I posted this on the Fusion site but figured I should also post it here. Give you an insite into the Fusion kit and my first impressions. This is my first CNC project and I have alot to learn still. I will hopefully post my progress so others can compare what direction I have taken to CNC my X2 mill. I believe the total package will be about $1720 when all is done. Then add an additional $150.00 for Mach 3. I may sell of all the spare parts I now have on hand and further reduce my costs.
Its a long post so here goes
X2 Fusion kit with preloaded ball screws, my first impressions and installation thoughts.
First I have a HF X2 mill with the little machine shops belt drive retrofit kit installed.
My first impressions out of the box, everything was intact and not damaged. Never having used ball screws I first started running the ball screw ball nuts up and down the shaft. I noticed varying degrees of side to side play from rock solid to loose fitting. I emailed Fusion and the reply was side to side play should not affect the performance of the screw. The Y axis was tight, the X axis was a little loose, and the Z axis was very loose. According to Home Shop CNC both pieces vary in dimensions from Nook. My assumption was that the preloaded Ball nuts were tighter than normal Ball Nuts? With this response and what I have read, I got started.
Sadly no instructions, even though I am mechanically inclined some procedures on the Z axis I wound up doing twice. The whole procedure took about 3 hours not including my mistakes. A DVD would be great here maybe someone could ask Swarfrat.com to whip one up for everyone, lol.
First the Z axis:
I removed the Z axis drive components that came with my HF X2 mill. Everything including the gear rack. I used the included HF column limit stop to keep the head from sliding down and crashing into the table. I also took off the tension arm screw (new style x2 mill) so the head can be moved up beyond the top of the column and down closer to the table. I loosened the gib screws so the head can move freely. This was my first mistake, once you mount the new Z axis ball nut block the gib screws are covered so you cannot adjust the Z axis gib screws again. I also realized that the Z axis limit stop gib lever is in line with the new ball screw. I found this to be an annoyance and it made it harder to set the kit in place (my experience). I also noticed that the large cap screw used on the inside of the column to attach the ball nut block was a tight fit for all 10MM hex wrenches I owned. I found an old 10mm shortie and cut of an additional ½ inch off in order to get it into the cap screw. The Z axis motor mount should be installed with the mills head very low to the table so you have clearance to drill and tap the top motor mounting plate. This is the only modification to the mill, two holes and they are above the old upper limit stop. So if you need to go backward (non CNC) it’s no damage done.
Z Axis procedure as I see it
1. Set the mills head at the midpoint of the column and set the Z axis limit block so the head cannot slide down.
2. Remove the upper limit stop bumper and screw; save the screw you will need it later.
3. Do not loosen any gib set screws and make sure they are property adjusted and locked down tight before you proceed any further.
4. Remove the outer screw from the new style spring tension arm and swing the arm upward. Hold the arm while doing this it’s under tension. I do not know if you will need to do anything with the long spring arm style support.
5. Remove all of the drive components from the mill (pinion drive assembly), its 4 cap screws, and the cover plate (2 Philips screws). Save the two shortest cap screws you will need these later to mount the new Z axis ball nut block. The whole assembly should slide out in one piece (it is not necessary to take the handle off to remove the pinion drive but you can unscrew the three arms afterwards for storage). You can also remove the pinion Rack it won’t be needed and all that grease is messy.
6. Carefully slide the head up and over the top of the column (not off of it) to expose about half of the back of the mills head, again set the Z axis limit stop in place. You may need to do this slowly in small steps if you are working alone. I found the gib very tight near the top and had to use a c clamp for the final 6 inches of movement.
7. With the new Z axis assembly move the ball nut block as far down as you can get it from the motor mount then start to attach the ball nut block. The large screw comes off and is inserted through the back of the head (which is now exposed) this is tightened with a 10mm hex wrench (see comments above). The two front screws are inserted (the two short cap screws you saved from the drive assembly) make sure the block is aligned with the frame of the head then tighten the two screws. Next tighten the big 10mm cap screw. The sequence here is unimportant just eye ball square.
8. Remove the two screws and nuts from the Z axis motor mount (if you haven’t done this already), and then slowly lower the head down so the spindle is just above the table and the Z axis motor mount is sitting on the top of the column supporting the mills head. The motor should be low enough so you can work on the three mounting holes. Again use your limit stop.
9. Insert the screw you saved from the upper column stop into the elongated center hole and carefully align the ball screw parallel with the right side of the column and tighten (you don’t want the ball screw cocked at an angle when you start drilling).
10. Now drill and tap or dill and secure the two provided screws. Use a center hole punch if you have one you don’t want these two holes too far off center. Check the alignment of the ball screw to the column before you tighten the last two screws. There is some play on all screws to make adjustments. Your done.
As I removed the Z axis kit the first time to fix my gib screw mistake I cursed myself for not reversing the limit block so the lever was on the left side of the column and out of the way of the ball screw. Maybe some day I’ll fix it, but you will need to move the mill head off the column to flip it and with my luck something else will be in the way.
The Y axis was next. First I looked at the paper tube and decided not to attempt to remove the nut from the back side of the screw. A smart move as I later discover this would have been the wrong way. The issue here is removing the lock nut on the Y axis motor mount, you need a small spanner and I had none that small. I found a small piece of aluminum and made one using my bandsaw and several files. I used a wooden vise to hold the ball screw while removing the lock nut. The assembly was uneventful except I had to use a ¼’ thick piece of rubber and a pair of vice grips to hold the Ball screw while getting the lock nut back on, on the mill.
The X Axis also required a spanner of another size (same spanner I made worked fine here). You also must remove the original shaft from the X axis bearing seat, a small Arbor press helped me out but is not necessary. Remove and clean both bearings from the bearing seat, clean and repack them with quality grease before reassembly. Notes: motor mount on the left of the table and the shaft extension on the right between the table and the original bearing seat. Again not really any need for detailed instructions
So far everything feels tight but I have not checked it with an indicator. I am still awaiting a 4 axis drive kit from Xylotec. I managed to secure a long T handle Hex wrench into one of the loose motor mounts so I can rotate the ball screws. So far it looks like a vast improvement.
What I didn’t like so far
No detailed instructions… Hopefully my post will help others.
The Z Axis ball nut block which covers the gib screws… I wouldn’t mind drilling a few extra holes so I don’t have to dissemble the z Axis to make gib adjustments down the road.
List of tools you should have on hand before you get the kit. Hey I thought I had every tool known to man except two small spanner wrenches. Most of the kit can be assembled with a set of metric hex wrenches.
Woodenspoke