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As you have already pointed out, an experienced craftsperson can make just about anything even with limited tools. You keep asking (over and over) the wrong question, "will this machine do what I...

The Roland is not a rapid prototype machine, it's a mill. Their software may be a good bridge for some parts, but it won't be for everything. There is a reason decent CAM programs cost what they...

First off, take with a grain of salt a lot of things. You are asking this question on a forum full of enthusiast machinists, I'm guessing very few of which have any first hand experience with RP...

a) Bigger isn't always better
b) It's primarily to do with the inductance number. You choose a supply voltage based on the inductance of the motor (32*sqrt(inductance)). The 387 wants a higher...

Most likely because they are a better match for the driver stated. You'll get more out of the 381's with a G540 than the 387's at the limiting voltage of the G540.

I have a lot of things kicking around :) It pays to have unusual friends, and to frequent surplus places. I'll document the build when I do it though.

YouTube - IMG 0253
I did actually have plans to make useful parts just using the 4th axis to index dimensions, but I'm too entertained watching the axis spin and cut things like this little fan. ...

The chuck, using jaws and a scroll can wear unevenly, unlike a collet. TIR will most likely deteriorate over time, and can also vary dependent on jaw position. Most good quality chucks have rebuild...

I've hacked together my fair share in my day ;) I started machining with a lathe, and a milling attachment, these days I work as a toolmaker. Been a long road.
Personally I feel that if a tool is...

The point I was trying to make is that it's a good idea to learn to do things the "right" way before trying to build a jig, modify existing parts, etc. Once you really understand why things are done...

There isn't a use besides those described already, they are a deliberately short, rigid tool designed for starting holes and chamfering.

All very good points. I'd just like to add, and I'm sure you understand with the experience you have, is that a lot of times people see the need to "modify" perfectly well working things, to end up...

That isn't going to work as well as you might think. Take a look around and see how many big machines pin their assemblies for square after bolt through. Not too many. There are reasons...

Little test of some very rudimentary rotary axis programming. Still fun though, I want to try some other interesting shape combos. It's tough to focus clearly on small objects without a proper...

I would never personally put an end mill in a drill chuck, I generally don't count them to be any better than .003" TIR. There are a variety of other reasons not to use them, including the fact...

Most larger chucks use a taper mount, not a threaded mount. The 5/8" capacity chucks we have for the Bridgeports at work use a JT3. JT0 is common on smaller chucks as is a 3/8-24 thread. Taper...

Some more progress. I have got Mach 3 controlling the stock Sherline motor board using the 0-10v output from the G540. I measured the voltage between pins 1 and 3, which was below the 12v max...

First off holding a file to a part in a lathe can be VERY dangerous. Make sure you have a handle on the file, as getting the tang driven through your carpal tunnel isn't something you want to have...

Use math :
Sin(.1125) = X/0.75
You are solving for X which is the length of the side of the triangle that is on the outside of the circle .75 in radius.
I get .00147 and some which means that...

For whatever it's worth I managed to get the 0-10v signal of the G540 to control the speed of my Sherline spindle setup. I still need to do a little bit of fine tuning, and set some speed limits...

It has more to do with the way that the machine itself handles the loads involved in cutting the work. It's not a difference in how the tool contacts the work, it's how the loads are transfered into...

As others have said, there are many widely varying opinions when it comes to CAM software. You'll have to evaluate which software you need to get the jobs you want done the way you want.
If your...

According to the manual "ANALOG OUTPUT: This is a 0V to +10V opto-isolated analog output intended for use with VFD drives. VFD
OUT goes to 0VDC while the G540 is disabled. Connect VFD GND, VFD OUT...

Understand, there isn't a way to just wire the G540 to the stock spindle control board on the X2 with variable speed control. It wasn't designed this way, nor should you think of it as being able to...

I think you are somewhat confused on this. The feature as built was never intended to control an X2 spindle. It's meant to control a VFD, which will control the speed on a 3 phase motor. It is...

It's just a voltage out, 0-10v which is what most VFD's will take as input. Nothing difficult or complicated about it. The 540 is used a lot in smaller less expensive machines, which is also why...

I love my G540, but I almost wish I'd gone with separates. Higher voltage for one thing, which allows you to use a greater variety of motors, now and in the future. If the budget can stand it, and...

"Machined correctly" is not a term that ends in every part being to dimension +/- 0.000 . Parts machined within tolerance pass, but may still benefit from some fine tuning. Hand scraping takes the...

There are several projects you might enjoy reading, people who have essentially built their own machine. Several folks have done machines using large 8020 extrusions, I built mine using heavy...

The "genuine" 8020 is not all that cheap, but when all is said and done it's not that bad. You can go to www.8020.net and price stuff out, McMaster carries it as well (also all sorts of plastic...