[CNCfun&games]

TOTALLYRC:
Hope you haven't been faced with a similar Predicament!!

Wizard:
Have noticed you have been prowling around over in the RP Printer Forums,
Thinking about taking the Plunge???

ZipSnipe: Have been watching your thread with interest !!!


Installed My “Ultra” Cross Slide on the “old” Fixture Mill.
The prospect of having a Mill with both CNC and Manual capabilities
is very appealing to me.

However; to make this a viable solution the Head casting will have to be modified
to attach the Z axis motor mounting bracket, the pinion gear shaft will require an extension
for the belt drive pulley and the vertical column will require some machining to add an 8-10
inch rack and pinion assy. to raise and lower the Head because the Quill travel is only 3 ¼ inches.

Sounds like a lot of work...so.....Better get Busy!!

w. Smith, Mission Viejo, CA

[ZipSnipe]

Looking good, yeah I was wondering how you would do the z axis. Keep up the good work!!!!

[CNCfun&games]

ZipSnipe: The Z comes next

The tear down of the Fixture Mill Head Assy has begun
First the Motor & pulley, and then the top cover were removed.
The 4 Cap screws capture the Spindle support bearing as well as the bottom cover
because the head Casting is threaded.
The Pinion Gear & shaft were removed which allowed the Quill and Spindle assy
to slide free of the Head Casting.

Now I can design the Stepper motor mounting brackets and the Bearing configuration
to support the Pinion Shaft & its extensions.

It's been many years since I assembled this stuff and I forgot how it was put together.

However; the Quill - Spindle Assy with it's Timken Tapered Roller Bearings is off limits!!

W. Smith, Mission Viejo, CA

[ZipSnipe]

Well Mr.Smith. looks like ur on the right track. I too will be tearing my milling head apart and it has been several years since I put it together. Seems like we are on similar paths with two different outcomes. Yours to make it cnc mill and mine to make it a better manual mill.

May the shavings always be blue !!!!!

[wizard]

TOTALLYRC:
Hope you haven't been faced with a similar Predicament!!

Wizard:
Have noticed you have been prowling around over in the RP Printer Forums,
Thinking about taking the Plunge???

RepRap? That maybe a different Wizard as I've not been frequent to any of the repRap forums recently. I've thought about it but I need to get myself a CNC mill first. Frankly trying to balance the demands of the house (a new roof real soon) and other expenses is significantly impacting my CNC plans. However I've been able to acquire some freebies that might lead to a PC board sized mill.

ZipSnipe: Have been watching your thread with interest !!!


Installed My “Ultra” Cross Slide on the “old” Fixture Mill.
The prospect of having a Mill with both CNC and Manual capabilities
is very appealing to me.

Your thread is most interesting and considering the design of that fixture mill it would be ver versatile as both a manual and CNC mill. If I ever get the budget straight I might go for an all CNC machine myself.

However; to make this a viable solution the Head casting will have to be modified
to attach the Z axis motor mounting bracket, the pinion gear shaft will require an extension
for the belt drive pulley and the vertical column will require some machining to add an 8-10
inch rack and pinion assy. to raise and lower the Head because the Quill travel is only 3 ¼ inches.

Sounds like a lot of work...so.....Better get Busy!!

w. Smith, Mission Viejo, CA

As always waiting on more pictures.

[CNCfun&games]

The first task was to add a motor mounting plate to the left side of the head casting. A 1/2"
aluminum plate with a couple of bevels, milling on the side provided an acceptable fit. Then both
parts were drilled, reamed, and counter bored for the existing pinion shaft and double bearings.
After machining the motor adapter block, the motor was attached and the assembly was placed
on the head casting for a quick look. It became obvious that the motor should not be located
that close to the work area. This will require moving the motor back behind the head casting.
Another concept next time.

W. Smith, Mission Viejo, CA

[CNCfun&games]

Concept 2 utilizes a configuration which is similar to the one
used on the Y axis of the Cross Slide for this Mill.

The Motor is moved to a more convenient position with a set of pulley's and
a cog belt.

The location behind the head appears to be a much better solution......
Covering the cog belt should be easy....more next time.

W. Smith, Mission Viejo, CA.

[ZipSnipe]

Looking good bud!!! Love seeing the progress. This is the z axis right?

[CNCfun&games]

ZipSnipe:

yes!.... this is the Z axis Mod.

The motor placement seems to be OK.
Now a little paint and I'll reinstall the Quill Assembly.

The round colums look terrible....will have to break out the
rust remover!!

W.Smith, Mission Viejo,CA

[CNCfun&games]

Painted all the new parts, and assembled them without any problems.

The handle only requires one full turn for full travel. Not sure if that's
good or bad.....but time will tell.

The column's cleaned up reasonably well with only a little elbow grease
and some GOJO hand cleaner a friend told me about.

Next comes the big job of moving the vertical column up & down with a Rack & Pinion.
It's standard practice on drill presses....maybe I can obtain a Rack & Pinion Assy. "Ready Made".
I'll check the Grizzly & ENCO Catalogs.... any help would be appreciated!!

W. Smith, Mission Viejo, CA

[wizard]

Gojo for cleaning up rust! Never heard of that one before.

Painted all the new parts, and assembled them without any problems.

The handle only requires one full turn for full travel. Not sure if that's
good or bad.....but time will tell.

The column's cleaned up reasonably well with only a little elbow grease
and some GOJO hand cleaner a friend told me about.

Next comes the big job of moving the vertical column up & down with a Rack & Pinion.
It's standard practice on drill presses....maybe I can obtain a Rack & Pinion Assy. "Ready Made".
I'll check the Grizzly & ENCO Catalogs.... any help would be appreciated!!

W. Smith, Mission Viejo, CA

Junk yards might be a good place to scoop up an old drill press for parts. That is if you can find one that will even let you in.

[CNCfun&games]

Wizard: Use Scotch Brite as an applicator pad for the GOJO. It speds up the process.
Found the R&P on Grizzly for $27.

The 3Axis Fixture Mill will be ready to run with a couple of minor Additions.
1.- fabricate a cover for the Y axis Drive assy on the Ultra Cross Slide which inc. the linear rails.
2.- Install the Rack & Pinion on the vertical column.
3.- Complete the Controller (ala microwave oven) with the Gecko G540 and the power supply
in the enclosure with the Video Monitor.
4.-I can use the first of the 3 controller enclosures for all 5 of the machines I have in work
because the motors are all identical KE 23H2100-35-4B's.
5.- The Standard Cross Slide will retain the stock dovetail Slides and is in work now.

Hopefully I can show some real progress next time.

W. Smith, Mission Viejo, CA

[wizard]

Wizard: Use Scotch Brite as an applicator pad for the GOJO. It speds up the process.
Found the R&P on Grizzly for $27.

Learn something new everyday! The problem at my age is remembering what I've learned.

The 3Axis Fixture Mill will be ready to run with a couple of minor Additions.
1.- fabricate a cover for the Y axis Drive assy on the Ultra Cross Slide which inc. the linear rails.
2.- Install the Rack & Pinion on the vertical column.
3.- Complete the Controller (ala microwave oven) with the Gecko G540 and the power supply
in the enclosure with the Video Monitor.
4.-I can use the first of the 3 controller enclosures for all 5 of the machines I have in work
because the motors are all identical KE 23H2100-35-4B's.
5.- The Standard Cross Slide will retain the stock dovetail Slides and is in work now.

Hopefully I can show some real progress next time.

W. Smith, Mission Viejo, CA

Nice progress as it is!

[CNCfun&games]

It has been awhile since my last post but thought those of you have an interest in Pattern Making
might find some interest in my latest “adventure”.

The Project consists of the fabrication of a fairly large match plate Pattern with two cores which
provide the weight savers necessary to keep the raw casting weight down to about 130 lbs.

This is by far the largest and most complex part I have undertaken and posed some unique problems.

The first four pictures show general construction details,pic 5 shows that the pattern halves must match

perfectly before being attached to the "Match Plate".

W. Smith, Mission Viejo, CA

[wizard]

Good to here from you again! How did you make out with your mills?

It has been awhile since my last post but thought those of you have an interest in Pattern Making
might find some interest in my latest “adventure”.

The Project consists of the fabrication of a fairly large match plate Pattern with two cores which
provide the weight savers necessary to keep the raw casting weight down to about 130 lbs.

This is by far the largest and most complex part I have undertaken and posed some unique problems.

The first four pictures show general construction details,pic 5 shows that the pattern halves must match

perfectly before being attached to the "Match Plate".

W. Smith, Mission Viejo, CA

I'd comment on the pictures except for the fact that I haven't been able to open any attachments on any threads today. That being said what is it?

[CNCfun&games]

Wizard : Always enjoy your comments……Keep them coming!!
FannBlade: thanks for the vote of confidence!!

This time the basic Patterns will be attached to the Match Plate shown in Pic #1
of the last post.


To Digress: a word about pictures 5 & 6 Shown on my last post.
Pic 5 shows the two pattern halves joined together. This step is necessary
to sand any high spots or fill any low spots to insure that the patterns match perfectly.
Pic 6 shows the sanding sealer and the rubber sanding blocks used to provide smooth, flat
Surfaces.
These last two pictures also define the basic shape of the “SPINDLE HOUSING”.

Now this week’s post:

One of the long edges of the match plate was run thru the Jointer and identified with an arrowhead
on the centerline, and all critical dimensions are taken from that point.
After carefully measuring the pattern halves, the outlines were traced onto the match plate.

Then side one was glued to the match plate. Then the core supports were added.
Core supports are painted black for identification.

Next time: the core boxes will have to be carefully fabricated , and fitting confirmed.

W. Smith, Mission Viejo, CA

[CNCfun&games]

This time the work will be to fabricate two core boxes.
These boxes will locate the openings in the casting for mounting the spindle and
the access chamber for belt mounting and adjustment.
Core box #1 consists of one symmetrical cavity which can be used for both halves
of the spindle core. Pic #2 shows the basic spindle core ready for placement in the core box for
finishing.

Core box #2 is much larger and more complicated because it will create two mirror image cores.
This will be apparent when the castings are available for viewing.
Most interior surfaces formed by core #2 will have 15 degree draft for easy removal from the core boxes
And should also make for a nice appearing finished Casting. Pic#5 shows the core box ready for many coats of sanding sealer and block sanding.

I hope I’m not being too optimistic, because there is a lot of time and material resources wrapped
up in this process!!

W. Smith, Mission Viejo, CA.

[CNCfun&games]

Matchplate completed ???

The enclosed pictures show the completed configuration of the Matchplate.
It was placed on a temporary stand which supports and protects it
while the block sanding and finishing is finalized .

This was a very challenging part of the whole process. Great care was taken to
Properly locate the core supports to align the two cavities in the casting.

The next step will be to drop the pattern & core boxes off at the foundry.
Two test samples will be produced to “ proof” the design & approve
the new company selected to pour the castings.

Expect next week will be a REAL nail biter!

W. Smith Mission Viejo, CA

[wizard]

You have some nice work here! OK now I know this is a spindle housing but for what? It looks like the housing will have a bore for an awfully big spindle so I'm assuming this isn't for the other machine you have recently work on and reported here.

Matchplate completed ???

The enclosed pictures show the completed configuration of the Matchplate.
It was placed on a temporary stand which supports and protects it
while the block sanding and finishing is finalized .

This was a very challenging part of the whole process. Great care was taken to
Properly locate the core supports to align the two cavities in the casting.

I could imagine that being a big challenge. My background is more in die casting so I have to ask are the molds mounted permanently to the match plate? I could see where that might be a problem on bigger patterns but would think it would be easier for smaller items.

The next step will be to drop the pattern & core boxes off at the foundry.
Two test samples will be produced to “ proof” the design & approve
the new company selected to pour the castings.

You have more than one foundry locally? That is a shock right there.

Expect next week will be a REAL nail biter!

W. Smith Mission Viejo, CA

Will be waiting for the pictures.

[FannBlade]

Looking forward to the results!