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ClaudioG
06-15-2007, 12:16 PM
Hi Guys,

I figured now would be a good time to start a log of my build of a Joes CNC Model 2006 R2 build.

I've done a lot of reading of other great logs so hopefully mine will end up being at least 1/2 as useful for someone. There's a ton of great information here and elsewhere on the net.

I've got a long way to go, and a few other projects at home which I have to complete before getting too far down the track with this, so this project will take a while. I know it will be all too easy to get totally absorbed by this project and forget ever thing else, which has already happened with just reading about it.

I thought I'd get the ball rolling with buying a few critical components I can't get in Australia while I'm over here in the USA for the next few weeks and taking them back with me.

I'll be ordering the 1/2-8 2 Start ACME lead screws from MSC, DumpsterCNC bits, lovejoy couplers from Enco, bearings from VXB, a Hitachi Router from Lowes, T-Track & clamps from Rockler, ShuttlePro from Amazon and some mills. Oh, and a new digital camera for the photos and videos that everyone love.

I'll also be ordering a HobbyCNC 3-Axis kit with 305oz and probably having that shipped directly as I'll exceed my luggage weight limits (50lb per bag, 2 bag limit)

I have a few major stumbling blocks to overcome, the first of which is to convert Joes excellent plans to metric in order to be able to use metric thickness MDF and HDPE. I've done enough research and grovelling to be comfortable that this will get done one way or another.

I was more than happy to pay Joe for a kit but unfortunately the shipping costs to Australia tipped it over the edge. I would much rather be spending the money on other components than helping keep DHL, UPS or FedEx in business.

I'll also be checking out Kents excellent Joes CNC in Visalia while I'm over here in a few weeks so I'm looking forward to that.

I'll have lots of questions and have no doubt you guys have all the answers. I can then return the favour to the next rookie that comes along.

Cheers,

Claudio

joecnc2006
06-15-2007, 12:52 PM
Great look forward to seeing it and you converting to metric will help others, and sure people here can help with any question which may arise for you.

and most af all take your time and have fun.... :)

Joe

ClaudioG
06-15-2007, 07:03 PM
Hi Joe,

One question I do have which was asked before here;

http://www.cnczone.com/forums/showpost.php?p=296116&postcount=54

but I don't believe it was answered.

Do you need 3 or 6 Dumpster clamps as it appears as though you are using them at both ends of the the ACME thread in this photo

http://www.cnczone.com/forums/showpost.php?p=296965&postcount=64

Thanks,

Claudio

joecnc2006
06-15-2007, 07:27 PM
Hi Joe,

One question I do have which was asked before here;

http://www.cnczone.com/forums/showpost.php?p=296116&postcount=54

but I don't believe it was answered.

Do you need 3 or 6 Dumpster clamps as it appears as though you are using them at both ends of the the ACME thread in this photo

http://www.cnczone.com/forums/showpost.php?p=296965&postcount=64

Thanks,

Claudio



You will need 6, one on each end of all three axis......as shown in the second link.


Joe

ClaudioG
06-15-2007, 08:41 PM
Thanks Joe.

You might want to edit your original thread here as it states that 3 are required.

http://www.cnczone.com/forums/showpost.php?p=294415&postcount=37

Claudio

ClaudioG
06-16-2007, 01:29 AM
I'm just trying to decide what router bits I should get in the USA to cover me for cutting and carving MDF, HDPE and some aluminium.

Here's what I think is a good start, which I mostly stole from VCarve Pro

- 1/4" End Mill, 2 flute, up spiral
- 1/8" End Mill, 2 flute, up spiral
- 60 degree v-bit (diameter?)
- 90 degree v-bit (diameter?)
- ball nose (diameter?)
- 20 degree Engrave bit (0.02" diameter tip)
- Ogee 1/4" Radius, 1 1/4" diameter x 1/2" deep
- Roundover 3/8" Radius 1" Diameter x 1/2" Deep
- large bit for surfacing

I'm not too sure on what diameter bits to get for some. Any other suggestions? Are some not needed.

Most of what I will be doing is straight cutting, but I like VCarve Pro for the odd sign and would like to try and engrave some aluminium signs as well.

I assume I should be getting Carbide bits.

Can anyone suggest preferred USA based brands, part #s or suppliers.

Thanks

Claudio

Jason Marsha
06-16-2007, 08:31 AM
Here is what I use.

1/4" End Mill, 2 flute, up spiral Whiteside from Routerbits.com ru2100

1/8" End Mill, 2 flute, up spiral Whiteside from Routerbits.com ru1600

5/32" End Mill, 2 flute, up spiral Whiteside from Routerbits.com ru1700

60 degree v-bit 9/16" diameter ( 3 flute) Amana from Toolstoday.com 45733 Rather Pricey

90 degree v-bit 1" diameter MLCSwoodworking.com #7729

These are the bits I use nearly all of the time. Ball ends are in my next order.

Jason

ccsparky
06-16-2007, 08:42 AM
I'm just trying to decide what router bits I should get in the USA to cover me for cutting and carving MDF, HDPE and some aluminium.

Here's what I think is a good start, which I mostly stole from VCarve Pro

- 1/4" End Mill, 2 flute, up spiral
- 1/8" End Mill, 2 flute, up spiral
- 60 degree v-bit (diameter?)
- 90 degree v-bit (diameter?)
- ball nose (diameter?)
- 20 degree Engrave bit (0.02" diameter tip)
- Ogee 1/4" Radius, 1 1/4" diameter x 1/2" deep
- Roundover 3/8" Radius 1" Diameter x 1/2" Deep
- large bit for surfacing

I'm not too sure on what diameter bits to get for some. Any other suggestions? Are some not needed.

Most of what I will be doing is straight cutting, but I like VCarve Pro for the odd sign and would like to try and engrave some aluminium signs as well.

I assume I should be getting Carbide bits.

Can anyone suggest preferred USA based brands, part #s or suppliers.

Thanks

Claudio

Hello Claudio

Most of my bits are 1/4" shank with a few 3/8" and 1/2"
Here are some links to the sites where I've purchased most of my bits.
When given the choice of shank length I normally purchase the longer shank.
I've picked up a few router bit sets from Woodcraft when they have sales. If you subscribe to newsletters you'll benefit from catching the sales when they happen.
As far as diameter goes, When using spiral upcut bits the majority of cutting will be done with 1/8" and 1/4". On the V-groove bit side I just pick up a selection of what ever I can find, however I find that I use the 1/2" the most.

Router Bit World
http://routerbitworld.com/

2 Flute UpCut Spiral
CMT
http://routerbitworld.com/category_s/1304.htm
Freud
http://routerbitworld.com/category_s/256.htm

V-Groove
http://routerbitworld.com/SearchResults.asp?Search=v-groove

Ball (Round) Nose
Freud
http://routerbitworld.com/category_s/175.htm


WoodCraft
http://www.woodcraft.com/

V-Groove 90 degree selection
CMT
http://www.woodcraft.com/family.aspx?familyid=8250
Whiteside
http://www.woodcraft.com/family.aspx?familyid=8053

V-Groove 60 degree selection
CMT
http://www.woodcraft.com/family.aspx?familyid=8252
Whiteside
http://www.woodcraft.com/family.aspx?familyid=8054


Woodworksers World
http://www.woodworkersworld.net/v_groove_bits.shtml


Rockler
http://www.rockler.com/CategoryView.cfm?Cat_ID=271&keyword=router%20bits&cookietest=1&gord=1

Signmaking Set $39.99
http://www.rockler.com/product.cfm?page=17227&cookietest=1


American Carbide
http://www.american-carbide.com/Woodworking/RB.aspx

Hope this helps and have a great time!! :)

Bob

calgrdnr
06-16-2007, 01:46 PM
Nice link list of bits Bob , Thanks I am at the stage I would like some more bits. I bought the sign makers kit from Rockler they just don’t give you to many options. Nice bits though. I can definitely see the ATC in my future also.

Maybe you can make link to this list in the Joes Mods & Tips

Thanks again and no I haven’t forgot about Video will get one done soon I hope .

I am looking forward to meeting Claudio, Hopefully he can get some ideas from my setup .What to do and what not too.


Kent

ClaudioG
06-17-2007, 02:15 AM
Thanks Bob and Jason for the info on the bits. The signmaking set sounds like a good option along with the others.

Kent, I might be able to help with the video when I visit as I bought a new camera today in San Francisco. We're now in Sacramento for about 36hrs staying with my girlfriends (Jen) mother and then driving to L.A.

I'm hoping to drop into Rockler near Anaheim and buy the T-Track stuff and some router bits.

Last night I ordered the ACME and Lovejoys from MSC and the DumpsterCNC stuff so that should be here this coming week. Going to see if the local Lowes has the router otherwise I'll just order it off Amazon along with the ShuttlePro.

The jet lag has been knocking us about a bit so hopefully I'll get a good nights sleep tonight, ready for the big family day tomorrow.

Claudio

ClaudioG
06-17-2007, 01:26 PM
Hey Guys,

I went to Lowe's this morning to checkout the Hitachi M12VC router and noticed a Dewalt DW618 with similar specs but was a 50Hz/60Hz model which would be more suitable for Australian 50Hz power. I've got a stepdown transformer for the voltage conversion.

Does anyone have experience with this model? I've read the reviews at Amazon and they are a little mixed but most seem positive with a few major negatives thrown in so it's hard to make a decision.

The WD618 has variable speed 8,000 to 24,000RPM, soft start, spindle lock (spring loaded so 1 hand need to hold the lock), draws 12A instead of 11A on the Hitachi, 3 1/2" mounting collar (not sure what the M12VC is), 2 1/4 horse. As I said, very similar to the Hitachi.

Here's a link

http://www.amazon.com/DeWalt-Dewalt-DW618-Router/dp/B000BMGLYQ/ref=pd_bbs_sr_3/105-7258188-7207642?ie=UTF8&s=hi&qid=1182101079&sr=8-3

Thanks

Claudio

ClaudioG
07-14-2007, 08:43 PM
Well after spending 3 1/2 weeks in the USA, I've come back home with some hard or impossible to get items as well as some things which were cheaper than what they are here.

I went for a DeWalt DW618 router instead of the Hitachi because the DeWalt is rated at 50/60Hz and we use 50Hz power in Australia. I also bought a 2nd hand 1500w step down transformer in Australia before heading to the USA.

Some nice features of the DW618 are the removable power cord and spindle lock. Hopefully the quality doesn't let me down. This is a factory refurb model which I'm hoping has had a bit more time checking it out that the production units, but I could be wrong.

Here's a detailed spreadsheet with all the bits I bought and photos of the collection so far.

One item not shown is the digital camera I bought as well which is a Panasonic DMC-FX50. Very happy with the picture and video quality (check out Kents log for some I shot).

Lots of fun shopping around for this stuff.

Claudio

bp092
07-14-2007, 10:00 PM
Nice purchases! Looks like you have quite the array of tooling as well. Where did you get the spray gun? Any reason why you bought so many (looks to be) 1/4" spirals? Also how much did that usb jog device cost you? I think david has one of those as well.

ClaudioG
07-15-2007, 03:19 AM
The spray gun is a Lowes Kobalt home brand model. Looks like fairly reasonable build quality.

When I went to Rockler in Anaheim, I bought 2 High Speed Steel 1/4" up spiral bits as they didn't have the carbide ones in stock. Then I went to Woodcraft in Sacramento and bought a Whiteside solid carbide one. And when I visited Kent, he mentioned he got some HSS ones for $2 from Harbor Freight, so I decided to buy 10 of them to play with. I also bought a diamond coated set of bits for playing around with engraving glass and porcelain while I was there.

The ShuttlePro was US$80 inc shipping to Sacramento off ebay.

Most of these details are in the spreadsheet I attached.

Cheers

Claudio

crocky
07-15-2007, 05:30 AM
Hi Claudio,

Thanks for the tip on the Shuttle Pro, just bought one from ebay :)

You are getting a good lot of gear for that CNC....

Bob

ccsparky
07-15-2007, 08:49 AM
Claudio,

You got that thing built yet? ;)

Nice collection!
What is the large bit below the Rockler sign making bits, straight down from the T-9 bottle?

Thanks,

Bob

ClaudioG
07-15-2007, 03:44 PM
Claudio,

You got that thing built yet? ;)

Nice collection!
What is the large bit below the Rockler sign making bits, straight down from the T-9 bottle?

Thanks,

Bob

Almost finished Bob ;)

That bit is a Whiteside 1" cutting diam. straight bit which I will be using to plane the sacrificial board so that it's level with the machine.

Claudio

Reflow
07-18-2007, 08:37 AM
Hi Claudio,

Sounds like you had a good trip. I'm definitely jealous of all those goodies you brought back. :)

On the off chance, did you look into posting any of that stuff back while you were over there? I have come unstuck trying to find lead screws for my machine here. Was considering getting someone over there to forward the screws from enco or mcmaster-carr to me here, but have no idea if it is possible to send a 2m tube back and what it would cost. The USPS website refers to a restriction of 3ft, but it's hard to tell if that applies to a mailing tube or just big boxes.

--Scott

ClaudioG
07-18-2007, 04:43 PM
Hi Claudio,

Sounds like you had a good trip. I'm definitely jealous of all those goodies you brought back. :)

On the off chance, did you look into posting any of that stuff back while you were over there? I have come unstuck trying to find lead screws for my machine here. Was considering getting someone over there to forward the screws from enco or mcmaster-carr to me here, but have no idea if it is possible to send a 2m tube back and what it would cost. The USPS website refers to a restriction of 3ft, but it's hard to tell if that applies to a mailing tube or just big boxes.

--Scott

Hi Scott,

I called and then emailed MSC about sending stuff to Australia and they were meant to get back to me with a quote but never did. They said they do send to Australia.

Try sending an email to barrass@mscdirect.com and request a quote for the following to be sent to you in Australia and see if they reply.

2 x 01205996 1/2-8 2 Start Precision Acme Threaded Bar (6ft)

These are the new 2 start ones that Joe and others are now using, which are more expensive that the originals but work a lot better. You'll also need the DumpsterCNC stuff but that's easy to ship here due to lack of weight.

I'm pretty sure you cannot send it USPS but if you can email someone at USPS as well, it might be worth a shot.

If you look at my spreadsheet, you'll see that total weight for the 2 ACME's including tube is 10 lbs (4.45kg) and size of the tube is 6ft 2 1/2" long by 3" diameter

Did you try getting in touch with the guy in Melbourne about the ACME's?

I bought a spare set of Lovejoys if you are interested. The ones at Jaycar will need the ACME to be machined to 1/4" at one end. If you have spare bearings left over then I might be interested in those.

If there's anything else that you need that isn't so large that they won't ship to Australia, let me know as I can probably arrange forwarding.

By the way, how's your project coming along?

Cheers

Claudio

Reflow
07-19-2007, 07:26 PM
Hi Scott,

I called and then emailed MSC about sending stuff to Australia and they were meant to get back to me with a quote but never did. They said they do send to Australia.

Try sending an email to barrass@mscdirect.com and request a quote for the following to be sent to you in Australia and see if they reply.

2 x 01205996 1/2-8 2 Start Precision Acme Threaded Bar (6ft)

These are the new 2 start ones that Joe and others are now using, which are more expensive that the originals but work a lot better. You'll also need the DumpsterCNC stuff but that's easy to ship here due to lack of weight.

I'm pretty sure you cannot send it USPS but if you can email someone at USPS as well, it might be worth a shot.

If you look at my spreadsheet, you'll see that total weight for the 2 ACME's including tube is 10 lbs (4.45kg) and size of the tube is 6ft 2 1/2" long by 3" diameter

Did you try getting in touch with the guy in Melbourne about the ACME's?

I bought a spare set of Lovejoys if you are interested. The ones at Jaycar will need the ACME to be machined to 1/4" at one end. If you have spare bearings left over then I might be interested in those.

If there's anything else that you need that isn't so large that they won't ship to Australia, let me know as I can probably arrange forwarding.

By the way, how's your project coming along?

Cheers

Claudio

Hi Claudio,

Thanks for the contact at MSC, I fired off an email last night so I'll wait and see if I get a reply.

Postage for such a long tube seems like a real drag, I haven't spoken to anyone at USPS but from the website the chances don't look good. It seems to be ok on both the FedEx and UPS shipping calculators though. The cost on the other hand is a bit annoying us$160 for 75" 10lbs mailing tube. Neither seem to have a budget shipping option so that is overnight express pretty much. Interestingly I have been toying with there calculator and you can send anything upto 9ft long, shipping price is purely a weight thing. Need to find someone else who is interested in buying some you get a better deal shipping 20lbs than 10. $102 ACME, $115 postage anyone?

As for getting ACME in oz, I didn't give the guy in Melbourne a call. The prices from the other post looked good, but none of the thread options match what is available from dumpster. The same goes for other sources, Hobson who make a lot of fasteners actually make a 12ft length of 6TPI acme in a lot of sizes from 1/2" up. It's cheap for oz, $150 a length. But I'm guessing whatever nut arangement I use it will never be as good as getting the dumpster nuts.

Thanks for the offer on the couplers, I'll see how I go. If I make a dumpster order I was going to try his couplers with the acme thread cut into them. Although they probably won't be as forgiving about miss-alignement as the lovejoys. I really want to avoid any end machining. I actually got a quote for ballscrews since the ACME option is looking expensive anyway. The screws and proper end mounts where ok, but it was 3 lots of machining that pushed the price over the top.

I'll have to check how many I have left. I sorta went nuts when I had 100 of them and started using them for other things. We built some mates a camera dolly using 4 of the same angle and bearing setups as the machine uses. It runs along 1" PVC pipe tracks, with internals joiners so there is no bumps at the joins. Runs pretty smooth.

Thanks for the forwarding offer. I might be pushing my luck but the tube with the ACME would probably be handy if I go down that path. I'd arrange for UPS or FedEx to do a pickup. So would only need to be be there to receive it, put my address on it, and send it out the door. But I would well understand if thats too much of a pain in the arse.

I'll post some more progress in the other thread. If I get time this weekend I'll post some of my modified drawings for metric MDF as well.

--Scott

ClaudioG
07-31-2007, 06:16 AM
Well I finally got a chance to do something with the bits I've got so far.

Before I headed off to the USA, I bought an old step down transformer off eBay from someone in South Australia for AU$100 shipped. I received it a few days before I left and plugged it in straight away and it tripped my safety switch in the switch board so I was a bit annoyed. I didn't think I got ripped off but figured something happened during shipping. But didn't have time to mess with it up until now.

I checked out all the wiring and it looked OK, but I rewired the wall plug anyway. Plugged it in, stood back and powered it on with an insulated screwdriver in my hand, and nothing happened which was great. I then checked the output voltage and it was measuring around 121 Volts which was fine. Plugged the DeWalt router in, switched it on, then nothing!! Forgot to switch the transformer back on, doh! Switched it back on again and heard the purring of the router, and then I smiled from ear to ear :)

So for a total of around AU$230, I've ended up with a reasonably powerful variable speed spindle for use with the Joes CNC.

As mentioned previously, the DeWalt DW618 is rated at 50/60Hz so should operate at the correct speed over here and hopefully without the heat issues of 60Hz only routers.

I also bought an 8ft extension cord, so together with the removal power cord that came with the router, I should have a total of about 12ft to use which should hopefully allow me to mount the step down under the router.

As you can see in the photos, the step down is an old clunker of a thing weighing in at 16KG (35lbs) but it works.

Cheers

Claudio

calgrdnr
08-01-2007, 12:09 AM
All right Claudio power for the spindle this must mean we should see another working Joe 2006 soon :)

Glad to hear you have completed another step ... hows the renovation going ?

I was just thinking. you already have two 6 foot screws .. You must be able to get Uni strut, It might be easier for you to make Joes latest. alot less conversion I would think ... just a thought. I really enjoy the 2006 . but I am thinking would be nice to have 4x4 or even 4x8 :D Maybe next year when I have more experience.



Kent

ClaudioG
08-01-2007, 12:18 AM
A small step, but an important one for me as the local suitable alternatives are few and far between as our router designs are based on fully integrated plunge base which are not that suitable for mounting on an overhead gantry.

The renos are going very slowly, as I've been flat out with my business and the guy doing the structural work has been busy too.

I must admit Joes 4x4 looks a little easier to construct, so if Joe decides to release his new plans and the timing is right then I might consider it. Mind you, I'd have to find space for a 4x4 first.

Claudio

ClaudioG
08-02-2007, 09:40 PM
Hi Claudio,

Thanks for the forwarding offer. I might be pushing my luck but the tube with the ACME would probably be handy if I go down that path. I'd arrange for UPS or FedEx to do a pickup. So would only need to be be there to receive it, put my address on it, and send it out the door. But I would well understand if thats too much of a pain in the arse.

--Scott

Hey Scott,

Just realised I didn't respond to this. If you want to go down this path then I'd be happy to organise the forwarding. Once delivered, arranging pickup is always difficult from a home so I should be able to get them to drop it into a UPS or FedEx store for you.

It would definately be worth getting others to help out with a bulk order and split the shipping costs. MSC might then also be more willing to ship directly if the order is of greater value.

The tube weighs 3.85lbs and each 6ft ACME weighs 2.97lbs. Mine didn't come individually wrapped in the tube and I was concerned that they may have been damaged rattling around together, but they appear OK. I did wrap them before carrying them back with me though. Maybe MSC can wrap each if requested.

Cheers

Claudio

ClaudioG
09-15-2007, 10:02 PM
Well there's not much happening in my CNC world as I've been busy running my business and renovating my house.

After many unsuccessful emails and phone calls to MSC to try and get a quote to ship some Acme to Australia, I finally got a response.

To ship 4 x 6ft Acme weighing about 16lbs, they want to charge US$765.00 for shipping!! And that doesn't include the $204.00 worth of product. I guess they don't really want to ship stuff to Oz as UPS only charge about US$230 for the shipping.

Fortunately I managed to bring back some for myself but I was hoping I could line something up for current and future builders of Joes and other CNC machines.

I've just ordered a 4 axis HobbyCNC kit and will be buying one of widgitmasters midi routers to help try and cure my CNC bug while I don't have the time to build the Joes. This will be a good training ground for me and give me a very capable portable machine when the need arises. More info on the machine can be found here;

https://widgitmaster.powweb.com/midi-router.html

and he has very detailed logs of how he built them here http://www.cnczone.com/forums/showthread.php?t=37739 and http://www.cnczone.com/forums/showthread.php?t=21872

I will try and run a more beefy spindle than the Dremel or Proxxon though.

Cheers,

Claudio

calgrdnr
09-16-2007, 02:15 AM
[HTML][To ship 4 x 6ft Acme weighing about 16lbs, they want to charge US$765.00 for shipping!! And that doesn't include the $204.00 worth of product. I guess they don't really want to ship stuff to Oz as UPS only charge about US$230 for the shipping.
/HTML]

Hmmm Maybe they wanted to deliver it in person .. wow hate to see what they would charge for Joe's Kit...

Glad to hear your still going to build one thought maybe you would be closer to starting ... all those part you got lying about ... It would drive me crazy :) I still need to lock mine down to the wall ,cut the lumber today. but had another project needed finished first. Making a stand for a swamp cooler going to try cool shop down next summer ... It should help but some days it will be to humid out. so I will just have to work with VCarve in the house :)

Let use know when you get started... so we can hound you to get it up and running :)

Kent

ClaudioG
09-25-2007, 06:34 PM
Well still not a lot happening with the Joes but I did order a HobbyCNC 305 kit and I also ended up buying a WidgitMaster midi router as I couldn't bear to wait any longer. Yesterday was like Christmas as they both arrived and I bought some spindles to play with as well.

The Joes will still happen but time is a major problem for me over the next few months at least. And it will also give me a bit more time to decide which Joes I build, assuming plans for the 4x4 will be released. I should also be able to use the midi to cut some of the small parts.

More info on the WidgitMaster midi can be found here.

http://www.cnczone.com/forums/showthread.php?p=346834#post346834


Cheers,

Claudio

ClaudioG
10-20-2007, 05:45 PM
It's been a while since posting so I am going to try and catch up on the last few weeks with the next few posts.

This thread started as a Joes log, but it's going to take a slight diversion before getting back on track with a Joes 2006 or 4x4 early next year. Most of what I post here will be relevant to the Joes anyway, with the odd bit of WidgitMaster tidbits thrown in.

On the 28th September I decided to start assembling the Hobby CNC Pro board. All was fairly easy given the great instructions provided and the only mod I made was that I used removable Phoenix connectors instead of the supplied blue screw terminal blocks. I believe using removable connectors is not recommended but I thought it would make testing and servicing down the track a lot easier. The only downside I can see so far is that the pinout etchings on the PCB for each of the connectors are covered up by these connectors.

Soldering the board took about 3 hours, with only one mistake at step 16 which was putting the LM317 in where the LM317HV was suppose to be. Even though the instructions VERY CLEARLY stated not to do this. So I probably lost 1/2 hour because of having to remove this component and soldering in the correct one.

I used a 12VDC 500mA power supply to test for +5VDC before installing the driver chips and was in range at 5.04VDC. Then once the remaining components were soldered in, I set Vref to 0.42VDC for each of the 4 Axis for the 305oz 3A motors I have.

Cheers,

Claudio

ClaudioG
10-20-2007, 07:03 PM
Assembling the case and power supply was a bit more of a challenge as the recommended Pactec DM-4 is not easily sourced in Australia and expensive and the power supply needed to be a 240V model.

So on 7th October I went to my local Jaycar store and picked up an ABS plastic 3U rack mount case kit (HB5155), 12V+12V toroidal 12.5A transformer (MT2130) and a few other bits. I also got a removable IEC 240v panel mount power socket (PP4005), some plastic knobs to go on the unused ends of the stepper (HK7742), some molex style connectors for each of the motors (PP2024) and a 2A slow blow fuse to use instead of the supplied 4A (for 240V instead of 110V).

Assembly started as soon as I got home but would be spread out over the next week or so.

Once the main components were assembled on the case, it came time to test the power supply and make sure I wire up the 12V + 12V in series correctly in order to get me 24VAC at 12.5A.

So I hooked it up, stood way back and switched it on, measured the voltage and got nothing! Forgot to switch it on at the front panel so tested again and this is what I measured;

243.7VAC from power outlet at wall.
25.8VAC output from transformer connected in series
32.7VDC output after rectifier

I was happy with that so connected up the HobbyCNC Pro board and measured the following;

23.95VDC at fan output
5.05VDC on the board at +5V

vref was reset to 0.42VDC for my 3A 305oz kit

All was good.

So I put a removal power cord in, removable molex connectors on the motors (with nylon cable braid) and will be putting in a panel mount DB25 connector on the back with a short fly lead inside the case to the HCNCPRO board, and removable connectors on the front panel for each of the motors once I find a suitable connector (any suggestions welcome).

Unfortunately the case seems a bit flimsy given the weight of the power supply so I might need to switch to a more sturdy metal one in the future.

The red cap on top of the large capacitor is from a butane refill bottle for my gas soldering iron. I stole the idea from Kent when I visited him in Visalia in June. This one snaps perfectly on top and a gillette shaving gel cap works just as well, with the added bonus of being clear so you can see what danger is beneath. The extra height of this case also allows me to stand the capacitor upright, which I assume is OK?

A bit more work is needed on the case but couldn't wait to get the machine working!

Cheers,

Claudio

ClaudioG
10-20-2007, 08:05 PM
Wiring up the motor ends with the Molex connectors was time consuming, stripping, crimping, soldering and inserting each strand but hopefully it's worth it in the end allowing me to easily remove and or swap out a motor if needed.

After doing each one, I connected the steppers to the HCNCPRO board, switching on the power supply and checking to make sure the motors at least locked up signifying they were getting some sort of power from the controller.

Finally after a week of fitting this work in between other commitments, I had all motors wired up and ready to go by the night of Sunday 14th October.

I had Mach3 already installed on one of my PC's, so I moved all the equipment into my lounge room (which is currently a construction zone), hooked it all up, configured it as per the great instructions and tutorials and I was able to get movement from each of the motors.

So I connected them up to the WigitMaster Midi and was able to move each of the axis.

Initial tests were done using an eval copy of Mach3, LazyCam and a 1/8" end mill on my Dremel Clone (Ozito from Bunnings) spindle. First off I did an air test by raising the Z above the work area and it appeared to be doing the right thing. It was now time for some sleep!

The next morning I put a test piece down and carefully held it by hand (wouldn't suggest doing this) I was able to cut an ABC but didn't look very good. It got better after some fine tuning of the motor settings in Mach3 and gradually got to a point where I was happy. After applying some silicon spray to each of the ACME's the machine appeared to be running well and the motors sounded good too!

I loaded up my eval copy of Vcarve Pro 4 and was able to find a sample that I could carve up with my limited range of dremel bits. I picked out some text from one of the samples and gave it a go. It looked great and the accurancy seemed to be pretty good.

I've been quite impressed with what others have managed to achieve with the Vectric software and what I just saw for myself, so I decided to drop ~US$1,000 on Vcarve Pro, PhotoVCarve and Cut3D. Our exchange rate is so good at the moment and you end up saving a little by buying the bundle so it was a relatively easy decision.

Cheers,

Claudio

ClaudioG
10-20-2007, 09:21 PM
I was now ready to do some testing of accuracy so I hopped on to Vcarve Pro and drew up a 1" circle and square then copied it so that I could test out a set of cutouts and a set of pockets.

The tests didn't come out all that great but were very close. I soon realised that the 1/8" end mill I was using wasn't quite 0.125" diameter I setup in VCarve, it was 0.120" so that would probably explain it. But I was out of time and would spend any other spare time playing with some more VCarving and worry about getting the accuracy sorted later.

Here's a quick sample video of the machine in action. I've got loads more but youtube doesn't appear to like uploading large files. And a photo of the end result.

http://www.youtube.com/v/fzQKDZ2MRS8

Actually, after I shot this video I decided to try and pause the machine as my crude little vac setup was getting too close to the material and it had a bit more depth to go. When I resumed the Gcode running I obviously did something wrong as the machine ended up being repositioned without raising the Z axis so I ended up forcing the spindle with the bit across the MDF and doing some damage to the bit and probably collet. Oops!

I ended up returning the Ozito rotary tool and swapping it over for a Dremel 300 as I wasn't happy with the collet. It's a lot better now but still want something a bit more powerful and with more bits available.

Later in the week I quickly drew up a prototype clamp in VCarve for a larger spindle with a 43mm mount, which is initially an Ozito router but will be a Milwaukee or Metabo if it works out. I cut it out of MDF (at around 9:30pm so my neighbours probably aren't happy) and it fit nicely. Still a bit more work to do on the design and to see if it will actually work on this machine, given it's 3 times the weight of a dremel. Then I'll cut it all out of HDPE and then possibly aluminium if I can.

I thought I'd also better make something quickly for my girlfriend, as I was spending far more time with the machine than with her!

And I then repeated the accuracy tests with results that impressed me! This is far more accurate than I could ever have imagined and need. So 0.001” translates to about 25 1000th's of a millimeter.

Cheers

Claudio

sc351cobra
12-02-2007, 12:12 PM
Claudio
Just found this thread. I am thinking of getting a midi. Saw your videos. Is spindle motor making the most noise?
How about some more pictures of the midi.
Thanks Lonnie

ClaudioG
12-02-2007, 02:42 PM
Claudio
Just found this thread. I am thinking of getting a midi. Saw your videos. Is spindle motor making the most noise?
How about some more pictures of the midi.
Thanks Lonnie

G'Day Lonnie

The spindle can be noisy at higher speeds so I try and keep the speed down if I can.

I'm busy with house renovations at the moment so the machine is packed away. If you are after specific photos then let me know and I'll see what I can do.

Can highly recommend the machine.

Cheers,

Claudio

Khalid
01-21-2008, 11:32 AM
good job:) keep posting ur artwork:)