Thanks! Just an update on the feed and speed on the 3003 al.....I tried turning down the rpm with bad results. I was @ 75 IPM, 18,000 RPM with decent results, tried 15,000 RPM and got melting. Then I turned it up to 22,000 RPM and it machined even cleaner! It seems 3003 likes extremely low chip loads. Probably really hard on the cutter, but surprisingly it is still sharp. Try to take too big a bite and it gums up real bad.
[edit] Totally wrong on that last account. My problem was that I wasn't turning down the RPM enough. I was trying to cut it like 6061 and lowered it a little bit and still got melting. I had to lower it a lot! I ended up finally getting chips @ 75 IPM 11,500 RPM with a two flute cutter. [end edit]
I got a quote for water jet cutting. Might do it as a last resort, very expensive. As long as I can keep up with orders with the Solsylva I'll keep cranking them out. It is doing a very clean and accurate job as long as I don't push it too hard.
My Z is the biggest source of flex. Probably be rebuilding that real soon. The chrome pipes have some give to them when the Z is extended. Probably keep the same design, but go with solid rod rails and replace all wood with aluminum. The alumiinum angle bearing mounts will be swapped for steel. That will be the fourth rebuild/upgrade on that part. That was always the plan once the machine was good enough to make some parts for itself.