I apologize for screwing this up or posting in the wrong area, if I have. I've been searching the forums and lurking for about six months, and I am still having trouble finding the answers I need.
I built my own CNC machine from a kit I bought from Build-Your-CNC. I am using a Porter Cable single-speed router, and just cutting wood. I don't even have plans for cutting anything but wood, as I'm a woodworker who likes the flexibility of ultra-detailed, ultra-accurate milling, not a machinist.
So here are the problems I have, and any help would be insanely appreciated.
1) My collet only accepts 1/4" shanks. I have ideas for projects I could build with other mills, but it's hard to find 1/8" mills on a 1/4" shank. I really need more flexibility in end mills, as I can't get much detail out of a 1/4" mill, and I would like to cut modeling kits that would require much tighter cuts than I could achieve with a 1/4" mill.
I am open to buying different mills. I am open to buying adaptors. I am open to buying different collets. But I don't know where to look for them, or which would work best. Any advice would be fantastic.
2) The things I've cut so far have been cut out of plywood or MDF. Both are creating burrs and splinters. For many of the projects I would like to cut, I need them to be smooth cuts. Sanding will remove the fur off the edge of the cut, but rounds over those edges in the process. Clean, straight cuts would be far better. I've seen wood cut on a CNC machine that has a remarkably clean edge, and would like to figure out how to achieve that.
I'm open to any suggestions. Different wood, different mills, changing feed rates - whatever would help.
3) My shop is a spare room in my house, and the dust is tremendous. I have a vacuum hooked up to the router mount that should be pulling the dust up inside it, but it's not working. Dust shoots out everywhere, and my shop is a mess. I have to spend almost as much time cleaning up after a cut as I do just running the mill. I would never keep a computer in such a dirty room, except that I need it to run the machine - which means I'm spending a stupid amount of time cleaning the dust out of the computer.
Does anyone have a good system for controlling and collecting dust?