Well, rahcheer on/in this ng we have a fellow who is, on numerous levels, a
swindler who cain't lube a spindle (except for maybe his own), and whose
credibility has done dwindled to zero a long time ago.
Whose brain might not fill up a thimble.
Is there a lyricist in the house?
My question was how would OTHERS make this part, not how *I* made it.
So EVERYONE that posts a viable process for making this part deserves
a PRIZE, eh?
The "PRIZE" would consist of the respect of your peers for formulating
a well thought out & reasonable plan to produce a good part to print.
So those that posted, or possibly will post, a procedure the could make
the part is an automatic WINNER!
I'll relate my own trials and tribulations (boo-boos & corrections)
concerning making the part probably later today.
Yeah, yeah, yeah....
So will my prize at least be bigger than the other prizes??
Can I request a substitute?
How bout a 5 gal pail of Prep H? I'm running low.... been a rough week....
Plus with Palin, I think ahma really haveta slap dat H on thick.....
She scares me so bad, I just sent the Obama-rama-ding-dong camp another
> I'll relate my own trials and tribulations (boo-boos & corrections)
Square up the two blocks on a mill, finish the thickness to size, leave the
sizes .1 big approx or more. Leave an extra .5 on the long side for holding
While in the mill cut the 2/4 pockets in the corners and do the holes.
Lay the block on its side and do the 2 tapped holes on the side.
Wire edm 1 pass finished with the reisitivity set high so the aluminum
wont ruin the resin. (try to use at least .010 diameter coated wire if
possible, and if it doesn't have to be dimensionally accurate, cut the wire
feed speed in half to save the wire material).
Cut the part off from the stock you left on the long side with the wire.
At the last 1/2 of the cut have it leave .001 stock, so when it comes off
you can file that grand off smooth.
(Should be able to wire each one in a half an our a piece max.)
1) Hold in vise, square and machine blanks
a) 6.000" -.001" x 3.000" x .750"
b) Machine 1/16 Outside Corner radiuses.
2) Hole in vise, stand part on side (6" side up)
c) Machine tabs drill and tap to finish dimensions
Soft Jaws http://tinyurl.com/5x7za9
3) Install Soft Jaws, chuck on .100" spacers
a) mill pocket 6.001 +.001" L, 3.000" W, .650" deep.
On Sat, 20 Sep 2008 14:04:32 -0700, email@example.com wrote:
I was assuming making it on VMC and not having a vacuum chuck. (Only
running two parts I error on the side of caution.)
Op # 1) Hold in vise, square and machine blanks
a) 6.000" -.001" x 3.000" x .750"
OP # 2) http://tinyurl.com/3q22yf
Hold in vise, stand part on side (6" side up)
c) Machine tabs, drill and tap 4-40 X 2 Pl
Tooling: Soft Jaws http://tinyurl.com/5x7za9 Install Soft Jaws, chuck
on .100" spacers, mill pocket 6.001 +.001" L, 3.000" W, .650" deep.
Over cut the corners so part is being clamped on sides not corners,
OP #3) http://tinyurl.com/4n6s7d
a) Drill & ream .157 dia. thru holes , drill & tap 4-40 thru
holes, Drill and Tap the two clamp holes as shown.
b) Rough and finish bosses & all 1/16 corner radiuses with lead
in and outs enough to blend with next (larger diameter) tool.
c) Cut wall profile leaving .060" floor.
OP #4) http://tinyurl.com/45hom9
When cutting the part out can plan on leaving breakaway tabs
to secure the part or pour fusible alloy to a level under the tapped
holes on side. I have fusible alloy so I would use it, and as an added
safety measure I would place 5/32" dowel pins in the .157 dia. X 5 PL
thru holes to secure the part as well.
a) Carefully clamp the part and bolt cut out down, install the
b) first part of the program will finish the boss on the side
4-40 holes then cut out the part.
It was a quick and dirty taking less time than trying to type
everything out. Ole lady is on an Alaska Cruse with family, I am home
alone (if you don't count 9 pets). I have every thing I need on my
laptop so I was sitting here watching the boob-tube drawing it up.
You should see the documentation I send to a shop floor...LOL.....even
a near-blind-one-arm-wino should be able to run the job.
Nothing revolutionary about it, just regular stuff. Actually I used
bits and pieces of some of the various replies that have been posted
here. I'll start writing it up after I'm done watching the Ryder Cup.
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