Beauty in The Beast: Webb 5BVK Barn Find/Conversion

When Jim first nudged me to get this thing modernized/ running CNC - I was a little skeptical.
Why do I need CNC?
Can you imagine just having a mill?!
Hell - I can buy a rotary table!
I'll be fine...

Hahahaha.
What can I say?

I am blown away with all that can be done with a CNC.
Few parts below as example.
One made free hand, one from a photo.
(A PHOTO!)
Damn.

First up - Jim encouraged me to improve my chops with some practice.
What better than fancying up the mill a bit more?
After some wrestling with the basics of Fusion 360 - I managed to design my first part.

For anyone else thinking of going down this road - I would offer the following encouragement:
1. You can download Fusion 360 for free - and maintain it free - if you are not doing it professionally. Google "Fusion 360 for personal use".
2. If you already have some experience with another program - like Adobe Illustrator, or Corel, or Auto Cad - you can start off by making your part there and importing the part to Fusion as a DXF file. Will speed you.

So I did.
And the first part I made was a "spine" for the Beast, to hold the conduit.
'Cause you know, overbuilding...

The spine in Fusion:
Screenshot 2023-08-20 at 6.42.02 PM.png


Which I then cut on the machine from a $8 piece of scrap:
IMG_4032 2.JPG

and then mounted that to the back of the machine to hold the conduit. (Note the critical aerodynamic holes cut to allow strong crosswinds to pass).
IMG_4036 3.JPG

Then it was on to making my first structural part - out of steel - for my Vespa.
I'm making a custom intake manifold, and needed a base plate.
Normally these are a nightmare of bandsaw and angle grinder - producing a decent one off part.

This time - since I had an existing one, I shot a picture of it and then simply scaled the photo in Corel to match the existing part width and height - tracing it to create a DXF file I could import to Fusion.
Screenshot 2023-08-21 at 8.49.30 PM.png
In Fusion, I traced that part and extruded it:

Screenshot 2023-08-21 at 9.14.07 PM.png

Fusion can create G code - and Jim is training me on how to do a "setup" that considers materials and processes.
In the above screen shot - you can see the steps I plan to take cutting it - which include drilling, making the inner pocket, giving that inner contour pocket a clean up cut, and then doing the outer contour.

And here it is being cut:


IMG_4012.JPG

And finally - here is the part.
I pride myself with my angle grinder skills - but this is something else all together.
IMG_4013.JPG

Two weeks of wrestling and cussing - and I am making parts.
If you are on the fence/ considering this for your own project - I would encourage you to take the leap.
So cool to be able to make custom parts with such high precision and quality for my various projects.
Learning a new skill - and having some fun (most of the time...)

Out of the gate with plenty to learn.
 
<snip

Two weeks of wrestling and cussing - and I am making parts.
If you are on the fence/ considering this for your own project - I would encourage you to take the leap.
So cool to be able to make custom parts with such high precision and quality for my various projects.
Learning a new skill - and having some fun (most of the time...)

Out of the gate with plenty to learn.

Congratulations on your accomplishments.
However, so any newcomers won't be mislead, this thread started 2.25 years ago.
What portions of the task were accomplished in the 'two weeks' mentioned?
 
What portions of the task were accomplished in the 'two weeks' mentioned?
Oh, that was strictly software operation/setup output/ running the machine. Hell - I took two weeks just to move the thing into my garage!

It was intimidating (was for me) to think about trying to make an actual part from an idea in my head.

2 weeks of frustrations was enough to get the basic hang of it - enough to allow me to make a few parts for projects.

My encouragement to others is: might feel like an insurmountable hill - and the software may have you cursing at the onset - but lots of help online and here.

Not so bad once u get out of the gate.
 
It can lead to a slippery slope, ask me how I know ;) . I wanted to upgrade from my small Jet JVM-830 knee mill (similar to a Clausing 8520) to a Bridgeport. A nice one showed up on Craig's List about 30 miles away. It had a circa 1982 Anilam Crusader II 2-axis CNC on it. I'd never used or even thought about having CNC, but the Anilam gives the best of both worlds (like Jim's set up on his Eagle); can be a manual machine or CNC. It didn't take me too long to learn and do some G-code programming on it and Holy Cow, much like you, it opened my eyes to the possibilities!

Slippery slope was I now craved CNC control on the Z. I considered converting over to a Centroid Acorn system and machining a quill control like Jim did on his Eagle. I ended up spending a lot more and bought a Tormach 1100 with a tool changer, 4th axis, etc.

I wish I was where you are at with the CAD. I'm still a strictly manual G-code programmer though my wife is a Unigraphics designer. One of these days. . .

Congrats and everything looks great!

Bruce
 
Thanks Bruce - the started with a Bridgeport and ended up with a Tormach with tool changer is a classic. I think I followed it here?

In any event - I found Fusion initially opaque and frustrating.
Two things that worked really well for me:
1. Corel is just so simple (in my view) to draw shapes with, tracing something and then adjusting was no trouble.
2. I imported that as a DXF file to Fusion - and figured out how to trace and extrude with some help on their site. I literally posted a few screen shots, and various people put video tutorials together showing me what to do. Amazing support community. Really broke it down to bite sized tasks that taught me how to operate the program.

Of course Jim has been instrumental in showing me how to output those files with settings that will make it machine nicely.

After making a few shapes in Fusion, its starting to get a little easier/less frustrating...
Now, if I only had a 4 axis Tormach.
 
Little machinery restoration beauty shot for your morning.
Elsewhere am restoring (re-fitting?) and repainting my 10EE.

Wanted something different than just paint.
Always kinda torn regarding beautiful paint on a working machine.
I mean - I love how it looks - but don't want to have to treat it as precious when I use it.

Jim gave me an idea for using "engine turning" on some of the surfaces.
Liked it so much - I just kept going...
¯\_(ツ)_/¯

Using the mill, and a "Cratex" 1/2" rod, I created a drilling program (thank Jim).
overlapped the circles about 30% and off to the races.
Here was a quick test run:
IMG_5641.jpg

Decided I would try to "capture" this texture between painted surfaces to make it stand out - and utilize in places that would get a lot of general wear and hot chips.
Looks nice.
More durable.

Here is a quick glamour shot of the apron.
When I get a minute - will post a 10EE thread that shows off some of the other parts in progress.
Hat tip to Jim for such a cool idea.IMG_5636.jpg
 
THAT is utterly beautiful!!
 
Ok, I have questions...
1.). What size of round stick did you use (I'm assuming it is round)?
2.) Is it a rubberized stick or solid?
3.) How is it chucked into your mill (can't see from the picture angle)?
4.) How much down pressure?
 
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