[BrassBuilder]

Alrighty...

My journey in rebuilding my X2 started with this mess:

http://www.cnczone.com/forums/bencht...tml#post994685

To make a long story short, I burned up the crappy motor on my mill when the spindle bearings went out. After looking over the situation and seeing that I was down for a while, I decided the mill could use some badly needed maintenance. Here is what I did:

I got a 23" length of 8" c-channel from the local metal place to reinforce the z-axis. I probably overdid it just a tad with all the socket screws, but I figured, the more the merrier. You can see various shots of the channel installed in the pics.

I think I found the idea on Hoss's site. From what I remember, there were a few pictures of various mods that people did to stiffen the z-axis on the X2. The channel looked like the cleanest install. I looked around Hoss's site, but I can't find the pictures now.

I installed a 2hp 220v treadmill motor in place of the now very junk X2 motor. The big problem here was that I had to make the mounts using my drill press, the bandsaw, files, and an electric drill. I thought I was going to have to gnaw on it with my teeth, but it didn't get that far. Posted a pic of it installed. I used part of the mount that I had there from the belt conversion and made a couple of new pieces.

While I was replacing the motor, I installed a KB-225D motor controller and then got the controller matched to the motor. Works great.

I rebuilt the head with new bearings from McMaster that are rated at 11,000 RPMs. Had to use a press at work to get everything apart and back together, but it went good.

After getting it all back together, I checked the tram and it was within .001. I decided to leave it alone.

I also dumped all the coolant and cleaned the storage tank (lol...some "storage tank." It's a plastic bin from Walmart). Ugh. What a mess. There was slime stuff all down at the bottom. Decided to dump the coolant and make a new batch since this was originally mixed up three years ago and had coolant and water added as needed. Cleaned up the pump and it looked as good as new when done.

Finally had it ready to run about 1pm today. Clamped in a piece of 6061 aluminum and started Mach3. All I can say is:

WOW!!! WHAT A DIFFERENCE!!!

With the old motor and no back reinforcement, I could probably run .010-.020 cuts in 6061. Today, I cut my part at .040 depth and I think I could have gone to .050 or more. The .040 wasn't giving it any trouble. I had the spindle running at around 4500 RPMs using a .250" carbide 3-flute end mill. The first part I cut before the mill went down took about 1.5 hours. The last part I cut after reconfiguring my g-code took about a half hour.

I included a shot of my motor covers. They are plastic store bins that I found at Menards. When I first saw them, I thought they looked really close in size for the NEMA 23 motors. They were an almost perfect fit. Just had to trim out the back and drill and tap a couple of mounting holes in the motor mounts. I lined each cover with self-stick weatherstrip tape to keep coolant from leaking through.

I have another motor coming for this. The one installed is for CCW rotation, but I have it running CW. I found a CW rotation treadmill motor on ebay and bought it last week. Hopefully it will show up here soon.

Thanks to everyone that has given me advice so far.

Mike

[eaglezsoar]

Good job! You must have many hours of work in that machine but it
sounds like it was worth it. Is it possible you have the McMaster part
numbers for the bearings? I will need to replace mine soon.

[hoss2006]

Nice work!
The column support page is here, I'll have to add yours to it.
http://www.hossmachine.info/Shop_Info.html#x2%20column
Hoss

[B-RAD]

Personally I'd loose that washer, the washer flexes.

I like the storage bin idea, I will definitely be doing that when I get mine CNC'd.


My improvements to my SX2 (2 forums)
Link 1
Link 2

Hoss - I haven't seen a column support as nice looking as mine(no arrogance), hopefully I could get mine on your page as well, kinda like the having a star on the walk of fame

[hoss2006]

Hoss - ....hopefully I could get mine on your page as well, kinda like the having a star on the walk of fame

Done!
Shop Info
Hoss

[B-RAD]

SWEET!

I think my mill is finally ready for CNC, so the both of you will be bugged alot pretty soon probably

I repped you Hoss!

[BrassBuilder]

Nice work!
The column support page is here, I'll have to add yours to it.
Shop Info
Hoss

That didn't take you long! I see it is already added. Cool.
Mike

[BrassBuilder]

Personally I'd loose that washer, the washer flexes.

I like the storage bin idea, I will definitely be doing that when I get mine CNC'd.

Are you talking the big washer on the back? I'm not sure that thing is doing much of anything now with all the bolts I have holding the column together. Besides, it nicely covers the hole in the back of the channel. Let's just say I had some issues in cutting a round hole with a holesaw....Trust me...it covers up some work I'm not real proud to show. LOL.

kinda like the having a star on the walk of fame

Yeah...I felt the same way when he said he was going to put it there.

Mike

[B-RAD]

Could you maybe get a big FLAT washer to use instead....

I bored my hole out using a large 3/4 drill bit, then used my boring bar on the mill to finish it.

[BrassBuilder]

Could you maybe get a big FLAT washer to use instead....

I'd probably have to make one. Not sure I will find one big enough in town to cover everything. It will have to be about as big as the one on it now.

So....is there an issue using the washer from the mill? I'm not understanding the concern very well. There are 8 bolts tying the channel to the base at the bottom and 15 bolts tying the channel to the column. If that stock washer is flexing, I'm not sure what it will affect.

But, maybe I'm missing something.

Mike

[BrassBuilder]

Could you maybe get a big FLAT washer to use instead....

I bored my hole out using a large 3/4 drill bit, then used my boring bar on the mill to finish it.

I see Hoss has your conversion on the page now. Looks good. Very clean and neat. I'll have to look around and see what I can find for a washer. If I hadn't screwed the hole up, it would have been a pretty simple to do.

Mike

[BrassBuilder]

Good job! You must have many hours of work in that machine but it
sounds like it was worth it. Is it possible you have the McMaster part
numbers for the bearings? I will need to replace mine soon.

The bearings you need are:

5972K342
McMaster-Carr
30x62x16 mm
$11.01

5972K365
McMaster-Carr
35x62x14
$12.52

These bearings are double shielded.

VXB.com has the bearings for $7.00 each, but I've had really good luck from McMaster and usually use them.

I have a few hours in the machine I was looking it over and now that I replaced the bearings and motor, the only original pieces are the basic mill itself: The spindle and housing, the column, and the base. The rest has been replaced with upgraded components or completely disposed of.

edit: for some reason the links are not going directly to the product page. Not sure what's up with that.

Mike

[eaglezsoar]

Thanks for the numbers for the bearings, Mike.
I also prefer McMaster for a lot of the things I purchase.
I don't have any experience with VXB but if they are cheaper
there is usually a reason, if you know what I mean.
Thanks again.

[B-RAD]

Your right, I wasn't paying close enough attention to how you bolted it on, sorry.

[LUCKY13]

Every little bit does help still, a new washer might not be needed but it may add to holding it some.


You can go to Tractor Supply store and they will have some washers like this, maybe even some that are ground. In my area thats the name of the store, there may be others where you live.


Jess

[Dougal]

Interesting work.
I'm the originator of the channel brace, I use 100mm (4 inch) channel as the webs fit nicely on the sides of the column for the best benefit. The wider the channel the more load is carried by the more flexible centre section. It's also less weight if you need to ever move it by hand.
The washer isn't a problem, it's only people playing around with minimal or no reinforcement that will see any benefit at all from a thicker washer. The 6mm or so in the web of that channel is doing the job nicely.

Regarding bearings, forget deep groove, go for taper rollers so you can actually set preload properly. I've just fitted one and will do the other when I shortly change to a belt-drive.

[BrassBuilder]

Interesting work.
I'm the originator of the channel brace, I use 100mm (4 inch) channel as the webs fit nicely on the sides of the column for the best benefit. The wider the channel the more load is carried by the more flexible centre section. It's also less weight if you need to ever move it by hand.
The washer isn't a problem, it's only people playing around with minimal or no reinforcement that will see any benefit at all from a thicker washer. The 6mm or so in the web of that channel is doing the job nicely.

Regarding bearings, forget deep groove, go for taper rollers so you can actually set preload properly. I've just fitted one and will do the other when I shortly change to a belt-drive.

I sort of wondered about that. I went with the 8" wide because then the channel reached across the two braces that I have my mill set on in the flood coolant booth. I was going to eventually tie the C-channel to the braces in the booth. I haven't yet and after running it, I'm not sure I will even bother. The mill is running around 10 times better than what it ever did new.

I'll keep the bearing advice in mind the next time I have to change them. I'm hoping it will be a long time though.

Would you have part numbers of the bearings you used?

Mike

[Dougal]

Would you have part numbers of the bearings you used?

Mike

Certainly.
SKF 30206 J2Q.

[hoss2006]

Interesting work.
I'm the originator of the channel brace, ....

Sorry but No, bilinghm beat you by about a year and a half.
http://www.cnczone.com/forums/428434-post31.html

On a similar vein, check out Arc Euro Trades special Super X2 Plus that has a solidly mounted column like an X3.
Model Super X2 PLUS Mill - Arc Euro Trade
Hoss

[Dougal]

Sorry but No, bilinghm beat you by about a year and a half.
http://www.cnczone.com/forums/428434-post31.html

Interesting, I haven't seen that one before. It is only half a brace though.

On a similar vein, check out Arc Euro Trades special Super X2 Plus that has a solidly mounted column like an X3.
Model Super X2 PLUS Mill - Arc Euro Trade
Hoss

I really like the table on that one. 145mm y travel too.