I am going to need an enclosure for the table on this mill. I could build a fairly low wall enclosure that would help "some," but I don't think it would have the level of containment that I would like. Alternatively suppose I could build an enclosure that encompasses the entire front of the mill and rest on the floor. Something with partially sealed shower doors that I step inside of to setup a job.
Neither really fits my needs. One that set inside the table would substantially limit my choice of vises, as well as my Y axis travel to some degree. One that was short enough to have limited affect on Y would not fully contain chips or coolant when doing fast machining or using a face mill.
One that sets on the floor and encompasses the entire front of the machine would be much more expensive, although probably simpler to build. I would have to add a floor sump of some kind though, and I am not really crazy about cutting a sink sized hole in the monolithic slab. It would also take up a lot more floor space.
The one design I thought of that might work is one that extends outward to the front of the table about 8-12" and back from the table an inch. This would give me nearly full use of Y and not limit my choice of vises. I could also extend the front and side panels up more than 2 feet for plenty of chip and coolant containment. My son even suggest a fold up two or three section rear panel so I could raise it if I have to lower the knee, and fold it down when I raise the knee.
My problem with the last solution is that I don't see it being rigid enough and solidly mounted enough to hold up and not shake during some types of machining without screwing it to the table. That is, drilling and tapping the front and back lip of the table to solidly and physically attach the enclosure to the table. I had considered laying the base of the enclosure over the lip and making a clamp to bolt it to the table without drilling and tapping, but the lip is the same height as the surface of the table. This would again limit my choice of vises.
If I hadn't been chastised by "real" machinists about it I wouldn't hesitate to drill and tap the table to facilitate my solution. Especially since there is already a cast iron parts and tool tray attached to one end of the table by the same method. One that looks to have been installed or atleast sold originally by Hurco as it has the same aged Hurco blue hard paint. However, I have been chastised to "NEVER EVER EVER CUT OR DRILL THE TABLE EVEN BY ACCIDENT," by real machinists. This leaves me with a bit of a quandry. I can theorize and even visualize compromise solutions that are clamped near the ends and left floating in the middle, but my gut tells me when I am making multiple short rapids it will shake apart that way.
Suggestions?
I would otherwise build something like this ~