And now for something completely rediculous

[Riceburner98]

Damn that's nice! Better than most of the Chinese castings that come on tools these days! No need to cover it with 1/4" of bondo and paint like they do... Out of curiosity, how much $ does it take to cast a 1-off of something like that if you supply a completed pattern? Do they charge by the pound, by time, both, or...? I can only imagine the stuff you'll make on that new beast of a machine!

[spoiledbrat]

I think they charge a little of both. Although we supplied the pattern, there was considerable form-work to accomplish. Several 2 x 12's, metal weldments to facilitate hoisting and flipping the boxes, and some decent carpentry to make the core-box for the area beneath boss for the lead-screw (vise).

The casting weighed 475lbs. Material consistency is excellent, based on later machining (for testing) of the risers and flue. Total cost for their iron and services was $1850.

This is higher than we were quoted, but the quote was based on a very rudimentary drawing, with less material. In the pursuit of the most excellent band saw ever, this cost is acceptable to us, and we would do it again.

Again, this is not my band saw. My machinist is spending 10X what he would have to to buy a band saw of similar capacity. There are bronze guide-rails for the blade tightening assy, among other rather exotic features. I realize this may seem silly to spend so much on this item. I think he would argue that this is functional, mechanical art.

Rob

[jsheerin]

Hi Rob,
Really nice casting - way nicer than any I have done. Out of curiosity, how did you find this place? I have some items I may want cast in iron in the future.

John

[spoiledbrat]

My friend found them in the yellow pages... Clarksville Foundry. They have been in business since before the Civil War. I may be speculating here, but I would think that most larger towns/small cities have a foundry. Those man-hole covers have to come from somewhere!

Rob

[spoiledbrat]

Another pic just came in from Taiwan... Thanks Kirk!

Rob

[eloid]

Another pic just came in from Taiwan... Thanks Kirk!

Rob

i dont think your going to need those cement pads you have.

[quadtech]

Those man-hole covers have to come from somewhere!

Rob

It's the global era. Some pics from New York :-)

[ktb100]

Another pic just came in from Taiwan... Thanks Kirk!

Rob

My pleasure. I will get more after paint. As for the man hole covers..... wow I had no clue.

Kirk

[spoiledbrat]

That is shocking. India and china? Maybe we don't want jobs here.

The cement pads are meant to bring the worktable up to approx 39 inches. I realize this is high for some people, but I am kind of tall, and so is the wife. I like a worksurface to be approx 6 inches below my elbows.

Besides that, I do not have the technology to get rid of those if I wanted to

[vishnu]

What advantage did you find having the frame made in Taiwan. Price or Time, Cos your country is better equipped. I have my next machine designed on 300 X 200 x 8mm thick tubes. Any input regarding the same would be of immense help.

[spoiledbrat]

I have never attained a formal quote within the USA. Would anyone with these capabilities in the states like to post a rough estimate of this machine frame cost within the states?

Machinework includes milling the shoulders for the rack/rail to include drilling and tapping for mounting hardware. This will occur on both the main frame, and the gantry beam. Cost should include 4500 lbs of steel!

Once I see a few rough estimates from capable shops, I will post what I am paying for these services. I feel that I am getting an excellent service at the right price.

Rob

[Khalid]

Hi Rob,
Will you cut steel on your this machine?.. The size and weight tell me that you will drill and mill Ferrous metal on this machine?

[spoiledbrat]

Khalid,

Nope. Just overengineered to cut wood. I wanted this machine to be as rigid as possible for quality of cut, with mass to absorb vibrations. The Y-Z carriage will be made of aluminum.

I may do some light cuts on aluminum if I am feeling silly; but I never designed this to cut ferrous metals.

Rob

[mactec54]

Hi spoiledbrat

It looks like the guys who poured the casting new what they were doing as well, they did a great job of the casting

[Khalid]

Hi Rob,
I have MDF machine that cut 200 IPM and the quality is great. You can see my work at following blog
www.my-woodcarving.blogspot.com

For me, Your this machine can cut Ferrous metal very easily
Regards

[ger21]

I have MDF machine that cut 200 IPM and the quality is great.

But can you cut 1" thick in 1 pass at 1000ipm? Rob might be able to.

On our big router at work, we don't cut anything slower than 500ipm, and rarely make more than 1 pass. Most cuts are done at 750ipm and up.

[spoiledbrat]

Ger,

What size servos would you put on this thing? I am still looking at 1Kw low inertia servos on all axis. I have run the SigmaSize software, and came up with excellent numbers on the 1Kw. A similar size/weight machine that I have seen only had 750w servos for the X.

Rob

[ger21]

I have no idea. But, I'll look at our Morbidelli on Monday and see if I can tell what size it uses.

[mactec54]

Hi spoiledbrat

I would stick with what you have picked 1Kw for your X axes any way, 850W would be my next choice, I would of gone with the 850W because you are gearing this way down
so the 850W would have enough power to move your monster

With the 1kw you most likely don't need to gear it down so much, & that will give you more speed in your X axes, which you will need

[ad_bfl]

Quick question, are you going to have the welded frame stress relieved prior to rough machining and then again after rough maching/before final machining?