New project - Mini VMC

[Hack]

Well after a few years of working with a poorly converted Mill / drill I have decided to begin a new build from scratch. I want to improve on a few things that I dislike about the mill / drill and that includes:

Get rid of the round column
Power the head, not just a quill
zero backlash ballscrews -I currently use screws from Mcmaster with single nut leading to much backlash
I want an enclodure on this one - tired of chips flying all around with way to much mess.
Gonna make the switch to Mach 3 software. Currently using Turbocnc and while this is fine, I use Mach on my router and like it better.
Accruate home switches on all 3 axis with trustworthly limit switches as well. N/A to my current setup as there is none!
Also, I enjoy building these things perhaps more then using them, so this should be a good time.

Feel free to tag along for the ride.

[Hack]

Figured the first thing I was going to need was a place to put this as I build it. My current workbench would probably suffice, but it is a bit small and is not to heavy duty. I was a bit concerned that as the steel for the mill accumulates, it might get a bit heavy for the bench and damage it. As a result, i figured I would start with the stand (to later be a full enclosure) and then move on to the mill.

Nothing fancy on the enclosure. You can see the 4 sheets of MDF and 5 - 2 x 4 x 8' long that I am using to build it out of. Later the sides will be framework with plexiglass windows or something similar.

A few pictures of todays progress.

[Hack]

Ok, made some good progress on the stand. I have pretty mych the entire base done now. Lot of screws, glue and a few hundred pounds of lumber. Should make it pretty strong.

The hole cut outs will later be the home for coolant and the pc. I meed to get some adjustable feet for the bottom now and look at painting the outside. The inside will get some bedliner or epoxy. Something to seal it. I also need to go to the Borg and pick out a drain and get it put in sometime as well.

As far as the walls of the enclosure, i will wait on them so that i have access on all 4 sides as i build this mill.

Pics below.

[Khalid]

very nice work.. I am anxiously waiting for next episode of the pictures.
regards

[alex_ku]

nice!!
following your progress.

[Teyber12]

thats a beautiful stand! sub'd

[Hack]

Nothing exciting to report. I got the adjustable feet installed on the bottom so I can now level it. I also took some time last night to putty all the screw holes in preparation for priming and painting. I hope to accomplish that task by the end of the weekend.

Gotta take some time out for Beer and Brats.

I'll keep you posted.

Dan

[Hack]

Beautiful evening tonight so I took some time to paint the outside of the base. Nothing fancy, just some gray exterior paint from the BORG. I still have to find a source for the bedliner that I want to use for the interior. I assume that this is something that I can just pick up at the auto parts store, but if anyone has a source they would like to share, please dont hesitate.

You can see I had some expert help tonight

Eye candy (although limited) is below.

Next is to get the bedliner on and then start the mill base (the good stuff!)

[brunog]

I still have to find a source for the bedliner that I want to use for the interior. I assume that this is something that I can just pick up at the auto parts store, but if anyone has a source they would like to share, please dont hesitate.

Dan,
Maybe you should take a look at Line-X products: www.linex.com

Best regards

Bruno

[Hack]

I did a bit of reading on the forums here at cnczone and noticed a few people the were unhappy using bedliner for the enclosure. One product (herculiner) popped up a few times with a minor complaint. That complaint was that it the finished product was rough and snagged the chips on occasion instead of allowing them to flow as they are supposed to. So as a result I decided against the bedliner stuff.

Instead I ended up fiberglassing the whole inside (tray) area of the enclosure today. Stinky stuff. I ended up breaking out my respirator less then 5 minutes into the process. Should have done it from the beginning. It helped alot. Now I have got it curing and I am looking for some white paint to go over it with when it dries.

I was looking for an epoxy paint at the BORG today, but was unable to find anything. All I saw appliance paint and something for tubs and sinks. The tub and sink would have worked I imagine, but it was a spray on item, and I had hoped to fine a brush / roll application. That and I am still not sure exactly what I am looking for.

What has everyone else used and where did you get it?

Dan

[Hack]

I was able to finish up the fiberglass work and then paint the inside of the stand. I used a tub and tile epoxy paint from Home Depot. Pretty nice looking stuff. I wish I would have taken the time to sand the imperfections in the fiberglass before I painted, but I hate sanding fiberglass. So I will live with the results. Sure will help brighten everything up though.

The paint is an aeresol can with no mixing reqired. About 45 bucks for 2 cans, steel wool, rubber gloves and some powdered TSP (cleaner). Didn't use all of the paint (close) but it is on quite heavy. Not sure if I will use it to finish the entire enclosure when I get that far as the cost would add up I think. I chose this product because I felt it would hold up to standing water. The enclosure walls wont necesarily need that.

What's next? I am finishing up the mill bottom and will be placing it in the stand this week or coming weekend. I want to hold off on cutting the drain until I get an Idea of where everything will go. Also, I have to wait 72 hours before putting anything on the white paint.

Pics below.

[Hack]

Well I had a good week in the shop. I was able to get quite a bit done. The first item is the base of the machine. It is about 14 x 29 and is made from 2 1/4" thick steel. I was able to source cheaply a few remnants of this material from a job that was done at a local shop. These pcs were the cutouts from a rectangular shaped part that they had done. Pricing was a bit more then scrap. They had already charged thier customer for it and anything I gave them above scrap prices was a bonus to them.

The pc was cut on a waterjet machine to the shape shown. I drilled 4 holes in it for the mounting feet so that it can be leveled properly. The part also has 5 drilled and tapped holes in it so that I can bolt the second layer of this base to it. The second part is shown. I am still milling it as required. The entire base will be 4 1/2" thick when done. This second base will recieve the linear guide and ball screws. I have also added holes so that I can later add a flexible bellows of some sort to keep the swarf out of the good stuff. Also machined into this pc are 9 holes to bolt the column to when ready.

I only broke one tap while working on this. I removed it with a 3/16 carbide endmill plunged slowly into the hole. Worked very well.

Next week will be working on the column and getting some linear rails on order. I am going with rails from HIWIN (25 mm). Will be buying them new.

Enjoy the pictures.