[Rodm1954]

Hi CNCfun&games,
That is a work of art. A good sized base with the top boxed over and the generous webs it looks like a winner to me. I wish I had your talent for design.
Look forward to seeing the casting of this.

[philbur]

I think the design would benefit from some internal vertical webs on the side sections. The horizontal webs do little to add resistance to simple bending in either the x or y planes. This would match my observations of cast and fabricated structures required too perform similar functions.

Just a thought
Phil

Jalessi
I will probably cast 5 pcs in the present design. If the rigidity isn’t adequate I’ll happily take your suggestion and enclose the rear of the column. Adding a core will definitely increase the stength and the complexity.

Johnc2309
The base weighs 33# and the column #40.
Those castings in bronze would be something!!

Rodm1954
Would appreciate your input.

HI All,
Enclosed are photo’s of the modified column.
I will start the pattern making this week, and post a comprehensive
photographic record of the build.

W. Smith

[CNCfun&games]

philbur: Thanks……. Good Idea, & easy to incorporate too!


HI All

I am presently planning how I will make the pattern for the new column.

I’m happy to start work on this project because it will give me an excuse
To break out a Harbor Freight 6” Rabbeting Jointer I purchased in December.

I will disassemble it and re-paint it with Rustoleum as part of retrofitting
it with a Grizzly Indexable Carbide Cutter Head. The cutter head is a magnificent
beast and I can’t wait to try it out. Nails & knots beware!!

If there is any interest, I’ll post some pictures of the installation along with the pattern
making process.


W. Smith

[johnc2309]

have you tried lost foam casting, i am starting to build a small mill and used this for my paterns. but i cant melt iron so mine is going to be bronze

[CNCfun&games]

Johnc2309,

I have never used the process!
Would enjoy seeing some of your work.
Feel free to post here.

W. Smith

[acssgt]

Hi CNCfun&games,

I just bumped into this thread today ... great work and reading.
You mentioned back in post 56 and 57 that you needed some advice on rack & pinion. I've done a little bit of work with a custon 25deg modular design we cut on our wire at work, but if you visit www.mechmate.com their entire machine build is designed using R&P and I REALLY like the self tensioning mount design there for both straight and gearhead (my personal choice) steppers.

If you haven't found the answers you were looking for I'd suggest a visit to that site (open downloads for registered members ... same basic ethics and principals as this site).
I think you may like their overall design once you look at it, I felt their approach to the linear bearings developed into some fresh new directions in the recent revisions.

Hope this helps you out.

Rob

[CNCfun&games]

acssgt,

Thank you very much for the link!!
That mechmate site is terrific....hard tearing my self away.
I'm presently on a patternmaking binge, but it was a pleasant distraction.
That site is very informative & highly recommended.

HI All!
The column pattern is coming along and i've decided to make a new base pattern similar to the existing 11 x 17 one which will be 17" x 19". It will
accommodate my modified Enco cross slide and also serve as a sturdy foundation for a bridge mill concept i've been thinking about. Will
make an additional pattern for a bridge side panel which will look
similar to the new column but only 2" deep. 2 will be required to
support a seamless tube about 2" x 4", 5/16" wall.
12" x 12" Travel OK?
Will post a layout soon for comments.

Hope to have a series of photo's posted in the next week.

W. Smith

[CNCfun&games]

Hi All,

Enclosed are sketches of the two new concepts!

I am presently working on the three patterns.
The purpose is to build the machines with gray iron
castings which will be capable of doing serious work.

The benchmill will use the modified Enco cross slide, and should be a
very inexpensive solution for the guy who wants to machine steel
with a minimum of tooth rattle.

The Bridgemill will be patterned after my existing Unit which is rock solid.
It will be configured to use the Enco slide or a Y axis integral to the Bridge.

Naturally all will be CNC-able.

Comments are always appreciated!!!

W. Smith

[CNCfun&games]

Hi All,

Finished the woodworking stage of the Upright Column for the Bridge Mill
and have begun the finishing process. Many coats of sanding sealer
with filleting & block sanding between coats.
Will start on the base in parallel while waiting for the sealer to dry.

From the earlier sketch it is apparent that I have made a couple of changes.
This is part of the evolutionary process in my case, because as I start
assembling the pieces of the pattern refinements become apparent.

More changes are in the works for the other side of the match Plate.

W. Smith

[THEBETTERONE]

That is indeed a very impressive project, I admire your skills.

[johnc2309]

Johnc2309,

I have never used the process!
Would enjoy seeing some of your work.
Feel free to post here.

W. Smith

this is one of my sand castings. i build fancy tattoo machines and have a small foundry and machine shop. i dont have any pics of the foam casting right now but when i cast my milling machine base i will get it on here. how do you think the bronze will do as a base

[ZipSnipe]

Nice work John!!!

[johnc2309]

thanks

[CNCfun&games]

Time to get back to work!!

Just returned from a 2400 mile Train Ride from Orange Cnty, California to Portland,
Oregon and Back.

THEBETTERONE:
Noticed this was your first post . Welcome to the CLUB!!

John 2309:
Thanks for posting your fine Casting. Your product development and sculpting skills
are enviable. I’m sure you will design and cast a very sturdy machine base.

W. Smith

[CNCfun&games]

Pattern making progress!

Enclosed is a picture of the rough column pattern, lots of details
remain to be fabricated before it is attached to the match plate.
Several changes were made to the column to add extra strength.

Jalessi take note!!
It will be closed and the pattern will be used for both halves.
This will require a core to make the inside of the part hollow.
Several cutouts will be added to the core to gain access to the interior.
New dimensions are : top 5” x 5” , base 6.5” x 8.75”, ht 20.75”


The Upright column for the bridge mill is being painted and block sanded to
achieve a smooth finish. That Norton sandpaper is terrific stuff.

W. Smith

[CNCfun&games]

HI ALL,

The Column Pattern is just about finished.
I’ll use the same pattern for the Cope & the Drag,
and put an extra protrusion on one core half to open
up the lead screw slot from the inside on one( the front) surface only.

A modification to the black , cone shaped core supports
may be necessary to keep the core from rotating.

The two core boxes will be completed, and then I’ll
be able to make that judgement.

I just received my Gecko G251’s so I hope to finish the
Cross Slide’s in the next few weeks.

[ZipSnipe]

Any Updates?

[foam27]

YOU BETTER NOT QUIT ! !

[CNCfun&games]

ZipSnipe: See update below.
Foam27: QUIT?……NEVER!!!!

Update:

1). Am concentrating on finishing the CNC mod’s to the 2 Enco CROSS
SLIDES.
a. Slide#1: ULTRA model with THK Rails & Blocks. Bearings & Delron Nuts
added to ACME Screws.
b. Slide #2: LOW COST model Utilizing existing dovetail slides with small
Oiler, Bearing & Delron Nuts added.
2 ). Assemble an Elec. Pkg. for the above, using G251’s, Mini I/O, Keling
Mtr’s & Pwr S.
3 ). Assemble my custom made “D” Series BOB for use with G540’s & cheap
computer cables.
4 ). Finish Knee Mill Modifications & assemble.
5 ). In my spare time I’ll investigate Pack & Pinion Drives and Auto Tool
Changers.
6 ).Work on my Moving Gantry ROUTER as time permits. See Thd # 69283.

W. Smith

[ZipSnipe]

Okay anymore updates?