King Midas mill conversion

[diy-john]

Today is an eve of first Anniversary of this build thread.

- Removed all crude -build structures from X-axis.
- Installed "intermediate build" components on X-axis

BEFORE:


AFTER:



Some other pictures taken today:

- These are for motor mount. 5mm thick aluminium, what I have had lying around. These are mock -pieces.
-- Will use 15mm thick aluminium soon.


- Once removed all the crude structures, had a chance to clean table.
- BEFORE:


- AFTER cleaning with denatured alcohol



It is still a crude build, but it is starting to make parts. Everything is coming more quickly now, that have taken first steps with G-code and CNC.

Got a smile on my face, when made mounting plate for motor. Keyd in coordinates, make mounting holes 47.14mm apart, as it says in technical data sheet. Guess what? The motor is a perfect fit for the plate CNC is amazing.

[Swarfing]

The best bit of this is where you said "intermediate build", this means a lot as you understand the pitfalls but not afraid to plough on. You learn a hell of a lot this way and it was the route i took when first started out. I worked out was bad by building bad, but i understood that. Training would cost you an absolute fortune. Well done!

[diy-john]

Yes, learning by doing. One year from start of thread now, and we are here.

Please how would you see a 'final X-axis build' like this?

1) Make sort of table-top, out of 15mm aluminium (or possibly 2 x 15mm = 30mm, even 3x15mm=45 mm possible?)
1.1) The top is level with current table top
1.2) Size of original table is 500mm x 130 mm
1.3) Size of new table top is extends current table top quite substantially (60mm at the mill-side of table, more at front)
- will not reduce travel, though.



Reasons why I would want a larger table top:
- keep chips away from ball screw
- perhaps aid attaching a larger item on table (would drill + tap holes. Threaded holes covered with plastic plugs, except when in use)
- add rigidity to X-axis
- add rigidity to motor mount

2) On either side of table, would have 15mm thick aluminium plates, like in photo (except photo has 5mm thick aluminium)
3) The "boxed sections" at either end of table, would add 15mm thick aluminium blocks between original table end, and bearing mounts.
- purpose: add rigidity both longitudal and horizontal


3.1) Motor mount: 2x15mm thick aluminium
- secure motor to larger 15mm thick table top (from above)

4) Bearing mounts on either end of table: 2 x 15mm thick aluminium

I see difficulties with the build in many ways. I am sure one would have been happier with a little bigger machine to start with. But this is what I have, and it will be a nice machine.

But do you see issues with this structure? Would one regret the larger table top?

Would appreciate comments :D

Thanks!

[Swarfing]

John personally i would stay as you are for now and complete what you started. I will almost guarantee that by the time you do complete this your thoughts will be completely somewhere else....A new build!

In most cases the size of the parts you think you may want to make in the future end up being smaller. After i finish my mill build i shall be making my router smaller. The reason for this is because i am just not using the whole thing and it is space i could do with back in my workshop.

The bigger the part you want to make lends itself more to being done manually i always find. If you happen to come across a larger table for a few quid then just buy it. It will save a lot of heartache in the end.

[diy-john]

Good point about larger items and most appropriate methods, and manual work. I will make this machine as good as I can. There will never be other one like it.

This week I have started to make the X-axis "final build". This is a slight revision of plan. I have realized time it takes to make the final build is going to be very long anyway, so not going to make Y and Z -axis any "intermediate build"... but next items are final.

On milling table there is a 708mm x 50mm new piece for X-axis. Had bought 15mm thick aluminium from Ebay for this purpose.



Dialled in G-code to cut a through-pocket (15mm depth), but to one's surprise, end-mill did not penetrate all the way through. Have measured thickness with a digital vernier, and plate seems to be 16mm ( 16.2 mm ). Had to rewise drawings.



I have cut the 708mm x 50mm parts with a cheap circular saw, bought for this purpose + blade made for aluminium. If you try this at home, please use a good respirator (aluminium dust) + eye protection. I did this part of work outdoors, due to mess it creates. Used piece of wood + clamps as a guide rail.



Resulting parts are quite straight, no curvature or windings to mention. There may be a 0.5mm difference to the 50mm I wanted, but I will not try to machine them any further. Will make holes and fittings as needed for this build. This part will attach to the "front of the X-axis -table". The 16mm thick part will replace current 5mm parts.

[Swarfing]

Nice one John good to see your back at it.