New Fabrication Project

[Red Rider]

I have a few days off now, so I finally got to finish up the rotor adapters. I finished cutting the center holes on the router table. A made a jig that allowed me to adjust the radius of the cutting. Using the left bit in the pic on post #30, I kept adjusting the radius, until I had the proper ID (47mm), then continued adjusting the depth of the cut (about 1/16" at a time), until I was about 7/16" into the 1/2" thick adapter. From there, I took the adapters to the drill press, and used a 1 3/4" hole saw to remove the last bit of material holding the centers in. Then, back to the router table, where I switched to the Flush Trim bit (right bit in post #30) to bring the entire hole to 47mm ID. I decided a rounded edge would look good on the outside surface of the holes, so I did that as well, once again using the center bit in post #30.

Next up, I needed to remove a lot of material from the backside of the adapters, to allow the discs to align properly with the calipers. So, once again I used the same jig, that I used earlier in this post, and kept adjusting the ID of the cutting, until I had the proper ID, then I kept cutting deeper, until I had achieved the appropriate depth. When that was done, I finished off the outside of the ID with a 1/2" diameter Round Nose router bit.

[ironchop]

Again, nice work

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[yaegerb]

I have a few days off now, so I finally got to finish up the rotor adapters. I finished cutting the center holes on the router table. A made a jig that allowed me to adjust the radius of the cutting. Using the left bit in the pic on post #30, I kept adjusting the radius, until I had the proper ID (47mm), then continued adjusting the depth of the cut (about 1/16" at a time), until I was about 7/16" into the 1/2" thick adapter. From there, I took the adapters to the drill press, and used a 1 3/4" hole saw to remove the last bit of material holding the centers in. Then, back to the router table, where I switched to the Flush Trim bit (right bit in post #30) to bring the entire hole to 47mm ID. I decided a rounded edge would look good on the outside surface of the holes, so I did that as well, once again using the center bit in post #30.

Next up, I needed to remove a lot of material from the backside of the adapters, to allow the discs to align properly with the calipers. So, once again I used the same jig, that I used earlier in this post, and kept adjusting the ID of the cutting, until I had the proper ID, then I kept cutting deeper, until I had achieved the appropriate depth. When that was done, I finished off the outside of the ID with a 1/2" diameter Round Nose router bit.

Don't know how I missed this thread. Damn mad scientist at it again!

[Red Rider]

Don't know how I missed this thread. Damn mad scientist at it again!

I've had this happen to me many times. I see a new thread, but based on the title, I never look at it. After I keep seeing lots of activity on the thread, I figure something interesting must be going on, and I finally decide to give it a look.

P.S. This is the project I was starting, when we talked on the phone.

[yaegerb]

I've had this happen to me many times. I see a new thread, but based on the title, I never look at it. After I keep seeing lots of activity on the thread, I figure something interesting must be going on, and I finally decide to give it a look.

P.S. This is the project I was starting, when we talked on the phone.

Ahhh, this is very neat fab work!

[Louis Mielke]

Very awesome work Red Rider!

[HairyJR]

Now that's some handy out-of-the-box machine work. Where I worked maintenance often needed in-place machining to repair equipment and it always amazed me what types of materials / tools / equipment / set ups used to complete the task. Now having said that I have racked my brain trying to imagine the set up you used. A couple pic's of the fixtures, rotor table or locating pins used would clear up and maybe allow others to perform something similar.

"HJ"

[Red Rider]

...I have racked my brain trying to imagine the set up you used. A couple pic's of the fixtures, rotor table or locating pins used would clear up and maybe allow others to perform something similar.

Thanks Harry. As requested, here's a pic of my router table setup. This white jig, in the center of the router table, was what I used for the majority of the work. In the center of the jig's circle is a 1/4" bolt. Both raw pieces of aluminum had 1/4" holes in the centers of them as well. The hole in the aluminum was slid over the bolt, then secured with a washer & nut. Then the aluminum was rotated around the bolt, resulting in round cuts. The green arrow points to the router bit. Adjusting the fence, at the back of the router table, changes the radius of the cuts, by moving the jig closer to, or further from, the cutting bit. The pieces of oak, on either side of the jig, are there to hold the jig centered, yet still allowing the jig to slide forward & aft (red arrow). The other jig & guide I used was shown in posts #19 & 23.

Here's the new rotor, and caliper relocation bracket mounted up.

[yaegerb]

Thanks Harry. As requested, here's a pic of my router table setup. This white jig, in the center of the router table, was what I used for the majority of the work. In the center of the jig's circle is a 1/4" bolt. Both raw pieces of aluminum had 1/4" holes in the centers of them as well. The hole in the aluminum was slid over the bolt, then secured with a washer & nut. Then the aluminum was rotated around the bolt, resulting in round cuts. The green arrow points to the router bit. Adjusting the fence, at the back of the router table, changes the radius of the cuts, by moving the jig closer to, or further from, the cutting bit. The pieces of oak, on either side of the jig, are there to hold the jig centered, yet still allowing the jig to slide forward & aft (red arrow). The other jig & guide I used was shown in posts #19 & 23.

Here's the new rotor, and caliper relocation bracket mounted up.

Fantastic!!!

[Red Rider]

I'm going to check this project off as, "complete."

On a side note, new computer purchase recently, and very fricken annoying that my "portrait" pics now post as "landscape" on here, regardless of how they are oriented on my computer.

Ok, I figured out my pic problem. Even though the pic is oriented properly on my computer, I went ahead and edited the pic by rotating it 180 degrees (which made it upside down), saved it, and then edited it again by rotating it another 180 degrees (which made it right side up again). Then I reloaded the pic to 3ww, and the edited pic is now oriented properly. Your necks will thank me later.

[yaegerb]

Turned out fantastic

[ironchop]

Red anodize is a nice touch.

Great looking machine with some cool features

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