A Texas rebuild…

This topic contains 33 replies, has 7 voices, and was last updated by  Jeffeb3 4 months, 1 week ago.

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  • #63919

    dkj4linux
    Participant

    On a sad note, back in May, my fishing/flying/golfing buddy passed away suddenly. He was the second of my two best friends lost in the last 11 months. Thankfully, neither of these men experienced prolonged suffering and were actively engaging in the things they enjoyed most up until the time of their passing. We’d all spent many great times together and they are both sorely missed.

    On a brighter note… back when we were actively building and flying our foam RC planes, I’d built Henry a MPCNC-based needle cutter setup… and, with his passing, the family has given that machine back to me. Since I already had a needle cutter setup of my own, I decided to scrap out his machine and rebuild/update it in a smaller form factor and suitable for light milling operations. i’d already purchased a Dewalt 660, way back when, for this very purpose.

    I spent several days printing all the new parts on my Prusa I3 MK2S and have begun assembling a 29″ x 29″ footprint machine. I’ve put it on a 30″ x 30″ wooden base… 1″ x 4″ whitewood boards, Kreg-jigged together, in two layers and with overlapping corners. The machine is essentially complete, mechanically, and now needs to be belted and wired up. I could reuse the old motors, of course, but I’ve decided to wait on new steppers, with longer leads/connectors, and a series wiring harness from Ryan… just to try and do it up to current standards. Those parts are due to arrive Wednesday… thanks, Ryan, for the prompt shipping!

    The following photos document my progress to this point — printing new parts, dismantling the old machine, and building up the new…

    More to come later…

    — David

     

     

     

    #63929

    Brandon
    Participant

    Sorry to hear about your loss of friends. 🙁

    So you’re downsizing to smaller dimensions. Did you have trouble with the larger size or did you get the old one working?

    -Brandon

    1 user thanked author for this post.
    #63936

    Jeffeb3
    Participant

    Sorry for your loss. It’s nice to have something to remember him by that also has a purpose. Seems like a good fit to me.

    That looks like a nice tight build. Should be a lot of fun. Are you going to mess with the PID controller for the dw660?

    1 user thanked author for this post.
    #63937

    dkj4linux
    Participant

    Brandon,

    I’ve built numerous MPCNCs for myself, and my friends, and have several MPCNCs, and variant machines, on hand now. This was a 4′ x 3′ footprint, original-design, MPCNC that carried a needle-cutter (a very light load) for cutting out RC planes and parts from 20″ x 30″ foamboard sheets. It worked great and was used by my buddy to cut out numerous planes… but I have one that size already and don’t need another. I haven’t used any of mine for milling harder materials in a while, however, and decided to upgrade to the latest and give it a go. It keeps me busy and off the streets… =;^)

    — David

    #63938

    dkj4linux
    Participant

    Hey, Jeff… thanks a lot.

    No real plan to do the PID thing but won’t rule it out on down the line. I thought I’d let you younger, smarter guys do all the “pioneering” on that front.

    — David

    #63980

    Ryan
    Keymaster

    Rough news, sorry to hear it. I think that is kind of a cool thing to do. A rebuild to remember.. Sounds it would have been be appreciated. I have some mementos, but that is just too cool, and it looks great!

    Can’t wait to meet these young pioneers…

     

    1 user thanked author for this post.
    #64005

    Otto
    Participant

    Hey dk where about in Texas are you? If your close to Houston, do you feel like helping an obnoxious kid out with some problems every once in awhile? You seem like you have a pretty solid grasp of these machines….

    #64026

    dkj4linux
    Participant

    Hey, Otto. Grumpy old man and “obnoxious kid”… what a match  😉

    Actually, I’m up in rural East Texas… about 65 miles southeast of Dallas. I’ve got a reasonable grasp of the basic machines and don’t spend a lot of time “accessorizing” them. KISS is king IMHO and Ryan’s original MPCNC design concept suits me just fine 🙂

    — David

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    #64048

    dkj4linux
    Participant

    I finished modding the Dewalt (removed the tool-free collar) and mounted it on the tool mount. Looks as though I easily have 17″-18″ of usable work area inside the frame. Should be plenty for most things I envision doing  🙂 :)

    My new stepper motors have made it to the post office this morning… hoping in time for delivery today. I want the longer leads and connectors so that I can use the series wiring harness I’d already purchased from Ryan. I’m trying to do this build as close as I can to the current MPCNC “standards”… — David

    1 user thanked author for this post.
    #64110

    dkj4linux
    Participant

    Mailman just delivered my new stepper motors. Also whipped up a stand for the new MPCNC… 28″ x 28″ and 30″ high.

    #64114

    Jeffeb3
    Participant

    Is that glass so you can convert it to a ZXY when you’ve got enough sawdust 🙂 ?

    I’ve never thought about using dust instead of baking soda. That might be pretty fun.

    #64119

    dkj4linux
    Participant

    Yeah, that’s a heavy 30″ x 30″ glass table top that I’ve had for years… purchased very early in our marriage, the frame is long gone.

    Don’t see a ZXY in my future… but I do look forward to seeing how that base frame might be used to advantage; i.e. dust containment, spoilboard with wedges, etc. It definitely makes the machine more sturdy when you’ve got to move it… and it sits nicely flat and solid on that piece of glass. I’m just hoping that it never gets in the way… 😉

    #64331

    dkj4linux
    Participant

    Aside from the balmy 109 degF temperatures outside, it’s been a pretty good day so far… postman is supposed to deliver my series wiring harness, been watching some really great golf on TV at The Open… and all while working on the MPCNC rebuild…

    =8^)

    #64335

    Ryan
    Keymaster

    109!!! I will not complain about it hitting 99 here. Dang.

    #64341

    dkj4linux
    Participant

    I’m sure Jason (jhitesma) is thinking 109 degF is down-right cool…

    #64512

    dkj4linux
    Participant

    Alright! Attempting to not be so “stuck-in-the-mud” for a change… here’s the near-finished (a few cosmetic things yet to do), and calibrated, Texas MPCNC rebuild. I hate to admit taking as much time as I did to get it running… mostly having to overcome my old mindset/procedures/workflow/senility and dealing with some dodgy, used, RAMPS hardware/drivers. Lots of “new” stuff for me to take in… the latest firmware, full-graphic LCD, T8 leadscrew, series stepper wiring, standard tool mount, etc. Whoa… overload! 😉

    But here it is — the new machine and stand… and obligatory crown plot!

    I’ll probably play with it for a few days — plotting, lasering, etc. — but I eventually plan to hang the Dewalt 660 on it and do a little light milling. Biggest hangup for me there is the noise and debris — and the current 110 degF Texas heat! — but I plan to set it up out on the deck, just outside the door, so I can quickly step outside for a minimal amount of time.

    Think it’s time for a nap… been workin’ so hard…

    — David

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    #64548

    Jason Dentler
    Participant

    and the current 110 degF Texas heat! — but I plan to set it up out on the deck

    I 1000% percent agree. My MPCNC is on wheels so I can take it to the back porch, listen to audio books, and sip a beverage.

    #65115

    dkj4linux
    Participant

    An update…

    I’ve done a few more pen-plots and I’m running out of excuses to not try a milling exercise. It’s still pretty warm outside and there are a couple of things that really should be done but nothing that should stop me from doing some preliminary cuts…

    Maybe tomorrow  =;^)

     

    3 users thanked author for this post.
    #65142

    Ryan
    Keymaster

    Yeah buddy that is looks finely tuned!

    1 user thanked author for this post.
    #65145

    dkj4linux
    Participant

    Thanks, Ryan. One of those things I noticed I need to do is change that arc segments value from 1 down to 0.1… that MPCNC logo shows that clearly. You had mentioned you might change that but it wasn’t the case in the latest firmware download.

    BTW congratulations on the new LowRider2 release… looks to be a tremendous success already. Great work… as usual!

    2 users thanked author for this post.
    #65151

    Ryan
    Keymaster

    arc segments value from 1 down to 0.1

    I need to double check them all I just looked and I have changed the dual marlin 2 to 0.15, maybe I missed a few firmware versions. I need to to get in there and get a Marlin 1 set in there so it is easy to flash again.

     

    BTW congratulations on the new LowRider2 release… looks to be a tremendous success already. Great work… as usual!

    Thanks, super cool day!

    #65516

    dkj4linux
    Participant

    Finally got off my lazy butt and prepared a little first MPCNC milling project. I tried to duplicate a small, milled, box enclosure for a pot I installed on one of my earliest BuildYourCNC-inspired machines. I took measurements, prepared a DXF using Onshape, brought it into Estlcam, and generated the gcode file… using Ryan’s intermediate milling tutorial as my guide. Then, of course, I found the rattiest, most twisted, piece of pine I could find… just to make this more of a challenge. Oh… and it was a full 3/4″  thick, which required pressing the stop collar off my 1/8″, single-flute, endmill. Finally, after all that, a part was produced… useless but successful   =8^)

    Old pattern part… I left off the notch…

    Surfaced 1mm off top of material first… shows the twist pretty well…

    Bottom side… almost complete through cut…

    New part with old pattern parts…

    I’m pleased. Hopefully, having now worked through the procedure, I’ll not be so lazy/reluctant about doing more of this stuff in the future…  😉

    — David

     

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    #65525

    Ryan
    Keymaster

    Nice. I recently looked at the intermediate tutorial….it needs some work. It is a bit hard to follow so I am glad you got through it.

    That board is as twisted as it gets! I bet the bottom didn’t finish because as you cut it probably started springing in a different direction.

    #65528

    dkj4linux
    Participant

    Nothing seemed stressed at all… this whitewood is super soft. Actually the part that’s not completely cut through (it was paper thin) is the part that was best supported underneath and against the spoilboard. I just didn’t compensate for the twist when setting DOC… 😉

    The guide was okay once I started concentrating a bit harder and really thinking through what you were saying. I thought about doing  your LCD endplate as my first milling project but decided that, without taking time to do the other endplate as well, I’d do something similar but simpler… 😉

    #65675

    dkj4linux
    Participant

    Alright! What should be the last update to my MPCNC milling adventure…

    The initial project successful — but pretty useless except for the learning aspect — I decided to commit to a real project… Ryan’s LCD enclosure endplates. Using Onshape, I imported the “left.DXF” file (from the intermediate tutorial) into a sketch and mirrored it to model both ends. Exported the dxf and used Estlcam to create the gcode. Found a 10mm thick, laminated flooring, cutoff from my scrap pile, and set  it up on the MPCNC. The laminated hardboard flooring milled beautifully and I couldn’t be more pleased with the result…

    — David

    #65685

    Jeffeb3
    Participant

    That’s flooring? It looks great.

    1 user thanked author for this post.
    #65687

    dkj4linux
    Participant

    Yep! The kids selected it when they/I remodeled my house… before they moved off to San Antonio. Got  it at Lowes. It’s a laminated hardboard/MDF (?), with smooth Melamine(?) and attached foam padding on the back… wood-grain pattern on top. Fake, but looks nice, and replaced a lot of old worn out carpeting… and I’ve got plenty of extra. May have to glue up a couple of panels and cut LR2 parts… if/when I get a bit more ambitious  =8^)

    #65690

    Ryan
    Keymaster

    Looks awesome, That is one of my favorite parts. I sold my display at MRRF but I didn’t want to let go of the ends caps I first milled, I brought them home.

    1 user thanked author for this post.
    #65694

    Jeffeb3
    Participant

    I wonder if it would fit on one of those free samples, I have a box of those. They seem pretty tough/dense, so they would be good for stuff like this.

    We are planning on doing the same thing with the floors on the first floor. We basically are just stuck because I want to do it myself, and my wife wants to have a contractor do it. The problem is, I think it will be less work for me to actually do it, than accommodate a contractor doing it.

    #65696

    dkj4linux
    Participant

    Though this says it’s 8mm thick, the boxes I have left specify 10mm. It locks together tightly with little/no fasteners and is super quick and easy to install… except for all the getting up/down that taxes the elderly and out-of-shape among us  =;^)

    https://www.lowes.com/pd/allen-roth-Barrel-Hickory-6-14-in-W-x-4-52-ft-L-Handscraped-Wood-Plank-Laminate-Flooring/1000404347

    It can also be a bit slippery for socked feet and pets that want to jump onto the sofa but, without the grandkids and their dog here, that’s not a problem for me…

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