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  1. #11
    Chaz's Avatar
    Lives in Ickenham, West London, United Kingdom. Last Activity: 17 Hours Ago Has been a member for 5-6 years. Has a total post count of 1,262. Received thanks 92 times, giving thanks to others 60 times.
    Quote Originally Posted by Nick View Post
    Chaz, that might work, how much does it weigh? I am based in Yorkshire, where about are you based?

    Just changed jobs, making very slow progress on the build at the moment.
    Hi, its fairly heavy (estimated 300-400kg). Pity you arent closer, I'm in Uxbridge / Ickenham, West London, Near the M40 / M25.

    Sure, happy to help if I can.

  2. #12
    Nick's Avatar
    Lives in East Yorkshire, United Kingdom. Last Activity: 18 Hours Ago Has been a member for 2-3 years. Has a total post count of 12. Received thanks 3 times, giving thanks to others 0 times.
    This is a bit delayed but I owe a big thanks to Chaz who has let me borrow his reference surface. It has been really helpful and I am not sure how I would of progressed without it. I tried to pick it up in a Fiesta, which unsurprisingly didn't work, thankfully it came on a pallet.

    I've been making slow progress, I settled for an angle grinder for the cutting of the cast iron blocks, it took forever... I have managed to rough scrape all the surfaces for the column.

    Click image for larger version. 

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    These blocks of cast iron are the ones highlighted below.

    Click image for larger version. 

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    I have also scraped the main cast iron block.

    Click image for larger version. 

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    They're not perfect but within 0.03 mm. I am making the mold and getting the inserts ready, I plan to cast the column next week. Just trying to work out how to drill 18mm holes through the 2 inch cast iron blocks, my drill press isn't up to it and I really don't want to have to buy a mag drill, I don't know if anyone has any other ideas?

    Nick

  3. #13
    Chaz's Avatar
    Lives in Ickenham, West London, United Kingdom. Last Activity: 17 Hours Ago Has been a member for 5-6 years. Has a total post count of 1,262. Received thanks 92 times, giving thanks to others 60 times.
    Quote Originally Posted by Nick View Post
    This is a bit delayed but I owe a big thanks to Chaz who has let me borrow his reference surface. It has been really helpful and I am not sure how I would of progressed without it. I tried to pick it up in a Fiesta, which unsurprisingly didn't work, thankfully it came on a pallet.

    I've been making slow progress, I settled for an angle grinder for the cutting of the cast iron blocks, it took forever... I have managed to rough scrape all the surfaces for the column.

    Click image for larger version. 

Name:	20180825_173005 (2).jpg 
Views:	97 
Size:	680.4 KB 
ID:	24898

    These blocks of cast iron are the ones highlighted below.

    Click image for larger version. 

Name:	Highlighted.PNG 
Views:	76 
Size:	25.9 KB 
ID:	24900

    I have also scraped the main cast iron block.

    Click image for larger version. 

Name:	20180826_163337.jpg 
Views:	85 
Size:	464.4 KB 
ID:	24899

    They're not perfect but within 0.03 mm. I am making the mold and getting the inserts ready, I plan to cast the column next week. Just trying to work out how to drill 18mm holes through the 2 inch cast iron blocks, my drill press isn't up to it and I really don't want to have to buy a mag drill, I don't know if anyone has any other ideas?

    Nick
    Scrape Scrape Scrape ....

    I was going to ask how you were getting on.

  4. #14
    Would the blocks fit on a lathe cross slide to drill the holes using a bit or boring head in the chuck?
    Or the other way around with the block rotating on a lathe face place and bit or boring head in the tailstock?
    Building a CNC machine to make a better one since 2010 . . .
    MK1 (1st photo), MK2, MK3, MK4

  5. #15
    Nick's Avatar
    Lives in East Yorkshire, United Kingdom. Last Activity: 18 Hours Ago Has been a member for 2-3 years. Has a total post count of 12. Received thanks 3 times, giving thanks to others 0 times.
    Quick update

    That was a great idea with the lathe cross slide although I couldn't quite get it to work, having issues with its size. I ended up getting a mag drill... Drilled 60 holes and tapped for the insert bolts.

    Click image for larger version. 

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    Mould made and epoxy poured, all 150kg of it. Got it done in about 90 minutes with two of us. Had some slight issues, no vibration, we ran out of pigment towards the end and the mould blew out on one side. But overall went ok, if anyone wants more details on how to go about this I could write a more detailed post / video.

    Click image for larger version. 

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    Will probably de-mould tomorrow.

  6. #16
    Nick's Avatar
    Lives in East Yorkshire, United Kingdom. Last Activity: 18 Hours Ago Has been a member for 2-3 years. Has a total post count of 12. Received thanks 3 times, giving thanks to others 0 times.
    It looks bigger out the mold

    Click image for larger version. 

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  7. #17
    Chaz's Avatar
    Lives in Ickenham, West London, United Kingdom. Last Activity: 17 Hours Ago Has been a member for 5-6 years. Has a total post count of 1,262. Received thanks 92 times, giving thanks to others 60 times.
    Quote Originally Posted by Nick View Post
    It looks bigger out the mold

    Click image for larger version. 

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    Lovely. Keep at it ....

  8. #18
    Nick's Avatar
    Lives in East Yorkshire, United Kingdom. Last Activity: 18 Hours Ago Has been a member for 2-3 years. Has a total post count of 12. Received thanks 3 times, giving thanks to others 0 times.
    Small update

    I've made a temporary stand and put the column on the base

    Click image for larger version. 

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    I don't have a square big enough to see how perpendicular it is. Has anyone bought a granite square ? the only one I can find is this one
    https://www.zoro.co.uk/shop/measurin...MaAg9CEALw_wcB

    I have been making slow progress with the table, I have reduced the table width to 240 mm and I've got two ground 25x50x1000 mm bars to use as the rail mounts.

    The table "offcut" from reducing the table size width has been cut into four and scraped flat and parallel to act as spacers. I was starting to scrape the table flat but the carbide came off my scraper...

    Click image for larger version. 

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    I am slightly concerned that there isn't enough support under the steel bars and they will deflect. You can see this in the renders below, with the overhanging steel bars and the small amount supporting epoxy granite. I'm thinking about adding some threaded rod or increasing the thickness of the epoxy, i'm not sure if this is necessary though, thoughts on this?

    Click image for larger version. 

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  9. #19
    Hi Nick,

    Very very nice project! I'm planning the exact same machine but first option is to use steel tubes filled with EG. Second is directly casting EG like you did. Anyway, will follow with great interest.

    Would you mind sharing your model for study, or maybe just give us dimensions of base and column?

    Thanks for sharing your experience, this surely prove helpful at some point...

    Cheers

    Envoyé de mon ONEPLUS A5010 en utilisant Tapatalk

  10. #20
    Nick's Avatar
    Lives in East Yorkshire, United Kingdom. Last Activity: 18 Hours Ago Has been a member for 2-3 years. Has a total post count of 12. Received thanks 3 times, giving thanks to others 0 times.
    Sure, it's not quite finished and I have had some difficulties with exporting it. All the joints have gone, does the iges file below work?

    https://www.dropbox.com/s/6w12be2b4w...0v19.iges?dl=0

    The rails are from the Hiwin website and I've used these models off grabcad

    https://grabcad.com/library/lichuan-servo-60st-m01...
    https://grabcad.com/library/ac-servo-110sy-04030-1
    https://grabcad.com/library/bt30-spindle-2

    The design is based around the cast iron surface plate and blocks that I bought, I think this has resulted in the base being too narrow and long.

    I think with hindsight starting with a welded steel filled epoxy structure would of been a good idea.

    I look forward to your build, let me know if I can help

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