Howdy, gang.
For the MOEPED 6 (remember the MOEPED?) I need some control cables routed over 1-1/8 inch tubing so I bought an aluminum two-piece shaft collar and placed some 3/32 holes in it. As expected, they wandered from the face drilled, coming out the back a bit off location. Then I got a couple of same-size same-type shaft collars in lightweight Delrin and used a 1-1/8 hole saw as a guide, clamping the aluminum jig collar over the Delrin work collar. I learned two things for my next try:
1) The holes are placed right on the drilled side of the jig collar, so THAT side should face the drilled side of the workpiece. Also, the second feature should go on that side of the work.2) Drills dig in Delrin. I am nursing a tiny thumb cut proving this. Next time, I'll clamp the collars and holesaw up in a six-inch three- jaw chuck that will resist lifting. I'd thought of a hold down the Super Shop has on it, but now that I've botched a part, the heavy chuck is clearly the way to go. It'll let the part float to follow the small hole; a hold-down wouldn't allow that. Yes, I know about blunting the edge. I think I should do that, too, next time
You know, it's a bitch to get this kind of shit right the first time. There goes about $38 worth of Delrin, but then again, here comes $38 plus worth of knowledge. If I didn't believe that, there'd be no freakin' way I could soldier on through this kind of disappointment. As is, I've pretty much seen it all before and am largely immune to the upset..
When finished, the collars will be around 9 inches apart on the tubing and the control cables will enter one collar, the sheaths will stop there, the cables will continue, and the sheaths will pick up on the other side. So the feature I am trying to make (eight times correctly the first time through) is a 3/32 through hole 1/2 inch long and a 6 mm stopped hole around 3/8 deep. It's not that hard. I could serial- ream the features and there'd be no digging. When finished, some cables will trip switches or measure control pressure with a strain gage and others will interact with each other to lock out overshifting. The OEM cable routing sucks; it's a bracket applied with fiberglass tape.
I sure am enjoying the Super Shop! It does everything well.
It's hard translating what you know into what you do the first time through.
Why is that?
Doug Goncz Replikon Research Seven Corners, VA 22044-0394