here's a photo of it mounted to the drill....


Attachment 461745

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Do you find it works better than the wheel?

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Originally Posted by micmcg

Do you find it works better than the wheel?

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Yes, it is infinitely better. The OEM wheel is just not ergonomic. With the 3 spoke, I can get the full travel with one smooth single-handed action.

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Originally Posted by KahoyKutter

Yes, it is infinitely better. The OEM wheel is just not ergonomic. With the 3 spoke, I can get the full travel with one smooth single-handed action.

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Great. I put a steering wheel knob on mine and it improved things but it’s still not great. Will do your mod.

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Originally Posted by KahoyKutter

And my plan to use an aluminium pipe as a sleeve to reduce the bore worked a treat with a bit of sanding. You will also have to tap a M8 hole for the retaining grub screw.

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Hey, do you have any material left over from the pipe?
I'd be happy to pay you, plus cover postage if you'd be willing to cut off a bit.
It would save me having to source and order the right pipe and would just end up wasting what I don't use.

What did you end up having to sand to make it fit?

I just ordered a PBD40 tonight and will also order that 3-spoke handle and do your mod. That wheel looks really awkward to use, and it sounds like your mod is way better!

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Originally Posted by azaram

Hey, do you have any material left over from the pipe?
I'd be happy to pay you, plus cover postage if you'd be willing to cut off a bit.
It would save me having to source and order the right pipe and would just end up wasting what I don't use.

What did you end up having to sand to make it fit?

I just ordered a PBD40 tonight and will also order that 3-spoke handle and do your mod. That wheel looks really awkward to use, and it sounds like your mod is way better!

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Mate, tbh I have no idea what I did with the leftover pipe but you're not really saving anything by getting it from me. Here's the eBay link of where I got it from. It's not very expensive and most of the cost is for postage which would be the same if I were to send it to you.

As for what you have to sand, you're going to have to see what the fit is like between your aluminium pipe's inner and outer diameter, the inner bore of the handle, and the diameter of the shaft on your drill. Each have manufacturing tolerances and all 3 could be totally different to mine. In my case I had to sand both the inner and outer diameter of the aluminium pipe to make it fit. This is easier to sanding the inner diameter of the handwheel hub (cast iron) and the shaft on the drill (hardened steel) as aluminium is quite soft and the tube is more accessible. Just sand a bit at a time and test for fit regularly. Even if you stuff up, you'll have enough aluminium pipe to make several sleeves if you need to.

Good luck.

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Originally Posted by KahoyKutter

Mate, tbh I have no idea what I did with the leftover pipe but you're not really saving anything by getting it from me.

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No problem.
I was thinking I might measure it up once it all arrives and then design up a few sleeves in Fusion 360 with varying tolerances and 3D print them.

BTW, Machinery House said they sold the last handle to me and that the manufacturer can no longer supply them. :down:
I'd offer to make up sleeves for others, but it seems like there's no point.

FYI it’s on sale again on Amazon right now for $299 as a Black Friday deal.


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I picked one of these up off Amazon, three day turn around, set it up yesterday and I have to say I’m impressed with it, quick set up, mounted on my existing drill bench, removed safety guard and fired it up after reading the manual (sure) .
very quiet compared to my hitachi drill mounted in my Record Power drill stand, laser is accurate enough for my needs, lights good. Positive depth stop, easy height adjustment and the chuck is a breeze to use.
very happy with it.

I got one of these last year when they were on special and a trial amazon prime membership gave free express shipping to replace an Ozito (I gave it to a mate as I really, really hated it), and have been using it heaps ever since, mainly with a 40mm forstner bit drilling 25mm deep holes in hardwoods.

It's performed absolutely stellar since day 1, no detectable chuck wobble, not the most powerful drill by any means but more than powerful enough for the purpose.

If you see them on special I'd highly recommend one! They're a really nice unit!

Such a joy not having to changes belts too like on my old Ozito, I know it's trivial but man I really hated that! And also when the stupid chuck would fall out!