Hi-
Ok- here's the situation. I am really interested in diving into CNC, retrofitting a mill of my own, building a CNC router, etc. But I'm recently laid off and I need to pay the bills doing web site dev. So- chicken and egg- I can't afford the time or money required to buy/build a cnc machine.

The best situation would be for somebody to pay me to learn...

I recently met some folks that run a local metal fab shop. They have 3 bridgeport class mills, one of which is a series 1 with the old boss controller, which doesn't work. When I told the owner that this machine can be retrofitted with higher res servos, and modern electronics that can talk to a computer, she was very interested. They currently draw things up in autocad, then machine them manually.

She wants to hire me to upgrade the mill and get them set up to do CNC machining. Here's the problem- I don't have any experience in this (yet)!

Of course, like many a consultant, I won't let that stop me! I hope to learn all about this in the process. She is aware of this and is ok with it- she basically trusts that I am an honest, competent person with a keen interest in CNC machining.

I figure I'll come up with an lcd display and touch panel tied to a dedicated PC (not laptop). I plan to use Mach 3 software.

I've been doing some research. I've come across several solutions.
* Flashcut has a pretty expensive kit ($8380 for servo, $5080 for steppers).
* AjaxCNC has a kit that re-uses the existing motors and adds new encoders for $3979
* AMR has a kit for $6800
* Visionnc sells centroid upgrades- don't know price

Alternatively, I would consider a piecemeal approach. However, since this will be my first CNC experience, it would probably make sense to go with a reasonably tried and true kit or at least parts list.

I am a fairly decent amateur machinist. I have excellent electronic tech skills and computer experience. I am simply lacking the CNC experience.

So- any advice would be welcome (other than give it up!)

BTW- I'd LOVE to find a Bridgeport BOSS machine of my own to do this to! For cheap!

Thanks-
Lynn Kasdorf
Waterford, VA

Does it have servos on it? If its a BOSS 6 or less it will have steppers. Anyway its fairly easy to get the bits and pieces and do it yourself and it will cost a lot less. I did my BOSS for £1500 ($3000) and that was inclucing the mill itself, computer, touch screen, new steppers, MPG etc.
Hood

I have a BOSS 5 running under mach. I am using the bridgeport motors and drives but I have removed the brains and inserted mach3. This upgrade, using hillbilly's breakout board, is by far the easiest and least expensive solution. You will only need a few hundred bucks and a little time to get things running if you have a stepper boss.

Good luck and have fun
Matt

I clearly need to go back and take pics and examine more closely.

I did write down the info on the motors: the x axis (probably the Y as well) had Boehm BM 4835 spec 4640 on the motor.

Probably a dumb question, but what is an easy way to tell if it is stepper or servo? Number of wires?

I didn't open up the control box at all. Maybe it will indicate the model of "boss".

I have been googling high and low and not found a summary of the different models of the Boss controllers.

It sounds like you do have servos as the steppers on these mills were either Sigma or Superior motors AFAIK. If you look at the pic of the mill before I retro'd it you will see what the original steppers look like.
http://mysite.wanadoo-members.co.uk/hoodsmachiningpages/Series1Retro.htm

Hood