Whats the best way to cut instrument panel

[mikeamick]

My 2000 lathe motor took a crap. I have a monster treadmill motor I have been
meaning to try out so now is a good time.

I am going to use the stock push buttons for the controls .. but ... I want to
orientate them a little differently.

I want to take a sheet of alum .. oh .. maybe 3/16 or so .. and cut some
openings into it for the push button boxes.

Anyways .. any hints on how to get a nice cut from the mill for the openings.
2 flute, 4 flute etc .. I'm sure I'll experiment and find out .. I was just looking for
some experienced suggestions.

Oh .. and btw .. there were several forums I could have posted this too .. but
I really would like to see this one get a little more action .. so .. here I are.

[Al_The_Man]

1/8" aluminum is usually ample for panel switches, I usually use 1/8" two flute for odd shapes, for PB's I use a Greenlee punch set, if you have any electrician friends, they may lend you their set for a day.
Al.

[mikeamick]

Perfect .... thanks

[mixdenny]

I have used a treadmill motor and control for a variable speed conveyor belt. It works fine, but one thing to bear in mind is the way the controls work. You cannot leave the motor set at a particular speed and turn it off and then come back on to the same speed. To stop you have to turn the safety switch off (remove the deadman key), then back on and and sequentially press the "increase" button a bunch of times to get back to speed. This is a safety feature built in to all treadmill controllers. I replaced the key with a regular switch but you still have to input the speed each time.

Dennis

[mikeamick]

It actually depends on the controller. I agree that most are like that .. but
I have 4 laying around and just went out and tested them. 3 were like
you said ... but 1 would allow me to have the motor speed set while turning
it on.

I was actually getting around this by using DART speed controllers. They
are only 30 or 40 bucks and don't have that characteristic. (ebay)

On the Treadmill controllers .. I also tried leaving it on and just connecting the
motor ... quite a lot of current ... cause quite a big spark ... grin

The DARTS also differ that way. I can leave the controller powered up
and connect the motor ... and its like the circuit doesn't go to town until
it senses the motor .. so it does this quite happily.

Here is a pic of my brute treadmill motor ... I was thinking of putting it
on my mill .. but .. it was a little big. And I now need one for my
lathe sooo ... on the lathe its going.

I've also included a pic of some of my treadmill stuff.


Thanks for the warning though.

Mike