The build is still 'incomplete' as I'm in the middle of making a power drawbar, but here are some photos below. The mill came with a staggeringly expensive set of Royal quick-change tool holders, but I'd eventually like to build an ATC and while the Royals are superb they are not compatible with my ATC plans.
Drawbar will be a single-stage air cylinder, pushing up on a 1.5:1 lever, which pushes down on an 8:1 hydraulic cylinder attached to the spindle top. The internal hydraulic cylinder shoves down a big ol' stack of bellevilles and releases the Tormach TTS tool holder. I plan on torquing the drawbar to 30ft-lbs - should give about 4500lbs of axial tension on the drawbar/collet so no tool pull-out. Tormach recommends 30ft-lbs, so I figured that would be good enough for me.
With the enormous spindle motor I didn't have room for a multi-stage air cylinder pushing directly down on the sprung drawbar, so I either needed a massive 4" cylinder with a giant lever running at 100psig and hanging way off the head, or the hydraulic thing. Should make for a fairly compact arrangement. If you're curious about the hydraulic deal, search for the Tormach Lever Operated Drawbar. The 'intensifier unit' is a spindle-mounted hydraulic cylinder with a 5/16" small piston and a 1" (I think) big piston. About an 8:1 or 10:1 ratio, and I'll be experimenting this weekend with how much stroke I need on the small piston to get the drawbar to release reliably. I've calculated I need about .800" to get .100" of drawbar movement - we'll see if that's enough to drop the tool.
The cylinder is done except for an air bleed, and it seems to work as planned.
Wiring is a bit messy as I've got the drawbar temp wires back in the enclosure waiting for me to get the solenoid valve and other junk installed.
If I recall, the quote for a bare-bones Skyfire was going to be north of $10k. There is a US dealer now, so getting hold of them would provide a much more accurate picture than what I can remember.
Inside cleaned up of all the silly conduit
Big-A$$ spindle motor
New control panel finished yesterday! Woo!
Monitor & PC out of the way. Hated them on the top of the mill.
Rearranged the basement for the new drain/coolant system and because there are no electrical bits to get wet now.
Back of the mill. Liquid-tite conduit because I don't want to cut a wire and to suppress the EMI/RFI from the VFD.
Closeup of the conduit. Also had to move the lube pump because it would siphon and get oil all over everything inside the enclosure.
Back of column. Drag chain made things easy since I have oil line, spindle power wires, coolant, encoder, spindle index signal, and (soon) drawbar air lines to get up there without tangling.
Awesome motor. Dirt cheap on Fleabay, came with an encoder I can sell for twice what I paid for the whole package. Too heavy, but the Z hasn't lost any steps at 100IPM with moderate acceleration.
220V box down below. VFD, power supply, relays for the coolant and lube pumps. Keeps the electronics from wigging out, especially the spindle encoder and limit switches.
Inside the 200 box.
Electronics and 110V stuff. All the safety stuff is run via mechanical relays. E-stop is tied to the VFD alarm, too - not just a 'software' stop. I tried to make this as 'industrial' as I could without blowing money on purpose-built safety relays and controls.
More of the electronics. Wireway covers are missing, and the wireways are, frankly, too full. Everything is too close together but everything is labeled and easy to trace. Using a CNCDrive 400ETH motion controller and a PMDX 126 BOB with PMDX 107 spindle control board. If I knew 6 months ago what I know now, I'd have gone with the 300ETH and a different BOB, but what I've got is working fine. I just want more inputs.
Finally, a shot of the extra drain through the base. Much, much nicer - no flooding the base out.