I like the 4th from the top. Great little design. You didn't mention the steel you used (or I missed it), but I believe Bos only does air quench steels (ie. stainless or tool steel)
After multiple emails and multi meter tests with Electric Motor Wholesale, I have a new drive on the way. I guess you only get 34 years out of a Leeson DC drive
Tonight my variable speed DC grinder started acting strange. It doesn't seem to change speed from 0-30 and again from 80-100. I usually run this grinder pretty slow, but now it won't get slow enough. Do the potentiometers go bad in the drives? Hoping it's something I can just fix.