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Everything posted by difalkner

  1. This is a short video on making an acrylic gauge to guide me in carving the neck on the guitar I'm building. David Here's the finished gauge - And the video -
  2. I don't have any of the Vectric line of products but I'm wondering if it has the feature like CorelDraw to save as an earlier version. I have CorelDraw X8 (18) and I can save files all the way back to version 11 or any version in between. I regularly save files as X6 for the laser shop so they can open my files. David
  3. Thanks, Guys!! It's been a good one so far; drove about 40 minutes south to the sawmill and picked up about 25' of unsteamed Walnut for projects. I should have gotten a better photo of the sawmill but this was so pleasant I took the photo here from the truck - it's a Wood Mizer and behind the shop (past the picnic table) are his two solar kilns. Walnut for today - David
  4. I actually haven't looked, John. It would be easy to make them available, for sure! David
  5. Looks good, Mike! You're really cranking things out on that new tool - good job! David
  6. Looks good to me, 4D. As a longtime photographer I love BW photos. And the vise is something I can use, so I'll make one soon. Thanks! David
  7. This little project of 26 Walnut awards used most every tool in the shop but I did my best to be efficient and consistent with the steps so I could make these as identical as possible. Here are the steps outlined in the video below - Enjoy! David
  8. Thanks, Herb! I'm glad you got something worthwhile out of this. David
  9. Thanks, Gerald! They wanted it like a ring with the diamond suspended between 'prongs' and this is as close to that as I could come to that concept. The front of the base will received a brass plate with the recipient's name and pertinent info to the award. David
  10. Point well taken, DAB. I'm not opposed to a guard, just don't have one. David
  11. Good points, DAB. I no longer have the guard, sorry. When I recovered my table saw a few years back the guard was not with it (loaned the saw to a friend, came back rusted, motor dead, and not much better than a boat anchor. I know, I know...). You could use a Forstner bit for the pockets but then you'd have to figure out how to make the bottom of the posts round. Then you'd have to deal with them being oriented correctly and staying that way while you tighten the screws so that the notches line up with the diamond. By keeping them square in section the orientation is easy. David
  12. 99% of what I cut is at 18,000 rpm mainly because that's where my VFD is set and I have rarely seen the need to change it. So that's sort of a 'fixed' speed for me although I can go from 6,000 to 24,000 rpm very easily. When I dipped my toe into the CNC waters my feeds were very slow - 1/4" upcut end mill at 50 ipm - and depth of cut very shallow - typically 1/16" with the same bit (that only lasted a week or so before I began speeding things up). Fast forward a few months and now my typical starting point for the same bit is still 18k rpm but feed rate is 150 ipm and depth of cut, depending on material, is 1/8" minimum and sometimes up to 3/16". One time I have cut 1/4" deep and it was just fine. Walnut is what I cut about 90% of the time but I cut Sapele, Maple, and Cherry the same. I've only cut Pine a couple of times and it seems like I pushed my envelope a bit on that - deeper cut, if I recall. I have a water cooled 3kW (4 HP) spindle on a very rigid machine and I've had people tell me I can cut 250 ipm at 1/4" depth of cut in Walnut with no problem, but I can't bring myself to dial it in that fast. One day, maybe. Many of the jobs I cut are short runs of 10 minutes or less so going much faster is only going to save a minute or two so there isn't much incentive to speed things up except for bragging rights. But there's always someone who will push a machine faster and harder so I wouldn't win much on the bragging rights contest. David
  13. Looks like it will be a very strong joint. How did you hold the work pieces when you cut them? David
  14. What kind of CNC machine do you have? The frame is by Fine Line Automation (FLA) and is the prototype Saturn 2x4. The gantry and cable chains came preset for tolerances and attached. I worked closely with Nate, owner of FLA, for about 5 months while this was being developed (all via text, e-mail, and phone calls – we’ve never actually met in person). We corresponded regularly on many of the details of his design so I knew what I was getting when it arrived and that some components were brand new to him, as well. Was it a complete machine that you assembled or was it a kit or a scratch build? I assembled it from the frame out, though I did disassemble some things on the frame and reassembled to my desired configuration and tolerance. I designed the electronics, wiring schematic, sourced all components, and fabricated necessary mounting hardware. Why did pick you that particular machine? It is a very heavy, stout, and rigid frame weighing somewhere in the 450 pound range without steppers, spindle, etc. I wanted the accuracy and repeatability that a rigid machine provides. What were some of the challenges you ran into? I’ve never built or run a CNC machine before. I couldn’t find a suitable wiring schematic or complete list of parts needed to make this work, at least in the configuration I wanted. What would you have done differently? Not much – pretty satisfied with my choices and build. I’d love to figure out how I can fit a 4x4 machine in our small shop! What improvements or modifications would you like to do, or are doing? The proximity sensors are in the path for destruction if an over-limit occurs. Nate, owner of FLA, has redesigned these locations largely due to my input and a couple of others who got early Saturn machines. Also, the mounting of the rack and pinion components need improvement and again, due to our feedback, Nate has improved these.
  15. I cut some Plexiglas for the first time and even though this is a simple project it seemed like a good one to post. Not woodworking but cool anyway; doesn't smell as good as Walnut - LOL! David
  16. Some of you have seen this documentation of our CNC build but many may not have been a part of this experience. It would take more time than I have available to edit this for specific time sensitive comments (i.e. ...tomorrow I'll get..., or ...I'm waiting on this part to arrive..., etc.) so it will be easier to just post this verbatim from my notes. Sandy and I took delivery of the frame about a year ago, July 8, 2016, so this story begins from that point. It will be a long post covering the entire build that took several months. Due not only to the breadth and detail of the story but also the somewhat limited time I have to dedicate to this it may take a couple of weeks to get everything posted. So let's dive in!! David +++++++++++++++++++++++++++++++++++++++++++++++ July 8, 2016 Building my 2nd CNC first, I hope. I have been researching for over a year, read a thousand threads and articles, and am hopefully building my 'second machine' for my first. There is still a ton to learn and that process will probably never stop. Of this I am certain, I will be in new territory for a while. For over 40 years I have been building things, doing hydraulics, pneumatics, and electronics builds and troubleshooting along with a lot of woodworking but have never used or built a CNC machine. This is going to be fun!! The machine is a new model by Nate at Fine Line Automation. It's a 'pro' series he calls Saturn and it is very heavy. Shipping weight was 525 lbs. for this 2'x4' model. Take away the OxBox and pallet and it's probably still 475 lbs. The frame is welded and stress relieved steel, powder coated Pantone 305. It has THK style linear bearings, rack and pinion drive, and the components are anodized black 6061 aluminum. I have a 3 Kw water cooled spindle and NEMA 34 stepper motors ready to mount. I'll be using the Hitachi WJ200-022SF VFD to drive the spindle. The actual cutting area is 28”x52” with 10” Z travel. The first order of business, now that it's here, was clearing out enough space in our shop for two CNC machines (our shop is the attached two-car garage). It has to set in one place while I build the stand where it will actually reside, so space for two in an already crowded shop. I'll be building a frame with 2x4's and maybe a couple of 2x6's. Then I need about 5 large friends to help me carry the CNC over to the stand. Picked up from FedEx and barely fit on a friend's trailer - OxBox container removed and setting on the pallet until I get the stand built - A few close-ups - Next step will be a trip to Lowe's for 2x4's and then make some sawdust. Hope you enjoy the ride with me! David
  17. The reason I began using Photobucket is because I didn't like the file size limit on the other forums, typically 640 x ??? but not very large though some have increased their allowable sizes. I wanted my images to be at least 1080 x 810 because I invest a bit of time and effort in doing good photography with editing (and video). As I posted on different forums, a dozen or so for acoustic guitars, CNC, woodworking, etc., it was just easier to have the photos in one spot instead of dealing with the different limitations on each forum. I have yet to look, but what is the file size and pixel limitation here at TPW? David
  18. Photobucket has changed their policies on 3rd party hosting, such as embedding photos in a forum, so my images may disappear at some point. I am considering other hosting options but I don't want to see these blocked so new images on this build, of which there are many, will be hosted elsewhere or I'll upload them directly to TPW. David
  19. It's time to wire the panel but I wanted to make certain there would be sufficient airflow on the stepper drivers, in particular the Z and future A (rotary axis) since they aren't right in front of the fan. This is a simple little test but it validates what I thought it would be like so the next step is laying out the hole placement for the components and then drilling/tapping for a bunch of 6-32 screws.
  20. Water cooled spindle, water cooled PSU, I thought. I was in error... David
  21. I may actually have all the components I need now to wire this up but in the meantime I decided to test my submersible water pump. It seemed fitting to do a little video so that's what I did and you may find it lightly entertaining, at my expense of course...
  22. More of the electronic components came in today but I am waiting on a 12V power supply (just ordered today due to a change in plans from the way I originally intended one component), a terminal strip, and a few connectors. I'll likely make a little platform for the 5V and place the 12V PSU under it to save some back plate space. I'll be sure to give it enough space for all to remain cool but there's no reason not to stack these. The pushbutton switches are both momentary with the green start button being NO and the red mushroom button being NC. The circuit I have designed will close the relays and start the power supplies and fans with the green button but nothing else will run until directed by the controller software. If I install a manual jog then that would work, though. The red button is not an emergency stop though it would have the same effect. It will cause the relays to open and there would be no power at all to the components. These pushbuttons will be at the opposite end of what I would call the 'front' of the machine so even though the red button is accessible I'll have other real e-stop switches located in better places for immediate use. The relays in the bottom right corner will be for 120VAC and 240VAC. Only one of the contactors will be used on the 120V unless I decide to split the load and use both. The 240V relay will only be used for the VFD/Spindle. Both will open in the event of a power loss and that ensures the system won't restart on its own when power is restored. I'm also allowing enough room for one more stepper driver for a future A axis installation. I'll go ahead and drill/tap the holes for it but will get the driver later. There will be a second and smaller fan to the right of the VFD and it will blow out. The bottom fan will blow in across the stepper drivers and power supplies. So this is what it looks like in my initial layout, which is of course subject to change - As you look at the photo of my initial layout you can see that once I start adding wiring, terminal blocks, etc. this will get crowded quickly. Each time I go to this larger box to consider how I'll arrange everything I just am so glad I got this by mistake and didn't have to use the smaller box. I should have done this mock up in CorelDRAW before I ordered the enclosure... We've been out of town moving my daughter to New Orleans and I'm still waiting on a couple of things before I start wiring, but I did manage to build the little platform mount for the 5V power supply. I'll get the holes drilled and tapped in the aluminum angle so I can mount the power supply but have to wait before committing to placement on the panel until the other things come in. Also, I'm starting a project with some beautiful Curly Maple and Walnut so I'll be bouncing back and forth between getting this wired up and doing some woodworking.
  23. I think I'll use it a little while longer but I'll make you a deal - you can come get my 8' bed Oliver lathe (10' long overall length) any time you want! I'll even make you a deal of a lifetime but you'll need to bring a low trailer and 4-5 strong friends - it weighs between 700 and 800 pounds. I'll even let you keep the dust it has accumulated...

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