CNCZone-
I've been avidly reading and learning from this forum for about two months now. I've finally made my own account as I feel that I am getting closer and closer to what I want to achieve. As you can tell by my name, I am a guitar player through and through. What I want to do is create and design all-aluminum pedalboards that will be worth their value. Everything on the market is heavy, crappy MDF or blown plastic. I started doing research on this a few months ago and have decided that the best way to about fabricating this stuff is by using a CNC router to do it. However, like everyone started off, I don't know a whole lot.
The K2 2935 has really appealed to me since it will hold the size of aluminum plates that I would need. I have some questions that I hope I could get some professional and experienced opinions on. So, without further ado, here it is.
1) To get the router up and running, I need the machine itself, the driver, and Mach3. What software could be recommended (that isn't too pricey) that I could design and execute my parts with? All the parts will be flat and will be bolted together. I don't think that I need to buy AutoCAD or anything that crazy, just looking around, I don't see why Cut2D wouldn't work. Any further suggestions would be awesome. Also, please tell me any other software or necessities that I'm missing to get a router up and running.
2) What kind of aluminum has the best strength-to-weight ratio? I would like these boards to be roughly 20x30 and they would be holding around 20lbs of effects pedals on them. Also, bear in mind that they would be constantly getting stepped on by the musician. I need something that won't bend, warp, or break.
3) How do you go about tapping holes through aluminum plating so you can thread a screw into them? Can that be feasibly automated or is that going to have to be done by hand? I would like to have all the plates held together by flat top machine screws so it would look nice. If anyone sees a problem with that, please tell me. I'd like to avoid welding since it isn't very aesthetically pleasing.
4) Is a lubrication system absolutely necessary for milling aluminum or can most problems associated with that be vetted by milling slower and making your passes less deep?
These are just the start of many more questions that I have for you guys. Any suggestions/tips/answers to any questions by some real pros would be greatly appreciated. Thanks!
-Nate